FORKLIFT TRUCK

MWP 14-1R • MWP 16-1R

MWP 18-1R
MWS 10-1R • MWS 12-1R

Prepared by
Documentation and Courses Dept.

KOMATSU FORKLIFT
Code: 60424511
MWP 14•18-1R
MWS 10•12-1R

• COMMON DIAGRAMS AND MANUALS

Use and Maintenance Manual, Programming with UCB97, MWP 14•18-1R
MWS 10•12-1R, Alarms
452006026 Menu Diagram UCB97, MWP 14•18-1R - MWS 10•12-1R
452106010 Power Supply Cables and Plugs MWP 14•18-1R - MWS 10•12-1R

• MWP 14•18-R DIAGRAMS

Functional Hydraulic MWP 14•18-1R
452006004 Cable and Harness Layout MWP 14•18-1R
452006005 Electric Panel Connections MWP 14•18-1R
452006006 Main Wiring Harness MWP 14•18-1R
452006017 Activity Table MWP 14•18-1R
452006018 Functional Electrical MWP 14•18-1R
452049159 Tiller Connections MWP 14•18-1R

• MWS 10•12-1R DIAGRAMS

452105029 Functional Hydraulic Dpx/Tpx GAL MWS 10•12-1R
452106005 Cable and Harness Layout MWS 10•12-1R
452106006 Main Wiring Harness MWS 10•12-1R
452106007 Electronic Panel Connections MWS 10•12-1R
452106022 Activity Table MWS 10•12-1R
452106024 Functional Electrical MWS 10•12-1R
452149153 Tiller Connections MWS 10•12-1R

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MWP 14•18-1R
MWS 10•12-1R

Use and maintenance manual

Programming with UCB 97
MWP 14•18-1R
MWS 10•12-1R

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MWS 10•12-1R

SUMMARY

1 INTRODUCTION ................................................................................................................ 5
1.1 BLOCK SCHEME OF THE SYSTEM HARDWARE....................................................... 5
1.2 SERIAL TRANSMISSION BETWEEN THE TILLER & COMBI ...................................... 7

2 COMBI CONTROL .............................................................................................................. 8

2.1 ARMATURE POWER CONTROL DIAGRAM ............................................................... 9
2.2 FIELD POWER CONTROL DIAGRAM ....................................................................... 10
2.3 PUMP MOTOR POWER CONTROL DIAGRAM ......................................................... 12
2.4 ENERGY RECUPERATION ........................................................................................ 13
2.5 I/O CONDITIONS OF THE COMBI ..............................................................................14

3 TILLER CARD ...................................................................................................................16

3.1 BLOCK DIAGRAM OF THE TILLER CARD ................................................................ 17
3.2 DUAL ACTION POTENTIOMETER .............................................................................17
3.2.1 TECHNICAL DATA .............................................................................................. 18

4 MDI DISPLAY .................................................................................................................... 19

5 TRACTION MOTOR .......................................................................................................... 20

6 PUMP MOTOR .................................................................................................................. 20

7 CONSOLE ......................................................................................................................... 21
7.1 PARAMETER CHANGE .............................................................................................. 22
7.2 TESTER .......................................................................................................................24
7.3 PROGRAM VACC ........................................................................................................ 26
7.4 ALARMS ......................................................................................................................26
7.5 CONFIG MENU ........................................................................................................... 26
7.5.1 ADJUSTMENTS .................................................................................................. 27
7.5.2 SET OPTIONS ....................................................................................................28

8 STANDARD CONFIGURATION AND PARAMETERS ..................................................... 29

9 ALARMS ............................................................................................................................32

10 OPTIONS .......................................................................................................................... 35

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MWS 10•12-1R

1 - INTRODUCTION
The truck control system consists of two fundamental logics, denominated as:
1 Control Combi
2 Tiller Logic (TILB)
The first one receives the control and the management functions of the truck and also the
management functions of the console (or PC console); the second one establishes almost
total interaction with the operator and is responsible for the management of the tiller commands.
This is illustrated in the block diagram of the system hardware Fig. 1:

1.1 - BLOCK DIAGRAM OF THE SYSTEM HARDWARE

RECTIFIER

BATTERY
TRACTION MOTOR
MAIN COMBI
CONTACTOR PUMP MOTOR
X1

KEY SWITCH

SAFETY AND MDI

AUXILIARY SENSORS DISPLAY
CONSOLE
PROPORTIONAL VALVE
FOR LOWERING - ON/
SERIAL LINE
OFF VALVE FOR LIFTING X3
TILLER LIFTING LOWERING
TILLER BUTTONS
LOGIC CONTROL GROUP

TRACTION
CONTROL GROUP

Fig.1 Block diagram of the system hardware

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MWS 10•12-1R

The communication between the COMBI and the TILB takes place through a serial type connector
RS232, enabling a considerable saving on the number of connection cables required:
As shown in Fig 2.

FIG. 2

The signals from the BELLY SWITCH (anti crush) and from CPOT. T2 (central point of the
traction pot 2) and from CPOT. S2 (central point of the lift/lower pot 2), do not pass through the
serial connector, but enter directly into the COMBI, giving a more secure communication.

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MWS 10•12-1R

1.2 - SERIAL TRANSMISSION BETWEEN TILLER AND COMBI

On this system the tiller card only transmits and does not receive data.
All signals transmitted from the tiller are received by the COMBI which displays an alarm if this
communication is interrupted.

Principle Characteristics
- Transmission frequency =2400 baud (bit/sec)
- 8 bit data,1 bit start, 2 bit stop, no bit parity
- Current controlled

The program transmits 4 bytes subdivided as follows:

1st BYTE the first 2 bit is a bit of recognition, the others carry back the digital signals.
2nd BYTE value of the traction potentiometer
3rd BYTE value of the lifting potentiometer
4th BYTE the last 2 bit is a bit of recognition, the others carry back the digital signals.

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MWS 10•12-1R

2 - COMBI CONTROL

TECHNICAL CHARACTERISTICS
GRADE OF PROTECTION IP54
WORKING TEMPERATURE -30º/+70ºC
SUPPLY VOLTAGE +24VDC
WORKING FREQUENCY 16KHZ
PRINCIPLE MICROPROCESSOR
CONTROLLER MICROPROCESSOR
MEMORY TYPE EPROM
POWER CARD TECHNOLOGY IMS
LOGIC CARD TECHNOLOGY SMD
TRACTION MOTOR EXCITATION TYPE SEPARATE
PUMP MOTOR EXCITATION TYPE SERIES
TRACTION POWER 200A-300A
LIFT POWER 250A-300A
CONSTRUCTOR
ONLY ONE PACKAGE FOR ALL VERSIONS

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MWS 10•12-1R

2.1 - ARMATURE POWER CONTROL DIAGRAM

The control of the armature voltage VMN is achieved with a set of power mosfet, connected as
in fig 3.

Fig 3 diagram for the VMN control

In the 200 A version:

Qi: set of 4 mosfet with integrated diode a channel n

Qj: set of 4 mosfet with integrated diode a channel n 200 A
C: set of 14 condensers connected in parallel

In the 300 A version

Qi: set of 6 mosfet with integrated diode a channel n

Qj: set of 6 mosfet with integrated diode a channel n 300 A
C: set of 14 condensers connected on parallel

The power MOS (PWM and FRE) are controlled by two inverted signals: when one is ON the
other is OFF and visa versa.
At maximum conduction, the MOS PWM is always on (MOS FRE always OFF).
At rest the MOS FRE and the MOS PWM are always OFF.

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MWS 10•12-1R

2.2 - FIELD POWER REGULATION DIAGRAM

On the other hand, the regulation of the field is achieved by the connection of 2 + 2 mosfets as
illustrated in fig. 4.

Fig. 4 Diagram for the field regulation.

Q26-Q29 Set of 4 Mosfet with integrated diode, a channel n 200A

300A

Forward Drive

The mos Q 27 is activated for the duration of the request for travel.
The mos Q 28 is activated with PWM ( f = 800Hz ) for the duration of the request for travel.
The mos Q 26 and Q 29 are held switched off.

Reverse Drive

The mos Q 29 is activated for the duration of the request for travel.
The mos Q 26 is activated with PWM ( f = 800Hz ) for the duration of the request for travel.
The mos Q 27 and Q 28 are held switched off.

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MWS 10•12-1R

Reverse travel

Forward travel

Fig 5 method of field regulation

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MWS 10•12-1R

2.3 - PUMP MOTOR DRIVE REGULATION

The regulation of the supply voltage VMN for the pump is achieved with a bank of mosfet as
illustrated in Fig 6.

Fig 6 Connection for the regulation of the VMN for lifting

Q: set of 5 mosfet with integrated diode a channel n 250A

D: set of 4 diodes

Q: set of 6 mosfet with integrated diode a channel n 300A

D: set of 6 diodes

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MWS 10•12-1R

2.4 - ENERGY RECUPERATION.

Energy recuperation is effective in the following conditions:
a) truck descending (a ramp or slope) with accelerator released
b) truck decelerating with accelerator released
c) truck decelerating with the inversion of the accelerator

We can now examine what is happening in the combi in these conditions:

1) Functioning as a motor.
- When PWM is ON, the current circulates around the motor and the MOS.
- When FRE is ON, the current stored in the motor is recirculated (in the same direction as
before) across the integrated diode in the MOSfre, which functions as a flywheel. In this case
the MOSfre, can also be off ( at the same time as MOSpwm).
2) Functioning as a generator.
- When PWM is ON, the current stored in the motor flows across the MOSpwm and recharges
the battery. The current does not flow across the integrated diode in PWMfre.
- When FRE is ON, the current stored in the motor is recirculated around MOSfre, which
functions as a flywheel. In this situation the MOSfre can not be substituted with the diode.
The current will not flow across the integrated diode in PWM.

Functioning as a MOTOR

Recirculating across
the diode

Current in the MOS

Functioning as a GENERATOR

Recirculating across
the MOS

Current in the diode

Fig 7 Functioning as a motor and as a generator.

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MWS 10•12-1R

2.5 - I/O CONDITIONS OF THE COMBI

We will now examine the input and output conditions of the combi, the inputs are divided in:
- Digital (safety sensors)
- Analogical (Traction potentiometer or lift/lower potentiometer)

The output is digital to the mos.

N.B. The term micro means the logic unit.

TO THE MICRO

GATE FOR THE DIGITAL INPUT

TO THE MICRO

GATE FOR THE ANALOGICAL INPUT

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MWS 10•12-1R

TO THE MICRO

VOLTAGE OUTPUT

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MWS 10•12-1R

3 - TILLER CARD
The tiller card is mounted between the dual action potentiometer and the forward/reverse lever
mechanism, as shown in Fig 3 below.

X3

DUAL ACTION
POTENTIOMETER
LEVER MECHANISM COM-
PLETE WITH MICROSWITCH

TILLER CARD

FIG 3

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MWS 10•12-1R

3.1 - BLOCK DIAGRAM OF THE TILLER CARD

DUAL ACTION
POT.
LIFT/LOWER

MICRO
DUAL ACTION
POT. X3
TRACTION
TILLER
CARD

TILLER BUTTONS
LIFT/LOWER

Fig 4

3.2 - DUAL ACTION POTENTIOMETER

In practice, it operates as a double potentiometer, in which the respective wipers are attached
to the same shaft that generates the rotary movement, as shown in Fig 5.

CURSOR POT. 1
CURSOR POT. 2

Fig 5

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MWS 10•12-1R

During the operation when pot. 1 is at maximum (8KΩ), pot. 2 is at minimum (0Ω) ; if the
potentiometer is fed with a voltage of +5 VDC there will be a variation of output as shown below:

SHAFT ROTATION (DEGREES)

A = POSITION AT REST
B = END OF TRAVEL TO THE RIGHT
C = END OF TRAVEL TO THE LEFT

The outputs from pot.1 and pot.2, are continuously compared by the combi, according to the
mathematical equation: POT. 1 + POT. 2 ≅ 5 V. If an anomaly of one or both potentiometers is
detected, the truck will be immobilised and an alarm will be displayed.

3.2.1 - TECHNICAL DATA

POTENTIOMETER TYPE DUAL ACTION

NUMBER OF WORK CYCLES 2 MILLION
MECHANICAL OPERATING ANGLE 2X50°
NOMINAL RESISTANCE 8Kohm
TOLLERANCE ±35%
ELECTRICAL OPERATING ANGLE 2X35°
LINEARITY ±2%
POWER 1W / 70 °C
STORAGE TEMPERATURE 80 °C
WORKING TEMPERATURE RANGE -30 °C / +80 °C
GRADE OF PROTECTION IP65

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MWS 10•12-1R

4 - MDI DISPLAY
This is the instrument which displays the state of charge of the battery (through led’s), the
number of hours worked and the type of alarm, if present (in the form of a number). There is
also an indicator for when slow speed is selected and also for the programmed maintenance
interval.
Communication with the combi is carried out through connector X2 using the same transmis-
sion serial used on the console.
The MDI display layout is explained in Fig 6:

Fig 6

1 = Red led
2 = Yellow led
3 = Yellow led
4 = Yellow led
5 = Yellow led
6 = Symbol for slow speed (tortoise)
7 = Symbol for programmed maintenance (spanner)
8 = Symbol for hours being counted (hourglass)
9 = Number of hours worked in numerals (to display the alarm only two numbers are used)

With 4 yellow led’s lit (2-3-4-5) the battery is 100 % charged

With 3 yellow led’s lit (2-3-4) the battery is 70 % charged
With 2 yellow led’s lit (2-3) the battery is 40 % charged
With 1 yellow led’s lit (2) the battery is 20 % charged
With 1 red led’s lit (1) the battery is ≤10 % charged

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MWS 10•12-1R

5 - TRACTION MOTOR
MWP 14•18-1R - MWS 10•12-1R:
A separate excitation motor with the following characteristics:
KOMATSU part no. 95325041.

Supply voltage +24V

Power 1.0 KW
Maximum speed 2800 rpm
Nominal armature current 55A
Operating current 11A
Insulation class F
Number of brushes 4
Brush life 5000 Hrs
IP 21

6 - PUMP MOTOR
MWP 14•18-1R:
A series wound motor with the following characteristics:

Supply voltage +24V

Power 1.2KW

MWS 10•12-1R:
Two series wound motors available with the following characteristics:

Supply voltage +24V +24V

Power 2.2KW 3KW

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MWS 10•12-1R

7 - CONSOLE
Connect the console to X2 and access the principal menu (MAIN MENU), containing the following
sub-menus:
- PARAMETER CHANGE
- TESTER
- PROGRAM VACC
- MOTOR DATA (Not available)
- ALARMS
- SAVE PARAMETER (Not used)
- RESTORE PARAMETER (Not used)
There is an additional menu available to configure the optional equipment or to make special
adjustments.

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7.1 - PARAMETER CHANGE
Entering the menu PARAMETER CHANGE, will display the parameter settings and enable the
modification of these parameters, in order to achieve the optimum performance of the truck, for
each individual application.
Parameter Name Meaning
ACCELER. DELAY Traction acceleration rate
DECELER. DELAY Traction deceleration rate with
accelerator released
RELEASE BRAKING Braking with accel. lever released
INVERS. BRAKING Braking with accel. inverted
CUTBACK SPEED 1 Speed with slow speed 1 se-
lected (proposed feature)
CUTBACK SPEED 2 Speed with slow speed 2 se-
lected (proposed feature)
CREEP SPEED TR. Voltage applied to the traction
motor during the initial movement
of the accelerator lever
SOFT WORKING Reduced acceleration, braking and
speed with the function “INALCA”
MAX SPEED FORW. Maximum forward speed
MAX SPEED BACK. Maximum reverse speed
MAX I TRACTION Current limit on traction
ARMA NOM CURR. Minimum nominal armature current
below which field weakening occurs
WEAK DROPOUT Value of the armature current
which corresponds to the drop
out from field weakening
FIELD CURR. MAX. Maximum field current
FIELD NOM. CURR. Nominal field current
PU. ACCELER. DEL Rate of acceleration of the pump
PU. DECELER. DEL Rate of deceleration of the pump
LEVER LIFT SPEED Lift speed from the potentiometer
or distributor micro
LIFT SPEED Pump speed with fast lift button operated Higher as level increases to 9
DOWN SPEED Lowering speed with button
(proposed feature)
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Adjustment
Accel. slower as level increases
to 9
Decel. Slower as level increases
to 9
Braking effect greater as level in-
creases to 9
Braking effect greater as level in-
creases to 9
Speed is greater as value in-
creases to 9
Speed is greater as value in-
creases to 9
Greater voltage applied as level
increases to 9
Effect greater as level increases
to 9
Higher speed as level increases to 9
Higher speed as level increases to 9
Higher as level increases to 9
Higher as level increases to 9
Higher as level increases to 9
Higher as level increases to 9
Higher as level increases to 9
Accel. rate slower as level increases to 9
Decel. rate slower as level increases to 9
Higher as level increases to 9
Higher as level increases to 9
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MWS 10•12-1R

Parameter Name Meaning Adjustment

R-SHIFT SPEED Pump speed for side shift right Higher as level increases to 9
L-SHIFT SPEED Pump speed for side shift left Higher as level increases to 9
SLOW LIFT SPEED Pump speed with slow lift button Higher as level increases to 9
operated
CREEP SPEED PUMP Voltage applied to the pump Higher as level increases to 9
during the initial movement of the
potentiometer
EV. ACCELER. DEL Opening duration rate for the Slower as level increases to 9
lowering EVP
EV. DECELER. DEL Closing duration rate for the EVP Slower as level increases to 9
MIN DESC. EVP Minimum voltage (current) on Higher as level increases to 9
EVP
MIN DESC. EVP FINE Minimum voltage (current) on Higher as level increases to 9
EVP. Fine adjustment
MAX DESC. EVP Maximum voltage (current) on Higher as level increases to 9
EVP
MAX DESC. EVP FINE Maximum voltage (current) on Higher as level increases to 9
EVP. Fine adjustment

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MWS 10•12-1R

7.2 - TESTER
Enables measurement of the components listed in relative states ON/OFF
Name Description Actual Value
BATTERY VOLTAGE Indication of the battery voltage 24 V ÷ 25.5 V
MOTOR VOLTAGE Value of the armature voltage OV at rest
VBATT at max speed unloaded
MOTOR CURRENT Value of the armature current 0 A at rest
25A at max speed unloaded
FIELD CURRENT Value of the field current 0 A at rest
7.5A at max speed unloaded
DESC. EVP VOLT. Voltage on the proportional
electrovalve EVP
TEMPERATURE Temperature of the traction pulse 25°C ÷ 30°C
controller (chopper)
TR. ACCELERATOR Value of the voltage relative to the At rest 2.3V ÷ 2.6V
traction potentiometer 1 and % of F/R lever: forward 0V
the maximum value F/R lever: reverse 5V
LIFT ACCELERATOR Value of the voltage relative to the At rest 2.3V ÷ 2.6V
lift/lower potentiometer 1 and % F/R lever: lift 0V
of the maximum value F/R lever: lower 5V
2 ND TR. ACCELER. Value of the voltage relative to the At rest 2.3V ÷ 2.6V
traction potentiometer 2 and % of F/R lever: reverse 0V
the maximum value F/R lever: forward 5V
2 ND LIFT ACCELER. Value of the voltage relative to the At rest 2.3V ÷ 2.6V
lift/lower potentiometer 2 and % F/R lever: lower 0V
of the maximum value F/R lever: lift 5V
1 ST TILLER SW. Tiller sensor 1 (standard) off = 3/5 VBATT
on = 0 V
2 ND TILLER SW. Tiller sensor 2 (optional) off = 3/5 VBATT
on = 0 V
FORWARD SWITCH Enables forward travel off / on
BACKWARD SWITCH Enables reverse travel off / on
CUTBACK SWITCH 1 Slow speed micro 1 off = 0V
(proposed feature) on = 3/5 VBATT
CUTBACK SWITCH 2 Slow speed micro 2 off = 0V
(proposed feature) on = 3/5 VBATT
BELLY SWITCH Rapid inversion safety micro (anti off = 3/5 VBATT
crush) on = 0V
LEVER LIFT SW. Distributor lift micro or enable off = 3/5 VBATT
lift potentiometer on = 0V
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MWS 10•12-1R

Name Description Actual Value

LEVER DESC. SW. Lowering enabled with off / on
potentiometer
LIFT SW. 1 Lift button on tiller off = +5 VDC
on = 0V
DESC. SW. 1 Lower button on tiller off = +5 VDC
on = 0V
LIFT SW. 2 Lift button on tiller off = +5 VDC
on = 0V
DESC. SW. 2 Lower button on tiller off = +5 VDC
on = 0V
LIFT BLOCK Lift limit sensor off = 0V
on = 3/5 VBATT
PLUG INPUT Battery charger plug micro off = 0 V
on = 3/5 VBATT
HORN SWITCH Horn button off = +5 VDC
on = 0V
RIGHT SIDE SHIFT Side shift right button on tiller off = +5 VDC
(proposed feature) on = 0V
LEFT SIDE SHIFT Side shift left button on tiller off = +5 VDC
(proposed feature) on = 0V
SELECTOR 1 Bridge 1, tiller family program off = 3/5 VBATT
selection❊ on = 0 V
SELECTOR 2 Bridge 2, tiller family program off = 3/5 VBATT
selection❊ on = 0 V
SLOW LIFT SP SW1 Slow lift speed button 1 off = +5 VDC
on = 0 V
SLOW LIFT SP SW2 Slow lift speed button 2 off = +5 VDC
on = 0 V
BATTERY CHARGE Percentage of full battery charge From 0 % to 100 %

❊
Bridge 1 Bridge 2
For TL model on off
For CL model off off

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7.3 - PROGRAMME VACC.

Programs the voltage output from the accelerator control which the combi will recognise as
minimum and maximum. The operation must be carried out for forward and reverse directions.
Procedure for forward direction: Press ENTER and the screen will display:

VACC SETTINGS
0.6 4.8

The display shows the voltage at maximum conduction in either forward or reverse direction.
If the values are correct press OUT to exit the program without making any modifications.
Press ENTER to modify the values.

MIN VACC MAX

0.0 ---- 0.0

The traction is disabled: Slowly rotate the accelerator to the maximum speed position and then
slowly release to the park position.
N.B. Sudden or harsh movement of the accelerator lever will cause error readings.
After adjustment is completed press OUT to confirm the settings. On the screen will appear:

ARE YOU SURE?

YES=ENTER NO=OUT

Press ENTER to accept and save the new values or press OUT to exit without saving the data.
In either case the display will return to the original screen.
N.B. Repeat the procedure for the reverse direction.

7.4 - ALARMS
This menu displays the last four alarms which have occurred on the truck and which have been
memorised by the system. Next to the alarm message is displayed the number of consecutive
times the alarm has occurred, the hourmeter reading when the alarm occurred and the tempe-
rature of the electronic control panel at the time the alarm occurred. (If the temperature displayed
is 0°C it means that the alarm occurred as the truck was switched on) The alarms can not be
cancelled with the UCB 97 2nd level
Example
VMN NOT OK
122H 0°C

7.5 - CONFIG MENU

The pages contained in this menu protect the configuration system CONFIG they can be opened
in the following way.
• Press simultaneously the ROLL UP and SET UP buttons for some seconds until the first
page is displayed.

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1. SET MODEL (not available)

2. SET OPTIONS
3. ADJUSTMENTS

7.5.1 - ADJUSTMENTS
The following settings are possible:

1. ADJUST. BATTERY:
Permits adjustment of the battery voltage setting. Press ENTER to select the function. The
valve can then be modified in steps of 0.2V by pressing the SET and RESET buttons. When the
desired value is displayed confirm the setting by successively pressing OUT and then ENTER.

2. MIN.ACC. LIFT: (OV)

Permits the setting of the minimum voltage value from the lift potentiometer. Press ENTER to
select the function and with the lever at rest, the setting can be confirmed by successively
pressing OUT and the ENTER.

3. MAX.ACC. LIFT: (5V)

Permits the setting of the maximum voltage value from the lift potentiometer. Press ENTER to
select the function and with the lift lever held in the maximum speed position, the setting can be
confirmed by successively pressing OUT and then ENTER.

4. MIN.ACC.DESC.: (0V)
Permits the setting of the minimum voltage value from the lower potentiometer. Press ENTER
to select the function and with the lever at rest, the setting can be confirmed by successively
pressing OUT and the ENTER.

5. MAX.ACC.DESC.: (5V)
Permits the setting of the maximum voltage value from the lower potentiometer. Press ENTER
to select the function and with the lower lever held in the maximum speed position, the setting
can be confirmed by successively pressing OUT and then ENTER.

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7.5.2 - SET OPTIONS

This menu permits the activation of relative functions and options.

1. HOUR COUNTER:
- RUNNING (active only when pump or traction motor is in operation)
- KEY ON (active continuously when the truck is switched on)

2. BATTERY CHECK:
- ON = lift lockout active when battery is discharged
- OFF = lift lockout not active when battery is discharged

3. SHIFT FUNCTION:
- ON = sideshift function activated
- OFF = sideshift function deactivated

4. LIFT BLOCK:
- ABSENT = lift limit absent
- PRESENT = lift limit present

5. QUICK INVERSION:
- BELLY = with anti-crush button pressed the inversion is continuous
- TIMED = with anti-crush button pressed the inversion is timed

6. PROPORTION LIFT:
- ON = lift/lower potentiometer activated
- OFF = lift/lower potentiometer deactivated

7. BRAKE IN QCK.INV:
- ON = F.E.M. activated with rapid inversion (Belly)
- OFF = F.E.M. not activated with rapid inversion (Belly)

8. EV TYPE:
- NONE = valve exit not enabled (pin 5 on X1 chopper)
- OPTION #1 = EVP valve exit enabled
- OPTION #2 = EV on/off valve exit enabled

9. CUTBACK SP. TYPE:

- NONE = slow speed not enabled
- OPTION #1 = two slow speeds enabled in forward and reverse
- OPTION #2 = one slow speed enabled in forward and reverse

10. SOFT WORK

- NONE = no slow speed function related to Tim.1 sens. And Tim.2 sens.
- OPTION #1 = slow speed active in relation to sens Tim.1
- OPTION #2 = slow speed active in relation to sens Tim.2

Rev. 06/01 Code: 60424511 Page 28

MWP 14•18-1R
MWS 10•12-1R

8 - STANDARD CONFIGURATION AND PARAMETERS

MENU PARAMETER

MWP 14•18-1 MWS 10•12-1R

ACCELER. DELAY 5 9
DECELER. DELAY 5 5
RELEASE BRAKING 5 5
INVERS. BRAKING 5 5
CUTBACK SPEED 1 9 9
CUTBACK SPEED 2 9 9
CREEP SPEED TR. 0 0
SOFT WORKING 9 5
MAX SPEED FORW 9 9
MAX SPEED BACK 9 9
MAX . I TRACTION 9 5
ARMA NOM CURR. 5 5
WEAK DROPOUT 5 5
FIELD CURR. MAX 9 9
FIELD NOM CURR. 4 4
PU. ACCELER. DEL 5 5
PU. DECELER. DEL 5 5
LEVER LIFT SPEED 9 9
LIFT SPEED 9 9
DOWN SPEED 5 5
R - SHIFT SPEED 5 5
L - SHIFT SPEED 5 5
SLOW LIFT SPEED 5 5
CREEP SPEED PUMP 0 0
EV. ACCELER. DEL. 5 5
EV. DECELER. DEL. 5 5
MIN DESC. EVP 5 5
MIN DESC. EVP FINE 5 5
MAX DESC. EVP 5 5
MAX DESC. EVP FINE 5 5

Rev. 06/01 Code: 60424511 Page 29

MWP 14•18-1R
MWS 10•12-1R

SET OPTIONS

HOUR COUNTER

MWP 14•18-1R RUNNING

MWS 10•12-1R RUNNING

BATTERY CHECK

MWP 14•18-1R OFF

MWS 10•12-1R OFF

SHIFT FUNCTION

MWP 14•18-1R OFF

MWS 10•12-1R OFF

LIFT BLOCK

MWP 14•18-1R PRESENT

MWS 10•12-1R ABSENT

QUICK INVERSION

MWP 14•18-1R BELLY

MWS 10•12-1R BELLY

PROPORTION. LIFT

MWP 14•18-1R OFF

MWS 10•12-1R OFF

BRAKE IN QCK.INV.

MWP 14•18-1R ON
MWS 10•12-1R OFF

EV. TYPE

MWP 14•18-1R OPTION #2

MWS 10•12-1R NONE

CUTBACK SP. TYPE

MWP 14•18-1R NONE

MWS 10•12-1R NONE

Rev. 06/01 Code: 60424511 Page 30

MWP 14•18-1R
MWS 10•12-1R

SOFT WORK
MWP 14•18-1R NONE
MWS 10•12-1R NONE

HARDWARE SETTINGS

SET CURRENT

MWP 14•18-1R 200A

MWS 10•12-1R 200A

SET FIELD CURRENT

MWP 14•18-1R 28A

MWS 10•12-1R 28A

ADJUSTMENT 01

MWP 14•18-1R 3
MWS 10•12-1R 3

ADJUSTMENT 02

MWP 14•18-1R 2
MWS 10•12-1R 2

LOAD HOURS MDI

MWP 14•18-1R OFF

MWS 10•12-1R OFF

CHECK UP DONE

MWP 14•18-1R OFF

MWS 10•12-1R OFF

CHECK UP TYPE

MWP 14•18-1R NONE

MWS 10•12-1R NONE

Rev. 06/01 Code: 60424511 Page 31

MWP 14•18-1R
MWS 10•12-1R

9 - ALARMS
NOTE: The letter “B” at the side of the alarm indicates that this alarm will immobilise the truck.
This means if the alarm is present when the truck is switched on the general contactor will not
be allowed to close. Furthermore if the alarm occurs during the operation of the truck, the
general contactor will be opened, immediately disconnecting the supply from the battery.

MDI ALARM PROBABLE CAUSES CORRECTIVE ACTION

EVP NOT OK EVP coil faulty Check for correct supply to
Current absorption Power mos for the EVP in the EVP
1 anomaly of the proportional short circuit Change the EVP
B lowering electrovalve Change the control panel
2 EB DRIVER KO Resistance anomaly on the Check the connection on
B Voltage on the driver for the FEM (too high) the E. M. brake
Brake not connected
electro-magnetic brake not correct Change the FEM
3 VFEILD NOT OK Field cables disconnected Check the cables and
B Field voltage not correct connections for the field
6 SERIAL ERROR #1 Serial cable interrupted Replace the control panel
B Communication failure Battery charge level very low Check relevant cables and
between the tiller card and Tiller card KO connections
the combi Control panel KO Check the battery
Replace the tiller card
EEPROM KO Possible cancellation of the Replace the control panel
13 Communication problem with EEPROM or defective
B the EEPROM, or reading error EEPROM
of the parameters during the
start up phase
PUMP ACC. NOT OK If the general contactor does not Check that the output of the
15 Lift potentiometer output close after switching on, the lift/lower pot. is correct at
B high without any lift/lower start up sequence may have rest
request been incorrectly carried out
16 MICRO CONTROL KO Logic unit not functioning Replace the control panel
B correctly
32 VMN NOT OK Value of the VMN at rest not the Replace the control panel
B Value of the armature same as the battery voltage Check that the motor is
voltage not correct Value of the VMN not operating correctly
decreasing as the PWM
increases during drive
CONTACTOR CLOSED General contactor faulty Check that the general
37 The general contactor is Control panel faulty contactor is opening
B stuck in the closed position correctly
when the truck is switched on Replace the control panel

Rev. 06/01 Code: 60424511 Page 32

MWP 14•18-1R
MWS 10•12-1R

MDI ALARM PROBABLE CAUSES CORRECTIVE ACTION

38 OPEN CONTACTOR No connection on the general Check the connections on
General contactor opened contactor the general contactor
by the logic unit The logic unit has opened the Check for any abnormal
general contactor because a current absorption
fault was detected
49 I TR. = 0 (EVER) Motor disconnected Check motor cables and
No traction current in drive Current sensor faulty connections
or braking Replace the control panel
HIGH I TR. ST. BY Current sensor reading Replace the control panel
53 Rotor current (drive or error
B braking) high at switch on or Abnormal current flow
with no drive request through the traction motor
57 HIGH FIELD CURRENT Current sensor reading error Replace the control panel
B Field current high at switch Abnormal current flow
on or at rest through the traction motor
NO FIELD CURRENT No connection on the Check the cables and
No field current with traction general contactor connections for the general
58 requested or in the Bad or no connection on contactor coil
B monitoring phase when the the field Check the field power
traction is idle cables and connectors
60 CAPACITOR CHARGE Possible short circuit on Check for short circuits on
B Capacitors not charging up the output the output
Traction motor armature Check the connections for
disconnected the traction motor
TH. PROTECTION The temperature of the Switch off the truck and
Thermal protection on the chopper ≥77 C (there will be allow the panel to cool until
62 pulse controller (chopper) a performance reduction) or the temperature is below
over 90°C ( the truck will be the limit
immobilised)
BATTERY LOW Battery discharged below Recharge the battery
67 Lift lockout with discharged safe limit
battery
CONTACTOR DRIVER Command circuit for the Check the operation of the
75 General contactor not general contactor faulty general contactor
B closing after the start up
phase
TR. ACC NOT OK The output from the traction Replace the potentiometer
78 Accelerator output not accelerator is higher than the Replace the logic card
B correct programmed value at rest Carry out the program VACC

Rev. 06/01 Code: 60424511 Page 33

MWP 14•18-1R
MWS 10•12-1R

MDI ALARM PROBABLE CAUSES CORRECTIVE ACTION

79 INCORRECT START The start up sequence was
Check that none of the
Start up sequence not not correctly carried out
following were in operation
correct when switching the There was a function at switch on
truck on or a function has requested at switch on 1. Tiller sensor (tiller down)
been activated at switch on 2. Traction or lift/lower
accelerator
3. Any tiller buttons
98 _______________________ Automatic update of the Wait for one minute
hours on the hour meter
with the hours in the combi
99 CHECK UP NEEDED It is necessary to carry out In the set options put the
servicing as per the CHECK UP DONE to ON,
programmed maintenance switch off the truck and
interval switch back on again

Rev. 06/01 Code: 60424511 Page 34

MWP 14•18-1R
MWS 10•12-1R

10 - OPTIONS

COMPOSITION TABLE OF THE OPTIONS

1) “OPT” indicates the kit required to be incorporated in the group to obtain the option required.
2) “ ❊ “ indicates that the option can be activated (via the program) with the UCB console.
3) “ ____ ” indicates that the option is not available.

MWS 10•12-1R MWP 14•18-1R

452006040
MDI display + hourmeter OPT OPT

452006040
Lift lockout with OPT/❊ OPT/❊
Discharged battery

452006030
Lift limit switch ______ standard
standard

452018600 MWP 14•18-1R

452118600 MWS 10•12-1R OPT/❊ OPT/❊
Tiller sensor always active
(inalca)

452149160
Lift/lower potentiometer OPT/❊ _______

CHARGER

Rev. 06/01 Code: 60424511 Page 35

COMMON DIAGRAMS AND MANUALS

COMMON DIAGRAMS

ATTENTION!
The table below describes the contents of the following diagrams.

• 452006026 Menu Diagram UCB97, MWP 14•18-1R - MWS 10•12-1R

• 452106010 Power Supply Cables and Plugs MWP 14•18-1R - MWS 10•12-1R

CONVERSION OF THE MODEL NAMES ON THE DIAGRAMS

TL2 ............................................................................................................... MWP 14•18-1R
CL2 ............................................................................................................... MWS 10•12-1R

Rev. 06/01 Code: 60424511

COMMON DIAGRAMS AND MANUALS

Rev. 06/01 Code: 60424511

COMMON DIAGRAMS AND MANUALS

Rev. 06/01 Code: 60424511

MWP14•18-1R DIAGRAMS

MWP 14•18-1R DIAGRAMS

ATTENTION!
The table below describes the contents of the following diagrams.

• Functional Hydraulic MWP 14•18-1R

• 452006004 Cable and Harness Layout MWP 14•18-1R
• 452006005 Electric Panel Connections MWP 14•18-1R
• 452006006 Main Wiring Harness MWP 14•18-1R
• 452006017 Activity Table MWP 14•18-1R
• 452006018 Functional Electrical MWP 14•18-1R
• 452049159 Tiller Connections MWP 14•18-1R

CONVERSION OF THE MODEL NAMES ON THE DIAGRAMS

TL2 ................................................................................................................ MWP 14•18-1R

Rev. 06/01 Code: 60424511

 FUNCTIONAL HYDRAULIC MWP 14•18-1R


  

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MWP14•18-1R DIAGRAMS

Rev. 06/01 Code: 60424511

MWP14•18-1R DIAGRAMS

Rev. 06/01 Code: 60424511

MWP 14•18-1R DIAGRAMS

Rev. 06/01 Code: 60424511

MWP 14•18-1R DIAGRAMS

Rev. 06/01 Code: 60424511

MWP 14•18-1R DIAGRAMS

Rev. 06/01 Code: 60424511

MWP14•18-1R DIAGRAMS

Rev. 06/01 Code: 60424511

MWS 10•12-1R DIAGRAMS

MWS 10•12-1R DIAGRAMS

ATTENTION!
The table below describes the contents of the following diagrams.

• 452105029 Functional Hydraulic Dpx/Tpx GAL MWS 10•12-1R

• 452106005 Cable and Harness Layout MWS 10•12-1R
• 452106006 Main Wiring Harness MWS 10•12-1R
• 452106007 Electronic Panel Connections MWS 10•12-1R
• 452106022 Activity Table MWS 10•12-1R
• 452106024 Functional Electrical MWS 10•12-1R
• 452149153 Tiller Connections MWS 10•12-1R

CONVERSION OF THE MODEL NAMES ON THE DIAGRAMS

CL2 ............................................................................................................... MWS 10•12-1R

Rev. 06/01 Code: 60424511

MWS 10•12-1R DIAGRAMS

Rev. 06/01 Code: 60424511

MWS 10•12-1R DIAGRAMS

Rev. 06/01 Code: 60424511

MWS 10•12-1R DIAGRAMS

Rev. 06/01 Code: 60424511

MWS 10•12-1R DIAGRAMS

Rev. 06/01 Code: 60424511

MWS 10•12-1R DIAGRAMS

Rev. 06/01 Code: 60424511

MWS 10•12-1R DIAGRAMS

Rev. 06/01 Code: 60424511

MWS 10•12-1R DIAGRAMS

Rev. 06/01 Code: 60424511

 Komatsu Division
Viale De Gasperi, 7
I-20020 Lainate (MI) ITALY
Tel: ++39 02 93765-1 - Fax ++39 02 93765-450
FORKLIFT TRUCK

MWP18-1R • MWP20-1R

60424511

I ED. 06/2001
REV. 05/2003

INTEGRATION TO
WORKSHOP MANUAL
(SERVICE BULLETIN - NEW ELECTRIC CONTROLLER)

KOMATSU FORKLIFT
 MWP18-1R MWP20-1R

! I.B.S. Instrument + Hour meter

The indicator – hour meter device:
• Indicates the operation time (driving or lifting) of the truck
0 1/2 1 expressed in hours.
B
• Indicates the battery charge status, by displaying it on a 10
1
coloured LED-bar.
A • Indicates that the switch key is turned into position “I” by
10

lightening the LED-bar.

• Stops lifting whenever the battery discharge status
reaches 80%.

1
A) Display hour meter:
10 Whenever the hour meter runs, the hourglass at the left side
of the display blinks (approx. 15 times per minute). The figures
Hourglass visualised are 5 plus one decimal figure. The numbering is
progressive starting with zero.

B) Led-bar indicator relevant to the battery charge status:

• When the battery is charged at 100%, the LED 10 is
lightened continuously. Whilst the battery is discharging,
the LEDs are lightened one by one from the right to the
left.
0 1/2 1 • Whenever the battery is discharged at 70%, both LEDs
1 and 2 blink at the same time, indicating that the
accumulator shall be recharged (low level).
2 4 6 8 10 • Whenever the battery is discharged at 80%, both LEDs
1 3 5 7 9 1and 2 blink alternatively, indicating that the lift lock
threshold is reached.
• The instrument has a fixed reset voltage threshold, i.e. the
1 – 2: red LEDs
3 – 4 – 5: yellow-orange LEDs
shift from the indication “battery completely or partially
6 – 7 – 8 – 9 – 10: green LEDs discharged” to the indication “battery completely charged”
occurs only provided the supplied voltage has a value
>25,1 V (value specified by the manufacturer).
So keep in mind, whenever replacing a discharged battery
with a partly charged battery (with voltage <25,1 V), that the
instrument does not indicates the battery charge status
change, but does keep in memory the previous one.

Ed: 06/2001
Rev: 05/2003 1/17
 MWP18-1R MWP20-1R

! Access compartment to the battery charge supply cable (as previous release)

A= Access window
B= Battery charger plug
C= Coiled cable
D= Battery charge status indicator light
B
C D

4.3.4.1 Battery charge status indicator light

It is a three-colour LED (red, green, yellow), responsible for indicating the battery charge
steps and any failure.

Battery charge steps

1) The red LED, steadily lightened indicates that the battery is at the
very beginning of the charge process.
2) The yellow LED, steadily lightened indicates that the battery has
reached 80% charge.
3) The green LED, steadily lightened indicates that the battery has
reached 100% charge.
In-between each step, the LED blinks before changing colour.
LED

4.3.4.2 Alarm indication

LED status Alarm Probable cause Corrective action

type
Green blinking Step 1 lasting more than Check the battery density.
Timeout permitted. Replace the battery, if faulty.
Replace battery charger.
Red and yellow Battery Output voltage control Replace battery charger.
blinking voltage loss (logistics fault)
Red and green Battery Output voltage control Replace battery charger.
blinking voltage loss (logistics fault)
Red, yellow Semi-conductor Replace battery charger.
and green Thermal temperature too high
blinking
Whenever alarms are actuated, the battery charger does not supply current.

Ed: 06/2001
Rev: 05/2003 2/17
 MWP18-1R MWP20-1R

! Traction controller
! Function sketch of the new series 4520

Emergency Button
-B +B
24Vdc Battery

Tiller card
Traction controller

F1 Power fuse

MOTOR S1 S2

B- M B+

Traction

Lift control relay 0 1/2 1

2K2 1
10

Lift solenoid starter

2K1 Fork arms lift end stroke sensor

Electromagnetic brake
Motor
Warning horn
Lifting
-B

Tiller position sensor

Polarity protective diode

Emergency button coil

Lowering On-Off valve

Pc with 1314 Service Software Console Emergency button micro-switch

Ancillary circuits protective fuse

Ed: 06/2001
Rev: 05/2003 3/17
 MWP18-1R MWP20-1R

! Traction controller's technical specification

Such controller governs solely the traction motor with maximum currents by 200 A. The logic
and power units are lodged within a well dust-, drillings- and small parts-proof container
(IP53 declared by the manufacturer). The power transistors (Mosfet) are fitted on two metal
"T"-shaped brackets fastened on the aluminium plate located beneath, thus ensuring a good
heat dissipation. The chopper is really small-sized.

Traction controller main features:

Status LED
• Rated supply voltage 24V D.C.
• Maximum current for traction motor 200A D.C.
• High-frequency MOS technology (Static).
• Different function configurations available, which can
be selected by means of the console and meet the
user's various demands.
• Traction motor's good efficiency guaranteed through
the high shift frequency of the MOSFET power
transistors.
• High-frequency silent operation.
• Complete troubleshooting by means of the console
and the inner status LED.
• Braking with power recovery thus enabling shorter
brake strokes, increasing the energy available for the
battery and reducing motor and brake overheating.
• Throughout protected inputs and short-circuit proof
outputs drivers.

6X2 X3

The following table contains a detailed list of the controller inputs and outputs relevant to the
connector X3:

Pin Name Input Outp. Functions

1 / / / Not used
2 Fault 1 ♦ -B LED failures 1
3 Fault 2 ♦ -B LED failures 2
4 Mcd ♦ -B emergency button coil
5 Pot high ♦ Not used
6 Pot wiper ♦ Traction potentiometer wiper middle position
7 Pot low ♦ Not used
8 Aux driver ♦ -B electromagnetic brake
9 Mode sel A ♦ A (B+) Mode selection
10 Belly ck ♦ Not used
11 Rev ♦ B+ Traction micro-switch on fork arms side

Pin Name Input Outp. Functions

12 Fwd ♦ B+ Traction micro-switch on operator's side
13 Belly ♦ B+ Tiller safety key micro-switch
14 Mode sel B ♦ B (B+) Mode selection
15 Ts ♦ (B+) Tiller selection
16 Key ♦ B+ Switch key

Ed: 06/2001
Rev: 05/2003 4/17
MWP18-1R MWP20-1R

The following table contains a detailed list of the controller inputs and outputs relevant to the
connector 6X2:

Pin Name Input Outp. Functions

1 Receive data ♦ Data reception signal
2 Ground ♦ B-
3 Transmit data ♦ Data transmission signal
4 Supply ♦ Supply +15 Vdc (100 mA)

The controller enables operation in four different modes:

• Mode 1 (M1)
• Mode 2 (M2)
• Mode 3 (M3)
• Mode 4 (M4)
In each of the four modes eight parameters can be set independently from each other:
1. Maximum actuation armature current (M1-M4 DRIVE C/L)
2. Acceleration value (M1-M4 ACCEL RATE)
3. Maximum brake current (M1-M4 BRAKE C/L)
4. Brake value (M1-M4 BRAKE RATE)
5. Deceleration value (M1-M4 DECEL RATE)
6. Maximum speed on operator's side (M1-M4 MAX FWD SPD)
7. Maximum speed on fork arms side (M1-M4 MAX REV SPD)
8. Speed restriction when descending down a slope (M1-M4 RESTRAINT)

For selecting the function mode operate on the inputs X3:9 and X3:14 as follows:

Explanation:
Open = Not connected
Closed = Connected to B+

Modes selection table

Function mode X3:9 Input "A" X3:14 Input "B" Used for
Mode 1 Open Open Inching
Mode 2 Closed Open High speed
Mode 3 Open Closed Not used
Mode 4 Closed Closed Not used

Ed: 06/2001
Rev: 05/2003 5/17
MWP18-1R MWP20-1R

! Troubleshooting by means of a PC
Use of the Software “1314 PC Programming Station at level “OEM”

Serial port

Interface sheath

Conn. P.F Conn. 6X1 Truck

4 poles Molex 4 poles Molex Harness

WARNING:
Only trained personnel may use the troubleshooting unit. Changing some parameters or
configurations might cause hazardous conditions for the operator. (E.g.: traction speed
increase).
Prior to running any operation, the program 1314 Programming Station at Service level shall
be installed in the PC (Personal Computer), by using the CD-ROM Service Level, Pt. No.
45203609501 to be ordered to the Spare Parts Department in Lainate.
PC minimum requirements:
• Pentium processor II 233
• MS-Windows 95/98/2000
• 64MB RAM
• 1 x free serial port

Perform the necessary adjustments for a proper truck’s operation by connecting the
connector 6X1 to the PC by means of the interface sheath Pt. No. 45203652500 to be
ordered to the Spare Parts Department in Lainate.

Carry out the following procedure:

• Connect the PC to the 4 pole Molex connector 6X1 coming from the
traction controller;
• Supply voltage to the truck and close the key contact;
• Click on the program icon

It needs some time for the window (1) to appear; in the meanwhile the following screenful
appears:

Ed: 06/2001
Rev: 05/2003 6/17
MWP18-1R MWP20-1R

Then the window 1 appears automatically:

Enter the menu “Options” and select “Service” in “User Group” as shown in the following
screenful:

Enter the menu “Options” and click on “Change Protocol/Port”

The following screenful appears:

Ed: 06/2001
Rev: 05/2003 7/17
MWP18-1R MWP20-1R

Set “serial” and click on “Connect”; wait for approx. 1 minute, as long as the screenful of the
main page appear:

Now the connection has been successfully performed.

! How enter the main menus

The program 1314 Programming Station contains several menus matched to many functions,
some of which are typical of programs running in MS-Windows Environment. It is hardly
possible to explain each function, so we are going to illustrate the main ones. However,
anybody interested in broadening his / her knowledge in this matter, can call the user
guidance “Help”.

For entering the main menus the click the icon with the mouse (first left key and then right
key) as shown in the next picture:

The following pull-down menu opens:

You can enter one of the main menus with a double click of the mouse. The menus are:
• Device Information
• Parameters
• Monitor Test Data
• Device Functions
• Diagnose

Ed: 06/2001
Rev: 05/2003 8/17
MWP18-1R MWP20-1R

! Device Information Menu

It provides information relevant to the traction controller

Ed: 06/2001
Rev: 05/2003 9/17
MWP18-1R MWP20-1R

! Parameters Menu
It leads to the traction controller’s adjustment parameters.

Click on the parameter you intend to change; the following screenful will appear:

A
B

Click on the push buttons “A” or “B” to increase or decrease respectively the parameter
value: Click on “OK” to acknowledge your selection.

Ed: 06/2001
Rev: 05/2003 10/17
MWP18-1R MWP20-1R

! Monitor Test Data Menu

This menu allows displaying the currently monitored amplitudes.

! Device Functions
This menu is currently empty, as shown in the picture below:

! Diagnose
This menu allows displaying the current alarms (System Fault Monitor) as well as the alarms
stored (Device Fault History) and deleting them (Clear).

! System Fault Monitor

Click on the System Fault Monitor Menu; the current alarms are displayed, as shown in the
picture below:

Ed: 06/2001
Rev: 05/2003 11/17
 MWP18-1R MWP20-1R

! Device Fault History

Click on the Device Fault History menu; the stored alarms are displayed, as shown in the
picture below:

Click on the alarm, and you will get further information on it, as shown in the picture below:

! Clear
It might be useful to delete the failures history after reading it. For this purpose select
“Clear” (in the pull-down menu) appearing whenever clicking with the right mouse key in the
menu Device Fault History, as shown in the picture below:

You will be asked to confirm you entries.

Ed: 06/2001
Rev: 05/2003 12/17
 MWP18-1R MWP20-1R

! Program Menu
The Program Menu contains all adjustable parameters displayed together with their
adjustments.
The CD at Service level provides the following adjustable parameters:
Name Meaning Value
M1 –M2 – M3 - M4 The time needed for the controller to increase Min = 0,1 sec.
ACCEL RATE the motor actuation output from 0 to 100% in Max = 3 sec.
the function modes 1 –4.
M1 –M2 – M3 - M4 The time needed for the controller to reduce to Min = 0,1 sec.
DECEL RATE zero the motor actuation output whenever the Max = 10 sec.
acceleration demand decreases from 100% to
zero in the function modes 1 – 4.
THROTTLE DECEL The time needed for the controller to interrupt Min = 0,1 sec.
voltage supply to the brake (friction braking) Max = 1 sec.
whenever the gear engaged is released.
M1 –M2 – M3 - M4 The time needed for the controller to increase Min = 0,1 sec.
BRAKE RATE the brake current from 0 to 100% when Max = 3 sec.
reversing in the function modes 1 - 4
QUICK START The algorithm for high-speed start up, applied Min = 0
whenever the accelerator passes through a Max = 10
neutral position and the controller is not
shifted in the brake mode. The controller
increases temporarily its normal acceleration
value in order to prevail on the truck inertia.
The value increase makes the truck
acceleration reaction to the accelerator rapid
movements quicker.
TAPER RATE It determines how rapid the vehicle reverses Min = 1
its drive direction whenever the opposite Max = 20
direction is selected. For this purpose the
value needed for the field to change its
polarity shall be set. Low taper rate values
determine a rapid polarity change, causing
fast and abrupt reverse cycles. Higher values
determine a more gradual field polarity
change, causing slower and smoother reverse
cycles.
M1 –M2 – M3 - M4 Maximum traction speed with travel direction Min = 0 %
MAX FWD SPD toward the operator in the function modes 1 – Max = 100 %
4.1 - 4
M1 –M2 – M3 - M4 Maximum traction speed with travel direction Min = 0 %
MAX REV SPD toward the fork arms in the function modes 1 – Max = 100 %
4.1 - 4

Ed: 06/2001
Rev: 05/2003 13/17
MWP18-1R MWP20-1R

Name Meaning Value

CREEP SPEED Minimum traction motor speed at the Min = 0 %
minimum accelerator revolution. Max = 25 %
THRTL DEADBAND Accelerator dead area, i.e. the accelerator
field detected through the controller as neutral Min = 0 % (0,2V)
area before the governing area. Max = 40 % (2V)
THROTTLE MAX Accelerator voltage rate needed to ensure a Min = 60 % (3V)
100% output on the motor. Max = 100 % (5V)
THROTTLE MAP It is the PWM value expressed as percentage, Min = 20 %
relevant to the traction motor output with an Max = 80 %
accelerator working stroke by 50%,
AUX TYPE It determines the negative ancillary driver for
the electromagnetic brake:
0. Disabled
1. Enabled depending on the tiller sensor
command. Min = 0
2. Enabled depending on the tiller sensor Max = 5
command + drive acknowledge + belly
(Switch on + off).
3. As point 2
4. Enabled depending on the tiller sensor
command and switch off through belly.
5. Enabled depending on the tiller sensor
command + drive acknowledge + belly
acknowledge.

Ed: 06/2001
Rev: 05/2003 14/17
 MWP18-1R MWP20-1R

! Monitor Menu
In the Monitor menu current information on the inputs, outputs and controller temperature are
displayed.
It is useful to check the controller for proper function whenever installation for the first time,
and to detect and solve any problem.
The values displayed depend on the battery status as well as the operations performed
through the truck just in that moment; for this reason in the table a symbolic value ## plus the
corresponding measurement unit are indicated. As far as ON and OFF are concerned, it is
understood:
• ON, the corresponding function is enabled.
• OFF, the corresponding function is disabled.

Name Description Displayed

value
THROTTLE Voltage value relevant to the traction potentiometer in ##%
% in respect to the max. value.
FIELD CURRENT Traction motor field current value. ##A
ARM CURRENT Traction motor armature current value. ##A
FIELD PWM Duty cycle applied to the motor field in %. ##%
ARM PWM Duty cycle applied to the motor armature in %. ##%
BDI % Amplitude relevant to a peculiar function.
LOAD VOLTAGE Amplitude relevant to a peculiar function.
BATT VOLTAGE Battery voltage. ##V
Ω
MOT RES x 10mΩ Amplitude relevant to a peculiar function.
HEATSINK Heat sink temperature in °C. ##C°°
TOT SRVC X25 Amplitude relevant to a peculiar function.
+TOT SRVC Amplitude relevant to a peculiar function.
TRAC SRVC X25 Amplitude relevant to a peculiar function.
+TRAC SRVC Amplitude relevant to a peculiar function.
FORWARD INPUT Traction switch status on operator’s side. ON / OFF
REVERSE INPUT Traction switch status on fork arms side. ON / OFF
MODE INPUT A “A” Input status for selecting function mode. ON / OFF
MODE INPUT B “B” Input status for selecting function mode. ON / OFF
INTERLOCK Tiller sensor input status. ON / OFF
EMR REV INPUT Tiller safety key input status. ON / OFF
MAIN CONT Emergency button coil output driver status. ON / OFF
AUX DRIVER Electromagnetic brake output driver status. ON / OFF
SYS MODE Amplitude relevant to a peculiar function. 0-6

! Faults Menu
In the Fault Menu the failures currently detected by the controller (“System Faults”) as well
as the failures of the past ("Fault History") are displayed.
The failures are displayed by means of a code and a descriptive text. Whenever several
failures are displayed, scroll the list up and down with the relevant arrow keys.
It is useful to delete the failures history after reading it. For this purpose select “Clear Fault
History”.
You will be asked to acknowledge your entries. Use the (+) arrow for increasing (yes) and the
(-) arrow for deleting.

Ed: 06/2001
Rev: 05/2003 15/17
 MWP18-1R MWP20-1R

! Alarms (displayed by PC in the “System Fault Monitor” Menu)

The alarm is inhibiting whenever it does not allow the main solenoid starter close when
switching on, and when it makes the main solenoid starter open during the truck’s operation.

ALARM PROBABLE CAUSES CORRECTIVE ACTION

MODE INTERRUPT Function mode shift Release the throttle to restore the traction
(Not inhibiting, but from Mode 1 to Mode 2 mode.
traction not or vice-versa.
permitted).
FIELD SHORT Motor field or main Check the solenoid starter coil and the field
(Inhibiting) solenoid starter coil connections and replace any faulty
short-circuited. component.
Filed resistance too low.
CURRENT SHUNT Current sensor fault. Restart the truck; if the alarm remains
FAULT active replace the system.
(Inhibiting)
EMR REV CHECK Belly key already Perform current sequence.
(Inhibiting) depressed when starting Check the micro-switch status.
or before tiller has given Check the tiller sensor status.
acknowledge. Replace any faulty component.
FIELD OPEN Field wires detached. Check the motor harness and the field
(Inhibiting) resistance.
HPD Incorrect sequence Perform current sequence:
(Not inhibiting but when starting the truck 1. Key
traction not or actuating any 2. Tiller sensor
permitted). function. 3. Forward or reverse drive micro-switch.
4. Accelerator potentiometer.
If the alarm remains active replace the
faulty components.
HW FAILSAFE Troubleshooting circuit Restart the truck; if the alarm remains
(Inhibiting) faulty active replace the system.
LOW BATTERY Battery voltage too low: Check battery status. Try and recharge
VOLTAGE < 17V battery. If the alarm remains active replace
(Inhibiting) the battery.
M - SHORTED Incorrect wiring. Check the wiring and repair it, if necessary.
(Inhibiting) Controller short-circuited If the alarm remains active replace the
internally. system.
MAIN CONT Main solenoid starter Check the main solenoid starter for status
WELDED sticking when starting. and replace it if faulty.
(Inhibiting when
starting)
MISSING Solenoid starter coil Check the wiring and repair it if required.
CONTACTOR open when starting. Check the main solenoid status for status;
(Inhibiting) replace it if faulty.
CURRENTLY NO No failure existing.
FAULTS
OVERVOLTAGE Battery voltage too high: Battery incorrect. Connect to a 24V battery.
(Inhibiting) >30V

Ed: 06/2001
Rev: 05/2003 16/17
MWP18-1R MWP20-1R

ALARM PROBABLE CAUSES CORRECTIVE ACTION

SRO Incorrect sequence Perform current sequence:
HPD when starting the truck 1. Key
(Not inhibiting but or actuating any 2. Tiller sensor
traction not function. 3. Forward or reverse drive micro-switch.
permitted). If the alarm remains active replace the
faulty components.
THERMAL Traction speed If the temperature is too high, switch the
CUTBACK reduction caused truck off and keep it in stand-by, as long as
through controller the temperature is decreased under the
temperature too high: limit.
+85°C or too low: -25 °. If the temperature is too low, check
whether the controller heating kit is
provided and it does function properly.
Replace whenever faulty

Ed: 06/2001
Rev: 05/2003 17/17
 1 2 3 4 5 6 7 8 9 10 11 12

4H1

Q1 S2 Q1 2K1 S1 6P1 6P2 2Y2 2X1 nk21

6 5 4 3 1 4 1 2 6X3 2X1 :0 :1 :2 :3 50 W [16] 25 1
3 :1 :2 :3 :4 :5 :6 :7 :8 6X1 :1 :2 :3 :4 30 nk13a
A 3 A
lm8 lf4 nf4a 1 2 1 50 4H1

nk13a
nk13a
nk13a

nk13a

nk13a

nk13a

nk13a

nk13a
nk8a
nk21
50 W [49] 49 2
nk13a

.
54

45

35
52

55
56
57
58
38

17

41

42

42

44

20

46

21
28

27
48
V1

19

40
Vista montaggio

W[3 8]

W[1 6]

W[4 1]

W[4 2]

W[1 6]

W[4 4]

W[1 8]

W[4 0]
per fornitore

W[5 5]

W[5 6]

W[5 7]

W[5 8]
W[4 6]

W[1 6]

W[4 8]
W[4 2]

W[1 8]

W[4 5]

W[4 6]

W[3 2]

W[1 5]

W[1 8]
nk21

nk21

nk21

nk21

nk21

nk21
30

nk21

nk21
1 70 50 W [16] 26

0 4]
. :1 V1

50
50
W[4
50

50
50
50
50
50 W [18] 18

50

70
nd5

50

50

70

50

50

50
50
50
50
50
50
50
5
. :2

F2

30

50
B B

30

30

50
7S1

2K1

2 60
S1

50
X4 30
:1 1 70 50 W [41] 41 . :1 F2
lm16
:2 50 W [40] 40 ns5 + nsh
. :2

5 80
:3
:4 4 W [4] 50 1 60
:5

5 50
47 54 46 Saldatura
:6 6 W [6] 50 45 50 W [44] 44 :30 2X2
:7 9
1 70 50 W [9] :85 rf5b
C :8 8 W [8] 50 Saldatura Saldatura Saldatura Saldatura Saldatura C
50 45 :86
30 30 2 00 1 40 2 50 W [45]
2K2
A1 :9
50 37
W [32] :87
:10
16 18 31 15 22
:11 12 W [11] 50
17 19 32 50 23
:12 11 W [12] 50
27 20 33 51 24
:13 13 W [13] 50 50 W [16] 24 X5
29 21 34 52 25 :1
:14 14 W [14] 50 35 53 26 50 W [32] 33
:2
:15 15 W [15] 50 36 28 50 W [49] 49 sf16
:3
:16 16 W [16] 50 37 29
:4
30 50 W [48] 48.
:5
1 50
D 50 W [46] 47
:6 D
50 W [15] 51 :7
6X2
lm4 55 W [55] 50 50 W [13] 13
:8
:1
56 W [56] 50 50 W [12] 12
:9
:2
A1 57 W [57] 50 1 20 50 W [11] 11
:3 :10
58 W [58] 50 50 W [6] 6
:4 :11
50 W [14] 14
:12
A1 32 W [32] 50 50 W [16] 30
nk8a :13
50 W [32] 36
:14
-B

:15
.
E :16 E
.

X3
50 31
N° Sezione Colore N° Sezione Colore
W [32]
:1 sf10
50 W [9] 9
1 ... ... 30 1x0.5 RD :2
50 W [15] 53
2 ... ... 31 1x0.5 BK :3
50 W [8] 8 :4
3 ... ... 32 1x1 BK 2 50 50 W [16] 22
4 1x0.5 BN 33 1x0.5 BK :5
50 W [32] 34
:6
F 5 ... ... 34 1x0.5 BK
50 W [15] 50
F
6 1x0.5 GN 35 1x0.5 BK :7
50 W [16] 23
7 ... ... 36 1x0.5 BK :8
50 W [4] 4
:9
8 1x0.5 YE 37 1x0.5 BK
50 W [38] 38
9 1x0.5 OG 38 1x0.5 OGWH :10

10 ... ... 39 ... ... 2B1, 7K1, 7B1, Y1

11 1x0.5 WH 40 1x1 RDYE
12 1x0.5 VT 41 1x1 RDGN
13 1x0.5 GY 42 1x1 YEGY
14 1x0.5 VTWH 43 ..... .... A 27.01.03 R.V. Modifica funzionale sollevamento 301566
G 15 1x0.5 YEBU 44 1x0.5 WHRD Data Cont. Modifica CID fit Toler. G
16 1x1 RD 45 1x0.5 BNWH Quote di verifica Materiale :
Peso
17 1x0.5 RD 46 1x0.5 OGBK Quote ausiliarie Codice grezzo :
18 1x1 RDBK 47 1x0.5 OGBK Data Nome in kg
Denominazione
19 1x1 RDBK 48 1x0.5 GYGN Dis. 26.09.02 R.V.
20 1x0.5 RDBK 49 1x0.5 YEBK Cont. Complessivo serie di cavi Status :
21 1x0.5 RDBK 50 1x0.5 YEBU Approv.
.
22 1x0.5 RD 51 1x0.5 YEBU Manuf.
.
23 1x0.5 RD 52 1x0.5 YEBU Stds. Scala :
24 1x0.5 RD 53 1x0.5 YEBU

Numero disegno
H 25 1x0.5 RD 54 1x0.5 OGBK 45203801001 H
26 1x1 RD 55 1x0.5 GNBK
27 1x1 RD 56 1x0.5 BUWH Requisiti a norma WN 22465 - TG grossolana S Foglio: 1

28 1x0.5 RD 57 1x0.5 GYYE :A : di :1

Lingua : Italiano Documento riservato
29 1X1 RD 58 1x0.5 BNYE
Protezione secondo DIN34 Sost. Orig.
1 2 3 4 5 6 7 8 9 10 11 12
 TRASLATION page: 1/1

Drawing No. 45203801001

Colore = Colour

Complessivo serie di cavi = harness assembly

Modifica funzionale sollevamento = Lift function modification

N° = Number

Requisiti a norma WN 22465 - TG grossolana = Requirements in compliance with factory standard WN 22465 - GENERAL ALLOWANCE rough

Saldatura =Welded joint

Sezione =Section

Vista montaggio per fornitore = Assembly view for supplier

 TRASLATION page: 1/1

Drawing No. 452049171

COD. = PART NUMBER

EMESSO PER PRODUZIONE = ISSUED FOR PRODUCTION

LATO INFERIORE = BOTTOM SIDE

LATO PULS. BELLY = BELLY KEY SIDE

LATO SUPERIORE = TOP SIDE

LEVA TRAZIONE = TRACTION LEVER

MICRO SICUREZZA INVERSIONE (BELLY) = REVERSE SECURE MICRO-SWITCH (BELLY)

PREMERE = PRESS

PULS. CLAXON= HORN KEY

PULS. DISC. SX SUP. = LEFT TOP LOWERING KEY

PULS. M. LENTA DX INF. = RIGHT BOTTOM INCHING KEY

PULS. M. LENTA SX INF. = LEFT BOTTOM INCHING KEY

PULS. SOLL. DX SUP.= RICHT TOP LIFT KEY

SCHEMA FUNZIONI TIMONE CON PULS. MARCIA LENTA = TILLER FUNCTIONS DIAGRAM WITH INCHING KEY
 TRASLATION

Drawing No. 45208020000

EMESSO PER PRODUZIONE = ISSUED FOR PRODUCTION

 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

BK 1x25 YEGY 1x1

1x0.5
RD 1x0.5
Circuito in
7B1 Y1 2B1 Sigla Funzione corrente

RD
4H2

I
A B 6P2 A

1x0.5
:1 A1 Controllo elettronico trazione CURTIS 3-12, 26-41

NO

NO
RD 1x0.5
:1 :1

O
+

+
-

-
:1 :3 :5 2Y2 A2 Scheda timone 34-53

BN

BU

BN

BU
BK

BK
RD 1x6
V1 2B1 Sensore di finecorsa sollevamento 33-37

3
1
2

RD
RD
Q1 S2 Q1 7K1 7B1 Sensore di prossimità timone (uomo morto) 28-31

1x0.5
7S1

BK1 1x0.75

BK3 1x0.75
BK2 1x0.75
:2
F1 Fusibile sicurezza marcia - sollevamento 12

RDBK 1x1 RDBK

:2

RD
:2 :4 :6 :2 F2 Fusibile sicurezza contr.elettr., sch.timone, ausil. 13

1x1

RD
1x1
9F1 Interruttore termico a bimetallo 28

:4
:3
:2
:1
G1 Batteria 1

BK 1x0.35
RD 1x0.35
GN 1x0.35
YE 1x0.35
:10
1x25

:9
:8
:7
:6
:5
:4
:3
:2
:1
G2 Raddrizzatore 3-6

:3

:1
:2
RDGN
B B

BK
:1 4H1 Avvisatore acustico 46
:1 X3 2X1
G2 :1 :2 :3 :4 X0 :1 X3 2X1 B 4H2 Segnalatore a LED tre colori 4
2K1 Teleruttore sollevamento 20

:2
:4
:3

:1
F1 F2 2K2 Relè sollevamento 21-23

:10
S1 7K1 Relè di presenza rete 27-28

:9
1x0.5 :8
:7
:6
1x0.5 :5
:4
1x0.5 :3
:2
:1

:3

:2

:1
:2
7K1 :2 :2 6X1
RDYE 1x1 1M1 Motore trazione 13-18

1x0.5
OGWH 1x0.5 6X1

1x0.5
1x0.5
C 2M1 Motore sollevamento 20 C

:4
:3
:2
:1
6P1 Contaore CURTIS+blocco sollev. batteria scarica 54-59

1x0.5
1x0.5
6P2 Console CURTIS 54-57

BUWH 1x0.5
GNBK 1x0.5
BNYE 1x0.5
GYYE 1x0.5
BK 1x6
:1 Q1 Sezionatore 12
1x6

YE 1x0.5
BK

:4 BN1x0.5

+24V
:15 YEBU
X2

1x0.5
1x16
230 1R1 Potenziometro trazione timone 50

BK
4H1 9R1 Resistenza per cella frigorifera -30*C 28

:16

:4
:3
:2
:1
:9
S1 Interruttore a chiave 18

:8
D 6X2 D
X4 S2 Microinterruttore 13
A1 :2

2
A1 1S4 Microinterruttore trazione FWD 51

OG1X0.5
B + BK 1x16 1 1
X1:1 1S5 Microinterruttore trazione RWD 52

YEBU
B-
A1 1S6 Microinterruttore 53

3
BK
1S7 Pulsante marcia lenta 37
D D S

1M1 :1 :3
G
S
G
S
G
D A1 1S8 Pulsante marcia lenta 40
1V22-23 1V26-27 1V1-9 MG

2C1-7 2K1 2S1 Pulsante sollevamento forche 43-44

:10

:14

:12
:11
:13
E 2S2 Pulsante sollevamento forche 46 E

:1
:2
:3
:5
:7

:6
2S3 Pulsante discesa forche 48-49

1x0.5

1x0.5
M- A2 F1 F2

VTWH 1X0.5
1x0.5
1x0.5
1x0.5
1x0.5
G1 :2 :4 2S4 Pulsante discesa forche 49-50

RDBK1x0.5

1x0.5
S1 BK 1x4 . . .

WHRD1x0.5

GYGN

YEBK

RDBK
S2 BK 1x4 4S1 Pulsante avvisatore acustico 50-51

WH

GY
VT
GN
YEBU 1x0.5
7S1 Pulsante arresto di emergenza 12-16
D D D
7S2 Pulsante di sicurezza timone 53-54
2K2

1x0.5
G G G
OGBK 1x0.5
S S S 2X2:30 2X2:85 RD
F
1V24-25 1V28-29 1V10-21 V1 Diodo 18 F
BK
X1:2

:11x0.5
:141x0.5
:131x0.5

:21x0.5
XA Connettore MOLEX 12 poli 35-48

1x0.5
1x0.5
1x0.5
BNWH1x0.5
XB Connettore DUFLEX DUBOX 7 poli 49-53

:16
:15

:12
:11
:10
:9
:8
:7
:6
:5
:4
:3
B- XC Piazzole 35
2X2:87 2X2:86
BNWH XD Cavi saldati senza connettore 53-54
X5 XE Connettore AMP 2 poli 35-37
1X0.5
X5 XF Connettore AMP 2 poli 38-40
XG Connettore AMP 2 poli 41-44

:8
:7
:6
:5
:4
:3
:2
:1
XH Connettore AMP 2 poli 45-47
RD 1x7

:16
XI Connettore AMP 2 poli 47-49

:15
:14
:13
:12
:11
:10
:9
:8
:7
:6
:5
:4
:3
:2
:1
G G
6X3 XL Connettore AMP 2 poli 49-50
6X3 XM Connettore AMP 2 poli 50-51

BK 1x0.5
RD 1x0.5
XN Connettore DUFLEX DUBOX 4 poli 51-53

BK12 1x0.5
BK11 1x0.5
BK10 1x0.5
BK9 1x0.5
BK8 1x0.5
BK7 1x0.5
BK6 1x0.5
BK5 1x0.5
BK4 1x0.5
BK3 1x0.5
BK2 1x0.5
BK1 1x0.5
XO Connettore MOLEX 12 poli 35-48
B X0 Connettore MOLEX 4 poli 4
X1 Connettore batteria 1
-HRM

h
X2 Spina SCHUKO 2P+T 16A 250V 6-9
X3 Connettore SAAB 10 poli 27-36

:12
:11
:10
:9
:8
:7
:6
:5
:4
:3
:2
:1
M +HRM X4 Connettore MOLEX 16 poli 27-41
H 2M1 H
X5 Connettore SAAB 16 poli 31-48

BK
XO
XO 2X1 Connettore DIN 43650-PG9 40-48
6P1 2X2 Connettore MTA 5 poli 21-23
1R1 1S4 1S5 1S6 6X1 Connettore MOLEX 4 poli 54-57
6X2 Connettore MOLEX 4 poli 54-58
:12
:11
:10
6X3 Connettore MOLEX 8 poli 54-58

:1
:9
:8
:7
:6
:5
.4
.3
:2
Y1 Freno elettromagnetico 33
BK1x0.5

7S2
1x25
1x25

2Y2 Elettrovalvola discesa forche 44

BK

1x7
BK

I I
BK

9R1 XA XB
2

XC A2 XD
2

9F1 XE XF XG XH XI XL XM XN

J J
1

1S7 1S8 2S1 2S2 2S3 2S4 4S1

BK1x0.5

B- B 28.02.03 A.G. Introdotto LED batteria in carica 301512

Data Cont. Modifica CID fit Toler.
K Quote di verifica Materiale :
Peso K
Quote ausiliarie Codice grezzo :
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 43
41 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Data Nome in kg
Denominazione
42 Dis. 16.09.02 R.V.
Cont. Schema di collegamento Status :
Approv. elettrico
Manuf.
Stds. . Scala :

Numero disegno
45208020001
L L
S: Foglio: 1
Disegno a norma WN 10-754
Lingua Documento riservato A: di 1
: :
Italiano Protezione secondo DIN34 Sost. Orig.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
 TRASLATION page: 1/3

Drawing No. 45208020001

(uomo morto) =(deadman)

Avvisatore acustico = Warning horn

Batteria = Battery

c. pot. soll. = Lift potentiometer wiper

c. pot. trazione = Traction potentiometer wiper

Clacson = Horn

Console CURTIS = CURTIS CONSOLE

Contraore CURTIS+ blocco sollev. batteria scarica = CURTIS Hourmeter+ lift block system with disharged batetry

Controllo elettronico trazione CURTIS = CURTIS Electronic traction controller

Diodo = Diode

Elettrovalvola discesa forche = Fork arms lowering solenoid valve

Freno elettromagnetico = Electromagnetic brake

Funzione = Function

Fusibile sicurezza contro. elettr. sch. timone, ausil. = Electronic controller, tiller card, ancillary users safety fuse

Fusibile sicurezza marcia - sollevamento = Traction - Lift safety fuse

 TRASLATION page: 2/3

Drawing No. 45208020001

ingr. belly = Belly input

ingr. c. pot. traz. = Traction potentiometer wiper input

ingr. chiave = Switch key input

ingr. FWD = FWD input

ingr. RWD = RWD input

ingr. sens. timone (uomo morto) = Tiller sensor input (deadman)

Interruttore a chiave = Switch key

Interruttore termico a bimetallo = Bimetal thermal switch

micro FWD= FWD micro-switch

micro RWD = RWD micro-switch

Motore sollevamento = Lift motor

Motore trazione = Traction motor

out/dig Discesa = out/dig Lowering

out/dig soll. = out/dg Lifting

Pulsante arresto di emergenza = Emergency stop key

 TRASLATION page: 3/3

Drawing No. 45208020001

Raddrizzatore = Battery charger

Relè di presenza rete = Network relay

Relè sollevamento = Lift relay

Resistenza per cella frigorifera -30 °C = Resistance for cold storage -30 °C

Scheda timone = Tiller card

Segnalatore a LED tre colori = three-colour LED indicator

Sensore di finecorsa sollevamento = Lift end stroke position sensor

Sensore di prossimità timone (uomo morto) = Tiller proximity sensor (deadman)

Sigla = Identification

Teleruttore sollevamento = Lift solenoid switch

usc. freno = Brake output

usc.puls. emergenza = Emergency key output

 1 2 3 4 5 6 7 8 9 10 11 12

A 7S1 A

9R1
7K1
6P1

9F1
2Y2
4H1 2K1
4H2
F2 X4 +HRM

V1 A1 usc.puls.emerg. h
(MAIN CONT.DRIVER) :4
B B -HRM B
ingr.chiave
(KEYSWITCH) :16
A2

1
2
3
4
5
6
7
8
S1 (MODE SEL.2) :9

(EM.REV.CHECK) :10 :3 clacson

(POT LOW) :7 Y1 :5 out/dig discesa

non utilizzato :1 :6 out/dig soll.

F1 soft working
G2 B+ (MODE SEL. 1) :14 :12 soft working
C usc.freno :1 C
(AUX.DRIVER) :8 +24V
7K1 ingr.RWD
(REVERSE) :11 :9 micro RWD
G1 2K1
ingr.FWD
(FORWARD) :12 :10 micro FWD
ingr.belly
(EM.REVERSE) :13 :8 belly
ingr.c.pot.traz.
1M1 S1 (POT WIPER) :6 :11 c. pot. trazione
2M1
(POT HIGH) :5 :2 B-
+ +
M M ingr.sens.timone(uomo morto) I I
(INTERLOCK) :15 O 7B1 O 2B1 :4 c. pot. soll.
230 a.c.
D - -
D
(FAULT 2) :3 NO NO
:7 soft working
S2 (uomo morto)
M- (FAULT 1) :2

B-

6X2 :1 1

:2 2
2K2
:3 3
E E
:4 4

6P2

Sigla Funzione
F F
A1 Controllo elettronico trazione CURTIS
A2 Scheda timone
2B1 Sensore di finecorsa sollevamento
7B1 Sensore di prossimità timone (uomo morto)
F1 Fusibile sicurezza marcia - sollevamento
F2 Fusibile sicurezza contr.elettr., sch.timone, ausil.
9F1 Interruttore termico a bimetallo
G1 Batteria
G2 Raddrizzatore B 28.02.03 A.G. Introdotto LED batteria in carica 301512
G 4H1 Avvisatore acustico Data Cont. Modifica CID fit Toler. G
4H2 Segnalatore a LED tre colori B Quote di verifica Materiale :
Peso
2K1 Teleruttore sollevamento Quote ausiliarie Codice grezzo :
2K2 Relè sollevamento Data Nome
Denominazione in kg
7K1 Relè di presenza rete Dis. 16.09.02 R.V.
1M1 Motore trazione Cont. Schema di collegamento Status :
2M1 Motore sollevamento Approv. elettrico
6P1 Contaore CURTIS+blocco sollev. batteria scarica Manuf.
6P2 Console CURTIS Stds. Scala :
9R1 Resistenza per cella frigorifera -30*C

Numero disegno
H
S1 Interruttore a chiave 45208020002 H
7S1 Pulsante arresto di emergenza Foglio: 1
V1 Diodo S:
Disegno a norma WN 10-754
Y1 Freno elettromagnetico Lingua Documento riservato A: di 1
2Y2 Elettrovalvola discesa forche : :
Italiano Protezione secondo DIN34 Sost. Orig.
1 2 3 4 5 6 7 8 9 10 11 12
 TRASLATION page: 1/1

Drawing No. 45208020002

Introdotto LED batteria in carica = Introduced LED for charging battery

Schema di collegamento elettrico =Electric wiring diagram

 1 2 3 4 5 6 7 8

A 0A2 A

DN8 0Z2
B B

0Z4
300µ TABELLA DI VERITA'
C C
0V1
2Y2 SEQUENZA DI ATTIVAZIONE
FUNZIONE
MOTORE-POMPA 2Y2

0V3
SOLLEVAMENTO FORCHE ON OFF

DISCESA FORCHE OFF ON

D D
+
0P1
+24 V M 0.75cm3/t
0V2 0V4
- 2.4MPa
0A1 (240bar)
24V 1.2kW 0 26.09.02 A.G. Emesso per produzione 301478
S3=10% Data Cont. Modifica CID fit Toler.
112 242 0Z3 Materiale :
E 450µ
Quote di verifica Peso E
Quote ausiliarie Codice grezzo :
in Kg
Data Nome
Denominazione
Dis. 09.09.02 A.G.
Cont. Schema di collegamento Status :
Approv. idraulico
0Z1 Manuf. .
0.75dm3 Stds. Scala :

Numero disegno
45208020200
F F
S Foglio: 1
:A : di :1
Lingua : Italiano Documento riservato
Protezione secondo DIN34 Sost. Orig.
1 2 3 4 5 6 7 8
 TRASLATION page: 1/1

Drawing 45208020200

Discesa forche = Fork arms lowering

EMESSO PER PRODUZIONE = ISSUED FOR PRODUCTION

Funzione = Function

Motore-pompa = Pump-motor

Scheda di collegamento idraulico = Hydraulic connection diagram

Sequenza di attivazione = Actuation sequence

Sollevamento forche = Fork arms lifting

Tabella di verita' = Matching table