Manual Cinta Charlatte

TECHNICAL MANUAL
Use/Maintenance,
Spare Parts and Drawings
CBL 150 48V
Customer: LESMA
AR : 127849 Serial N°: 322 to 323
Vers. 00
POUR NOUS CONTACTER
CONTACT US AT
CHARLATTE MANUTENTION
Z.I. Route du Boutoir
89210 BRIENON SUR ARMANCON
FRANCE
S.A.V. : Tél. 03 86 43 04 55
After Sales & Tech. Dpt : +33 386 430 455
Sce Commercial France : Tél. 03 86 43 04 54

Export Dpt : +33 386 430 453
Fax : 03 86 43 04 66
Fax : +33 386 430 466
CHAPTER 1
GENERAL INFORMATION
89210 Brienon sur Armançon
FRANCE
Tél : (33) 03 86 43 01 30
CHAPITRE 2 : SPECIFICATIONS ET DESCRIPTION
CHAPTER 2 : SPECIFICATIONS AND DESCRIPTION
1.1 – WARRANTY PROCEDURE

The tractors are covered by a 12 months warranty period or 800hrs, 1st term reached. This
warranty does not include maintenance parts or operations. Warranty acceptance will be
given by CHARLATTE on receipt of the claim, or after damaged parts are examined by our
services or supplier.
Each warranty claim (to be sent by mail or fax) must mention the following info:
- tractor’s serial No and hourmeter
- failure description
- part refs and description if any needed
The parts will be sent with a warranty ref, together with a delivery note. Damaged parts will
have to be sent back to CHARLATTE within 15 days after delivery of replacement ones,
together with the delivery note (we can eventually give you our TNT account No for the return
costs).
Parts must not be thrown away or destroyed without our agreement. Damaged parts will be
examined, and should examination reveal a mis-use or normal wearing, replacement parts will
be charged to you, together with freight costs for shipment and return of parts (a report of
examination will be sent to you).
In any case, customer must not dis-assemble tractor or any of its sub-assembly without prior
agreement from CHARLATTE. Dis-assembling a sub assembly will bring to a warranty refusal.
In any case, a warranty request must be sent BEFORE any work is done on the unit. Should we
be informed of a breakdown repair after the job has been done, then warranty will not apply,
and customer will bare the costs. We will give you a warranty ref as soon as your request is
made, and this ref will have to be mentioned on the technical report. The report of labor must
be sent to us BEFORE INVOICING, for approval.
1.2 - OPTIONS:
- with handbrake
1.3 - VARIATEUR DE TRACTION / DRIVE AND BELT CONTROLLER
02/10/2007
N°Var 632T86305
Logique 662T86305
1.1.1 Trac Pers IMAX 500A

1.1.1a Trac Stat BELTIMAX 80A Munich
1.1.2 Trac Pers Accel 3,5s
1.1.2b Trac Stat BELT SPD1 25%
1.1.2c Trac Stat BELT SPD2 50%
1.1.2d Trac Stat BELT SPD3 90%
1.1.2e Trac Stat BELT Accel 1,5s
1.1.2f Trac Stat BELT Decel 1,0s
1.1.2g Trac Stat Trc Ilim Tmr 8s
1.1.3 Trac Pers Decel 0,1s
1.1.4 Trac Pers Creep Speed 0%
1.1.5 Trac Pers Dir.Plug 200A
1.1.6 Trac Pers Ntrl.Plug 200A
1.1.7 Trac Pers Foot Plug 250A
1.1.8 Trac Pers Dir.Regen 150A
1.1.9 Trac Pers Ntrl.Regen 150A
1.1.10 Trac Pers Foot Regen 150A
1.1.11 Trac Pers Reg Delay 0ms
1.1.12 Trac Pers Max speed 100%
1.1.15 Trac Pers Cut Speed 2 12%
1.1.16 Trac Pers Cut Accel 2 0,1s
1.1.21 Trac Pers Bypass Out 900A
1.1.22 Trac Pers Bypass Delay 1,5s
1.1.23 Trac Pers F.W.In 50A
1.1.24 Trac Pers F.W.Out 50A
1.1.25 Trac Pers Steer Delay 25s
1.1.26 Trac Pers Seat Delay 2,0s
1.1.27 Trac Pers E.Brake Del 1.0s
1.1.28 Trac Pers Accel Zero 3,50V
1.1.29 Trac Pers Accel Full 0,20V
1.1.34 Trac Pers O.Tmp Zero 0,00V
1.1.35 Trac Pers O.Tmp Full 0,00V
1.1.36 Trac Pers Speed Lmt 0KPH
1.1.37 Trac Pers L0 V Init 60,0V
1.1.38 Trac Pers L0 V Cut 43,0V
1.1.39 Trac Pers Hi V Init 95,0V
1.1.40 Trac Pers Hi V Cut 97,5V
1.1.41 Trac Pers Bat.Prot 58,0V
1.1.42 Trac Pers Prol.Delay 0,1s
1.2 Traction
Status
1.2.1 Trac Stat Battery 85,0V
1.2.2 Trac Stat Motor 0,0V
1.2.3 Trac Stat Motor 0A
1.2.4 Trac Stat Temp 31°C
1.2.5 Trac Stat Mostet 10,5V
1.2.6 Trac Stat Capacitor 86,0V
1.2.8 Trac Stat Key 6,3Hz
1.2.9 Trac Stat Drive 0,0Hz
1.2.11 Trac Stat BELT 0,3Hz
1.3 Traction
Test
1.3.1 Trac Test Accel 0%
1.3.2 Trac Test Accel 5-00V
1.3.2a Trac Test Belt Demand 0%
1.3.7 Trac Test 0.Temp 0%
1.3.8 Trac Test 0.Temp 0.00V
1.3.9 Trac Test Forward Open
1.3.10 Trac Test Reverse Open
1.3.11 Trac Test FS1 Open
1.3.13 Trac Test Seat Open
1.3.16 Trac Test Cutback 2 Open
1.3.20 Trac Test Handbrake Closed
1.3.21 Trac Test Footbrake Open
1.3.28 Trac Test BeltFwd SW Open
1.3.29 Trac Test BeltRev SW Open
1.3.30 Trac Test BeltStp Sw Open
1.3.32 Trac Test Ver V3 12A
1.3.33 Trac Test Ser No 7070757
1.4 Traction
BDI
1.4.1 BDI 54% Charge Left
1.4.2 BDI Battery Volt 80V
1.4.3 BDI Reset 2,20V/Cell
1.4.4 BDI Empty 1,88V/Cell
1.4.5 BDI Warning 30%
1.4.6 BDI Cut out 20%
1.5 Traction
liste des fautes
Fault Log to reset log
1.6 Traction
Setup
1.6.1 Trc Setup Chap Select On
1.6.2 Trc Setup Accel Linear
1.6.3 Trc Setup BDI On
1.6.4 Trc Setup Str Trig F+B
1.6.5 Trc Setup Econ cuts I Off
1.6.6 Trc Setup Bypass in I lim On
1.6.7 Trc Setup SRO On
1.6.8 Trc Setup Braking Prop
1.6.9 Trc Setup Plugging Const C
1.6.10 Trc Setup Truck Ride On
1.6.10a Trc Setup Truck 1 Beltloader -1
1.6.12 Trc Setup Pin 5 Seat Sw
1.6.13 Trc Setup Pin 6 BeltFdSw
1.6.14 Trc Setup Pin 7 BeltRvSw
1.6.15 Trc Setup Pin 8 BeltStpSw
1.6.16 Trc Setup Pin 9 Speed 2
1.6.17 Trc Setup Pin 10 0.Temp
1.6.18 Trc Setup Pin 11 Accel
1.6.19 Trc Setup Pin 13 Handbrake
1.6.20 Trc Setup Pin 14 Footbrake
1.6.24 Trc Setup Cont 9 E.Brake
1.6.25 Trc Setup Cont 10 Belt Sel
1.6.27 Trc Setup Emb Stat Disp Off
1.6.28 Trc Setup Fault Log On
1.6.29 Trc Setup Service Log On
1.6.30 Trc Setup Full Speed 20Kph
1.6.31 Trc Setup Probe Frq 100Hz
1.6.32 Trc Setup Mode Stanedalone
1.6.33 Trc Setup Sw Lmts Spd Off
CHAPTER 2
SPECIFICATIONS AND DESCRIPTION
FRANCE
Tél : (33) 03 86 43 01 30
2.1 - SPECIFICATION :
2.1.1 Dimensions and performances :
Erreur ! Liaison incorrecte.

2.1.2 Drive motor:
Asynchronous motor..................................................................................48kW.
2.1.3 Electrical circuit:

Power….......................................................................................................48V.
Auxiliary......................................................................................................24V.
2.1.4 Battery:
Voltage..........................................................................................................48V.
Number of cells……….......................................................................................24.
Capacity........................................................................................450Ah / 575Ah.
Width of the box......................................................................................435mm.
Length of the box...................................................................................1010mm.
Height of the box.....................................................................................660mm.
Weight........................................................................................................876kg.
2.1.5 Chassis:
Welded and folded smooth steel sections
2.1.6 Suspensions:
Front.............................................................................................................rigid.
Rear.................................................................................................2 leaf springs.
2.1.7 Braking:
Type of master cylinder.........................................................double (front/rear).
Front brakes.................................................................................................discs.
Rear brakes................................................................................................drums.
Parking brake....................................................................................on rear axle.
2.1.7.1 Service brake

Master cylinder ordered dual circuit braking pedal.
2 front disc brakes:

Outside diameter of disc.............................................................................247 mm.
Thickness of the disc......................................................................................10 mm.
2 rear drum brakes:
Outside diameter of drum...........................................................................255 mm.
Thickness of the drum....................................................................................45 mm.
2.1.7.2 Parking brake

Mechanical parking brake activated by means of hand lever.
2.1.7.3 Electric braking

By regeneration of energy when release of the accelerator pedal.
2.1.8 Front suspension:

Drive axle............................................................................................................
Spindle support.............................................................................roller bearings.
2.1.9 Drive Sytem

Type..............................................................................hydraulic power steering.
Operator command..................................................................rotative solenoid.
Drive axle............................................................ double effect steering cylinder.
2.1.10 Driving suspension:

Type.......................................................................................................Charatte.
Ratio……..................................................................................................17,45/1.
2.1.11 Front wheels:

Tyre........................................................................................................7.50 - 16.
Wheels.........................................................................................................6x16.
2.1.12 Rear wheels:

Tyre........................................................................................................7.50 - 16.
Wheels.........................................................................................................6x16.
2.2 - DESCRIPTION:
2.2.1 General description:
The vehicle is equipped with 4 wheels, 2 driving wheels at rear and 2 steering at front.
An electric motor powers the main steering system. This motor is fed by an industrial
type battery. The motor powers up the rear wheels through a reducer and a
differential.
Belt inching devices
Rear axle
Battery
Front axle
Hydraulic Operator compartment
group
2.2.2 Chassis:
The chassis is made of folded steel sections, which are welded together in a fix
mounting to guarantee the replacement of parts. The assembly is then cleaned,
primered and painted.
2.2.3 Belt structure:

The belt structure is made of standard folded steel sections. It is mounted on the
chassis through the front and rear lifting arms (option).
Belt structure
Front lifting arm
Rear lifting arm
Main welded chassis assembly

2.2.4 Front axle:

The front axle is a steel beam rigidly bolted on the chassis.
Fixed on each side of the axle:
- Spindle supports;
- Steering tie rod ends;
- Nesting assemblies (spherical seals);
- Spindles and hubs;
- Coupling bar assemblies;
- Brake discs;
A steering cylinder is mounted to the rear of the axle.
2.2.5 Front brakes:

The front brakes are disc brakes, which are handled by the first part of the
master cylinder.
2.2.6 Front suspension:

Rigid mounting which guarantee a higher stability during the belt use.
2.2.7 Steering system:

The steering includes an hydraulic group, activated by the deadman pedal, a
rotary solenoid (fixed on the steering wheel), hydraulic hoses and a steering
cylinder (on front axle). During steering wheel rotation, the pump releases an
under pressure fluid, which debit is calibrated by little increments via the
rotary valve to the steering cylinder, which makes the front wheels turn. In
emergency situations, the rotary valve will enable the fluid without using the
pump, to allow steering. However, driver will have to apply a bigger force to
make the steering wheel turn.
2.2.8 Rear axle:

The rear axle has been especially designed for this kind of vehicle and enables
the motor to be mounted directly on the carter of the rear axle.
2.2.9 Rear brakes:

Rear brake drums on the rear axle, activated by the second part of the master
cylinder, or by the park brake lever.
2.2.10 Rear suspension:

The rear suspension is composed of 2 leaf springs fixed on the axle with
calipers, with alignment, which enables to keep the correct mounting position
of the assembly.
2.2.11 Parking brake:

To avoid the unit to move when parked, and in any emergency situation, an eccentric
handbrake lever enables the brakes to be tightened through the brake cables and a
bevel.
2.2.12 Wheels/tires:
The vehicle is equipped of handling large fit wheels and industrial tires.
2.2.13 Main drive motor:

A driving electric motor gives the necessary force to the vehicle translation.
2.2.14 Belt motor:

An electric motor activates the belt rotation.
2.2.15 Hydraulic pump motor:

An electric motor feeds the hydraulic system and gives pressure to it.
2.2.16 Drive/belt controller:

When the handbrake lever is release, the controller feeds the traction three phase
motor from the DC current given by the battery, and ensure the vehicle translation.
Moving and speed are handled by the operator by the direction lever, located on the
dashboard and the accelerator through the pedal. When releasing the accelerator
pedal, controller will handle electric braking through regen current.
When handbrake lever in ON, this controller will handle the belt moto reducer.
Moving and speed of the belt rotation are handled by the operator, through one of
the inching device mounted on the belt structure.
2.2.17 Converter:
The converter changes 48V current to 24V for the signals and accessories feeding.
2.2.18 Lighting system:

The whole lighting system is ensured by the operator through the dashboard
commands, and uses 24V bulbs. Additional lighting devices and corresponding
accessories depend on the customer's requirements.
2.2.19 Belt comm

Emergency stop button
Hydraulic pump lever
Remote control
Remote control
Emergency stop button
2.2.20 Operator's compartment commands:
2.2.20.1 Screwed to ground:
• Deadman pedal (activated by left foot)

• Accelerator pedal (activated by right foot)
• Brake pedal (activated by right foot)
• Handbrake lever
2.2.20.2 Dashboard is equipped of :
(1) an ignition switch (standard) or a key switch or smart key switch;

a steering wheel, activating the orbital valve and steering cylinder
(2) a forward/reverse lever (front, rear and neutral)
(3) a driving/belt mode switch
an emergency stop button
a horn/lighting rotating switch (park lights, main lights and dashboard symbols)
(depending on options)
a direction indicator's lever
a warning light switch
a work light switch (optional)
a front windscreen wiper switch (optional)
a rear windscreen wiper switch (optional)
a heater/defroster switch (optional)
a mechanical hourmeter
(4) a belt structure lifting switch
symbols :
• contact
• indicators
• headlights
• handbrake lever
• brake liquid
• slow speed
a controller display which informs of :
• the controller alarms (faults)
• the battery charge level
• the controller hours of work
• the selected mode of use (drive motor/belt)
2
• the handbrake position
1
3
2.2.21 Battery:
Traction industrial type battery of 48V. The 24 battery elements are mounted in a
steel mad box and linked in line.
2.2.22 Cabin:
Steel structure, securit glasses, hinged door, sliding side windows, heater/defrosted
in cab, 1 wiper blade on windscreen (cabin optional).
CHAPTER 3
USE AND APPLICATION
FRANCE
Tél : (33) 03 86 43 01 30
CHAPITRE 3 : UTILISATION ET FONCTIONNEMENT
CHAPTER 3 : USE AND PROCESS
3.1 - APPLICATION:
The right to drive this vehicle is reserved exclusively for personnel authorized by the
operator. The driver must be qualified to drive this type of tractor, and must have
received training providing him/her with knowledge of the vehicle, control and safety
mechanisms.
The belt loader has been designed to load and unload light freight and luggage to or from
the parking spot of an airplane. It was designed to drive on relatively leveled grounds.
The front or rear belt height can be modified by the hydraulic command according to the
different requirements.
3.1.1 Precautions and recommendations:
The mention «Precaution» indicated that the described operation could damage the
security of the persons, cause wounds (being able to be grave) to the staff using the
vehicle (and even to the persons being near), if it is not realized according to the
instructions.
The mention «Recommendation» indicated that the operation could damage the
vehicle, if it is not realized according to instructions
Precaution: the driving of this vehicle is exclusively reserved for the staff authorized by the
developer, the driver must be authorized in the driving of this type of tractor, and
he must have received a training to know the vehicle, the organs of command and
security.
The driver must be equipped with the individual protections necessary for the use,
particularly with security shoes, gloves, vest fluoresce.
Precaution: don’t try to start up the vehicle without having read and understood previously all
the instructions and the recommendations of this manual worker.
Precaution: do not use the vehicle if the level of the liquid of brake is below the mini level.
Precaution: do not use the vehicle if the brakes of service do not work correctly.
Precaution: do not use the vehicle if the brake of car park does not work correctly.
Precaution: do not use the vehicle if tires are not correctly inflated.
Precaution: do not use the vehicle if the battery is unloaded (except to drive it to the charging
station).
Precaution: do not use the vehicle if the level of water and the battery is insufficient.
Precaution: do not use the vehicle if the hydraulic group of direction doesn’t work.
Precaution: do not use the vehicle if the service maintenance affixed an information "out of
order" for noticed and not yet taken corrected failure.
Precaution: before leaving the vehicle, put the forward/reverse lever in neutral position,
activating the parking brake, switching off the lighting and cutting the contact.
Precaution: do not use the vehicle and do not make maintenance if you take drugs, painkillers
or if you are under the effects of the alcohol.
Precaution: this beltloader must be use to load and unload light freight and luggage to or from
the parking spot of an airplane.
In no circumstances must it be used to push (tractor, trailer, container, or any
other load) using the front part of the chassis
Precaution: for the maintenance, do not work in the electrical compartment if the battery is
not disconnected. Touch no electric component of the vehicle without having
disconnected the battery. To avoid short circuits, leave no metal object on the
battery.
Precaution: for the maintenance, do not work underneath the tractor until the maintenance
supports are correctly set up.
Precaution: before proceeding to an electric breakdown research or repair, lift the driving back
wheels and disconnect the battery.
Precaution: a battery which is being in charge or which has just been charged will product
hydrogen, do not smoke and avoid any flame or spark near the battery, an
explosion can provoke serious burns resulting of the sulfuric acid which the
battery contains.
Precaution: at the end of operation of maintenance or repair, it is necessarily to check that all
the safety devices are correctly adjusted and operational, and that no spare part
of the tractor was left in dangerous situation or omitted to be reassembled.
Precaution: while using the beltloader in traction mode, driver must be correctly installed in
the operator's compartment.
Precaution: Do never take passengers in this unit, to avoid any projection or crushing
Precaution: Check that there is no one on or close to the belt before activating the belt mode.
Precaution: Check the belt is switched off and the handrail is locked in good position before
using the belt as a bridge.
Recommendation: the driving of this vehicle is exclusively reserved for the staff authorized
by the developer, the driver must be authorized in the driving of this type
of tractor, and he must have received a formation to know the vehicle, the
organs of command and safety.
Recommendation: during the use of the vehicle, respect all the safety regulations and the
instructions of the site.
Recommendation: in the bends, the speed must be reduced.
Recommendation: disconnect the battery before towing the vehicle. Do not tow the vehicle in
a speed superior to 5 km/h,
CAUTION: Be careful during towing of the vehicle due to lack of power to assist steering and
braking device
Recommendation: the elements of the battery must never be exposed to superior

temperatures of 45°C.
Recommendation: for maintenance, if the vehicle must be lifted to work underneath, it is

necessary to use adapted equipment of lifting.
Recommendation: Do never throw hot water or steam on battery element(s)
CAUTION: the vehicle electronic system can create an electric discharge, even with battery
disconnected.
Recommendation: never use cleaning products, solvents or grease removers containing

mineral oil, petroleum, tetrachloride of carbon or by-products of
hydrocarbon.
3.1.2 Driving:
- When driving the tractor, follow all the safety regulations and instructions applied
on the site on which it is used.
- Check that no one is in front of (or behind) the vehicle before starting.
- On bends and during maneuvers, the speed of the tractor must be reduced.
- If a problem or a bad functioning appears during the driving, it is necessary to return
the vehicle and to indicate the incident to the service maintenance.
- Do not leave a vehicle without applying the parking brake, placing the
forward/reverse selector lever to neutral, switching off the lighting and cutting off
contact.
3.1.3 Before starting the unit:
a- Read this manual completely before using the vehicle. Get familiar to the
commands and their function before switching it on.
b- Check the vehicle by proceeding toe the pre-operational checkings (chap4).
Inform of any damaged, broken or missing part before any use.
c- Check all maintenance operations have been made.
d- Repair or replace any faulty part before using the unit.
e- Check all the instructions and security stickers are still in place and readable.
They are as important as any other equipment on the vehicle.
f- Clean any object or material from the unit or operator's compartment.
g- Check the batteries are correctly plugged and all covers are closed before switching
the vehicle on. A contact between an electric device and an electric wire or
energized circuit can generate wounds or severe electrifications.
3.1.4 Inching:
To avoid the driver or any other people to be hit by the vehicle, do not activate any
dashboard command from outside the operator's compartment.
a- For an optimum security, respect all security instructions indicated in the first part
of this chapter.
b- Climb in the operator's compartment.
c- The vehicle is equipped of an adjustable seat, which can be settled closer or farer
from the pedals.
CAUTION: Do NEVER try and adjust the seat while driving.
d- Fasten seat belt

e- Check the emergency stop buttons are released. Make sure the forward/reverse
lever is in neutral position, that the handbrake lever is on and the mode lever is in
traction mode.
f- When turning the switch or keyswitch, or when putting the smart key in place, the
vehicle switches on and the "contact on" symbol lights up on the dashboard.
g- Turn on the necessary devices (lights, work light or beacon)
To put the belt structure in required position, please refer toe "belt use instructions"
part of the manual.
NOTA: On some vehicles, a speed limit option is included, to limit traction speed when the
belt is not in its lowest position.
h- Push the brake pedal to ground and maintain it.

i- Press deadman pedal.
j- Select way of drive through forward/reverse lever.
k- Release mechanical parking handbrake, the red symbol "P" lights off.
l- Release the brake pedal and slowly press on accelerator pedal.
The vehicle is now moving. Press or release the accelerator pedal to speed up or down the
vehicle.
WARNING: Make sure there is no one and no object in front or at rear of the unit before
pressing the accelerator pedal (according to way of drive)
3.1.5 Stop:
a- release accelerator pedal;
b- Press brake pedal;
c- Once the unit is totally stopped, apply handbrake lever, "P" symbol lights on.
WARNING: Always apply the handbrake ON when the vehicle is not driving. Even if most of
the working areas are flat-ground, the internal little friction of the vehicle
requires the handbrake to be ON.
d- Put the forward/reverse lever to neutral position;

e- Switch OFF all the accessories;
f- To switch the unit off, turn the ignition switch or keyswitch to "OFF" or take the smart
key off its box.
WARNING: NEVER STOP the tractor by pressing the emergency stop button or
by switching off the contact or by removing the smart key.
THE EMERGENCY STOP MUST ONLY BE USED IN EXCEPTIONAL

CASES OF DANGER.
3.1.6 Belt use instructions:
1st case: Mode selector traction/belt is on traction position.
In this position, it is possible to both drive the unit and move safely the belt structure to
the required position, using the dashboard commands.
But it is not possible to make the belt rotating.
2nd case: Mode selector traction/belt is on belt position.
a- Handbrake lever applied, forward/reverse lever in neutral and selector on belt

mode. Check the vehicle is powered up.
b- Use the lifting command levers to adjust belt height.
Always take into consideration the airplane and airport premises when lifting the belt.
WARNING : Make sure there is no one close to the belt before pressing the belt rotation
way of drive button.
c- Select way of rotation of the belt by pressing the forward or reverse sway, located close to
the remote control devices of the belt (see chapter 2).
d- Adjust belt speed by successive pressures on the lever.
e- To stop the front/rear movement of the belt, press the stop buttons of the belt.
WARNING : DO NEVER STOP the belt by pressing the emergency stop button.
THE EMERGENCY STOP MUST ONLY BE USED IN EXCEPTIONAL

CASES OF DANGER.
3.1.7 Belt hydraulic handpump lever in case of emergency :

It enables to lift and lower down the belt in case of emergency when there is no
power supply.
The handpump is under the hydraulic comparrtment door.
1) Open the door.
3
2
2) Unscew the protection cap.
3) Tighten the scroll wheel all the way
by hand.
4) Close the valve.

5) Stick the handle in the pump.
Handle mounting
place
6) Push on the button on the distributor

and use an allen wrench if needed to
help.
7) Pump
Front cylinder
Rear cylinder
8) Release the button.

9) Open the valve to position the lever.
10) Close valve.
11) Put the handle back to its mounting place.
12) Loosen the scroll screw all the way by hand.
13) Screw the protection cap back.
14) Close and lock the door.
CHAPTER 4
MAINTENANCE
FRANCE
Tél : (33) 03 86 43 01 30
CHAPITRE 4 : MAINTENANCE
CHAPTER 4 : MAINTENANCE
The maintenance of this vehicle must be exclusively made by the qualified personnel,
the mechanical and the electro-technical engineer.
The maintenance must be made in appropriate premises, equipped with devices and
means of lifting adapted to this type of vehicle.
The maintenance staff must have received a training to know this type of vehicle, and
be equipped with the necessary individual protections according to the operations to
be made.
4.1 - SPECIAL PRECAUTIONS
4.1.1 Towing:
If the vehicle is u/s on site and that this breakdown requires the towing to a workshop,
then towing must not be done at more than 5km/h.
- Before towing the unit, switch the contact off, release handbrake lever and put
forward/reverse lever to neutral position.
- To end, disconnect the battery.
After the towing operation, apply handbrake lever. The unserviceable unit must be wedged on
the 4 wheel (each side of the wheels) for a better stability.
WARNING : - Always make sure there is no one between the towing vehicle and the u/s
one. If the front wheels of the broken down unit are touching the ground,
then someone will have to drive it.
- If the handbrake lever if the damaged unit is not applied before removing
the towing device, then the unserviceable unit may start and run without
control.
4.1.2 Lifting:
If the vehicle must be lifted to make works of maintenance or repairs, it is necessary
to use means of lifting adapted (lifting gallows or hydraulic ramp for the maintenance
of the rolling vehicles, the capacity of lifting superior to the mass of the vehicle)
Do not use a hoist with forks and lift the tractor by the side.
The use of this means of lifting is forbidden to the not qualified persons, to
scrupulously respect the detailed instructions for use.
The points of lifting of the tractor have to correspond to those defined by the
manufacturer: located on the 4 wheels, as close to the chassis as possible (see
chapter2.1).
Check the good functioning of the tractor on the carrier arms after a small lift
(approximately 30 cm).
Observe the tractor and the hydraulic ramp during every movement of rise or descent.
Go up or go down the vehicle at a regular speed and without jolts.
Take into account the center of gravity movement during any dismantling or assembly
of elements on the vehicle.
Do not work under the tractor before supports (gallows or deck) are correctly set up
and secured (locking in position).
4.1.3 Operations of maintenance (maintenance or repair) :

Before a breakdown research or electric repair, disconnect the battery and lift up
driving wheels. Do not touch any electric component of the vehicle without having
previously disconnected the battery.
To avoid short - circuits, leave no metal object over the battery.
The electronic system of the tractor can produce an electric shock even when the
battery is disconnected.
Do not smoke, and avoid any flame or spark near the battery, an explosion can
provoke serious burns because of the sulfuric acid which the battery contains.
Check that all the security devices are correctly adjusted after the repair or the
maintenance of the vehicle and that no detail of the tractor is left in dangerous
situation.
If there is an electric failure or an extreme overload, in particular in a completely
locked engine, the vapors which get free of the motor must not be inhaled. The heat
produced by a bad electric functioning or an overload can create harmful vapors due
to the combustion of the insulation materials. Disconnect the engine from any source
of energy before looking for the cause of the bad functioning. The engine has to be in
a well aerated place and poison gases which get free of it must not be inhaled. As
much as possible, we shall let the motor cool down and the vapors dissipate.
If a maintenance operation must be done with the belt in high position, then the belt
security supports must be used.
4.1.4 Change of wheel:
To change a wheel the jack must be installed:

- To the side of the wheel to be changed, under the lower part of the chassis (as
close of the wheel to be changed as possible).
- Apply the parking brake and wedge on the ground at the opposed side wheel in
the front and the back.
- Make this operation on a horizontal ground, away from traffic lanes.
4.1.5 Battery:
- A battery which is being charged or which has been loaded with product rejects
hydrogen.
- The battery elements must never be exposed to temperatures higher than 45°C.
- If the battery liquid exceeds the indicated maximum level, it will be blown outside
this one, which creates a density fall.
- Do not let the battery to discharge to more than 80% of its total capacity.
- Do never leave a flat battery without charging it for a whole night. The refill has to
be made at the end of the day.
- Check that the battery caps are perfectly tightened before the cleaning.
- Do never apply warm water or vapor on the battery surface.
- Do never to use cleaning products containing mineral oil, petroleum, carbon
tetrachloride or by-products of hydrocarbon.
4.2 - PERIODIC MAINTENANCE:

Periodic maintenance and servicing of the tractor ensure long component life and
optimum overall performances.
Service the tractor at the frequency indicated (See boards below).
EP1 - every day

EP2 - every 50 h or every month
EP3 - every 250 h or every 6 months
EP4 - every 500 h or every year
EP5 - every 1000h or every 2 years
EP5 - every 5000h
At 100 FIRST HOURS OF USE

Deck oil change
Control tightening torque on wheels and suspensions
Overall control tightening torque on bolts
EP1 - EVERY DAY

Check warning stickers, reflectors and headlights
Check wheels and tires and adjust if necessary
Check fluide leaks
Check the battery
Check brake pedal and adjust if necessary
Check handbrake lever and adjust if necessary
Check powersteering
Check controller display
Check belt commands
Check belt itself and adjust if necessary
Check hydraulic fluid levels
EP2 - every 50 h or every month

Check brake fluid levels
Check battery (cleaning and electrolyte level)
Check converter
Check tires inflation pressures
Check wheel fixing nuts and adjust if necessary
Check of the road lighting: lighting, indicators, beacon or flashing light
Check hydraulic tank waterproofness
Check master cylinder brake fluid level and adjust if necessary
Check oil level in hydraulic tank and adjust if necessary
Check rear protection carter and adjust if necessary
Check belt moto reducer : no leaks
Complete vehicle
EP3 - every 250 h or every 6 months
GENERAL CHECKINGS
Cleaning and visual control of the tractor’s general aspect
Check for protections and logos presence
Check for safety devices and instructions presence
Check of the road lighting: lighting, indicators, beacon or flashing light
Check direction and brake fluid levels
Put snouts back into place (if equipped)
Check tyres inflation pressures
Check dashboard indicators
Check proper functioning of electric devices
Check proper functioning of the horn and reverse sound buzzer
Check of the subjection direction (steerages)
Check for good service and park brake efficiency
Proceed with drive tests, forward/backward, with and without load
Check the security devices (battery circuit-breaker, deadman pedal, emergency stop, handbrake)
Check seats and adjusting efficiency
BRAKING AND TIRE
Check the wearing of front and rear brake pads and hoses, replace if necessary
Check handbrake cable and its adjustment
Check tires (cracking, scratches, grief...)
Check tyres wear, replace if necessary
STEERING
Check the steering tie rod ends and commands space
Check steering cylinder and fixing
Check the hydraulic circuit waterproofness
STRUCTURE
Check the covers assemblies, fixing and hinges
Check the handles, locks and cab’s windows
Check the absence of deformation or deterioration
AXLE / HUBS / AXES and PIVOTS (spindles)
Check front leaf springs and greasing them .Check (without dismounting) of the clearance in pivots
Check hubs
Check bolts for terminals
ACCELERATOR PEDAL
Check the pedal fixing and adjust mechanic stop
Check the return spring state and fixings
CONTROLLER COMPARTMENT
Check fixings and blow of dust from the controller deck
Check for waterproofness and correct it if necessary
Check power relays (contacts, circuit breakers, fuses, good tightening of flange, connections and relay)
Check wiring (cut, damaged insulation)
Check bolts for terminals
Check the breakdowns list with the can calibrator and make a «RESET»
Check the wiring line and the harness fixing elements
Check of the good state of the electric connectors
BATTERY
Check the battery plugs, cables and electrolyte level
Clean off the battery and the pins
Check the battery proper insulation
ASYNCHRONOUS MOTOR
Check good bleeding of condensats
Check the state of the entrances power cables waterproofness
Check of the good state of the electric power supply cables
Check the drive motor good insulation (megohmmeter) - between phases and towards the mass
ELECTRIC PART
Check wiring (cut, isolating damaged, tightening of power phases, connectors)
Check wiring line and wires fixings
HYDRAULIC MOTOR GROUP

Air blowing of the DC motor and check for brush wearing
Clean compartment
Check the hydraulic motor and pump insulation
DECK
Check oil reducer level and waterproofness
HYDRAULIC PART
Check the hydraulic hoses and pipes
Check command pressures
Proceed to a sample analysis of hydraulic group oil
Check hydraulic system waterproofness
LUBRICATION
Grease every visit (steering shafts, pivots)
EP4 - every 500h or every year

Control drive motor bearings
Replace the hydraulic oil
Replace oil reducer, check waterproofness
Adjust and grease wheel bearings
Check and adjust belt motoreducer brake
EP5 - every 1000h or every 2 years
Replace brake fluid (2 years)

Check the hydraulic motor bearings and replace if required
Check the hydraulic motor brushes and replace if required
Check the power contacts and replace if required
Check and replace if necessary belt motoreducer brake
Front wheel hubs : replace grease, adjust bearing course
EP6 - every 5000 h
Check the drive motor bearings and replace if required

Belt moto reducer : change oil
4.3 - ADJUSTMENT TORQUE FOR STEEL BOLTING:
Quality
5.8 6.8 8.8 10.9 12.9
class
Diameter C m.daN C m.daN C m.daN C m.daN C m.daN
6 0,62 0,75 1 1,40 1,68
8 1,48 1,78 2,37 3,34 4,01
10 2,98 3,58 4,77 6,72 8,06
12 5,07 6,08 8,11 11,41 13,70
16 12,24 14,69 19,59 27,56 33,07
20 23,87 28,65 38,2 53,71 64,46
24 41 49,2 65,6 92,24 110,7
27 59,87 71,85 95,80 134,71 161,66
30 75 90 120 168,75 202,5
Important: the values are given for assemblies dry.
4.4 - MAINTENANCE OF WHEELS - TYRES:

TIGHTENING TORQUE OF WHEELS:
Front wheels 18 DIN 25 m/daN

Rear wheels 18 DIN 25 m/daN
In the case of mounting inflated tyres:
INFLATION PRESSURE:
FRONT = inflated tyres 7.50 - 16

Inflated pressure: 8 bars
REAR = inflated tyres 7.50 - 16

Inflated pressure: 8 bars
4.5 - ASYNCHRONOUS MOTOR - Maintenance:

4.5.1 Running maintenance:
Control after stake on the way:

After approximately 50 operating hours, check the tightening of the motor fixing
screws.
Cleaning:
To ensure proper motor operation, remove dust and foreign bodies that could
block the radiator grille and gearcase fins.
Dry cleaning (blowing or compressed air) is always preferable to wet cleaning.
N.B.: Cleaning must always be carried out at low pressure from the center of the motor to
the ends to avoid the risk of introducing dust and particle onto the seals.
Draining the condensates:
Temperature differences give rise to condensation inside the motor, which must
be removed before they impair motor operation.
Condensate discharge holes located at low points on motors, allowing for their
operating position, then replaced (if they are not replaced, the degree of
protection of the motor would not be adhered to).
Clean the openings and plugs before reassembly.
Note: In the case of high humidity and a considerable temperature difference, we

recommend a shorter period.
Draining holes of the

condensats located under the
motor
4.6 - MAINTENANCE OF THE BATTERY:

4.6.1 Battery discharge limit:
Do not discharge your battery more than 80% of its rated capacity over a period.
Make sure that the discharge controller or limiter is operating properly (if you do not
have these devices the charging condition of the battery must be evaluated on the
basis of the electrolyte density).
To determine the charging condition:
- Measure the density of the electrolyte.

- Measure the temperature of the electrolyte.
- Use the conversion graph below (figure 1).
- A correct density measurement must never be carried out immediately after
filling.
GRAPH CONVERSION
DENSITY / CHARGE CONDITION
FIGURE 1
4.6.2 Battery charge:
4.6.2.1 When to recharge?

- When the battery is discharged by 35 to 80% of its rated capacity (discharge
controller or density measurement).
- When the battery is at rest for long periods (to compensate for the open circuit
loses and sulphatising). In this case carry out an equalization charge.
4.6.2.2 Where to recharge?

In a clean, well ventilated room, to eliminate the risks of explosion, and where smoking
is prohibited.
4.6.2.3 How to recharge?

CAUTION: Protection clothes, gloves and glasses must be worn whenever working around
batteries.
To charge a battery it must be supplied with direct current of suitable value and direction
enabling a CHARGER adapted to your battery to be used (in terms of voltage and capacitance),
your requirement (recharging time) and mains supply.
a- Starting the charge:

- Open the box cover to enable the gas to escape and allow better cooling of the
battery.
- Do not remove or open the cell plugs.
- Make sure that the charging unit is suitable for the battery and that it is operating
correctly.
- Top up to the maximum electrolyte level if a cell has a level lower than this
minimum.
- the charge can be done at the rear of the beltloader
b- During charging:
- Check that the temperature of the cells does not exceed 45°C (exercise particular
care in summer and in rooms with a high ambient temperature). A thermal surge
will damage the battery.
c- End of charging:
- As soon as the battery has received the quantity of electricity (ampere-hours)
required for full charge, the charging current must be interrupted. This
interruption is carried out automatically by different methods according to the
type of charger used.
- Measure the density to check that the battery is charged properly. (density table
/ charging status , according to temperature).
- Top up the electrolyte levels if necessary.
4.6.3 In case of problems:
When minor problems that could occur to a battery during its use have been quickly and,
properly evaluated and corrected, the service expected and the life of the battery are
improved:
PREVENTION = BATTERY LIF
PROBLEME CONSTATE CAUSES EVENTUELLE SOLUTION
Cells overfilled Do not exceed the max. level

Check the capacity of the charger.
Do not put the battery on charge
OVERFLOWING Over-charge
again if the density exceeds
1.220
Filling carried out before
Fill after charging
charging
Loss of electrolyte due to Fill to correct level after
UNEQUAL OR TOO LOW overflowing charging
DENSITIES LOW VOLTAGE Carry out an equalization
Stratification of the electrolyte
charge
Too low densities See ’’too low densities’’
OFF CELLS IN OPEN
CIRCUIT Short-circuit Clean the top of the battery
The charger is too strong for the Adapt a correctly dimensioned
battery cell
Air circulation insufficient Reduce the temperature of the
TEMPERATURE OF THE
between batteries on charge charging room
CELL TOO HIGH
Short-circuited cell Change the cell
Low or defective cell Change the cell
Install a battery with higher
Undersized battery
capacity
Increase the recharging time
Under-charged battery
and have the charger checked
BATTERY UNABLE TO
SUPPORT A NORMAL Defective cell Change the cell
WORKSTATION Defective or incorrectly
dimensioned cable or Replace the cable or connection
connection
Battery at the end if its life Replace your battery
4.6.4 Maintenance of the battery:
- Check the electrolyte levels once a week before charging under normal conditions of
use.
• High level: do not add water.
• Low level: add distilled or demineralized water.
- Top up the levels if necessary.
• With distilled or demineralized water.
• After a charge.
- Never add acid.
- Avoid overfilling.
- Never leave a discharged battery (sulphatising and risk of freezing of the electrolyte
in severe frost).
- Contact an agent of the battery supplier if a density correction is considered
necessary (overturning of battery).
- Clean the battery. It is essential to clean the battery to prevent the formation of salts
and current shunts that may result in serious problems.
- Wash the top of the batteries without removing the plugs to prevent penetration of
water into the cells.
- Dry in compressed air with clean rags or absorbent paper.
- Record the voltages, densities and temperatures at least once a month.
- Enter these measurements in the maintenance log supplied to you.
4.6.5 Equalization charges:
These charges enable slight daily under-charging of some cells, caused by supplies and by the
position of the cell in the battery, to be compensated for.
WHEN SHOULD AN EQUALISATION CHARGE BE CARRIED OUT?
- When the difference in density between the cells during recording of the corrected
densities of the temperature is greater than 2/100 after a normal charge.
HOW IS AN EQUALISATION CHARGE CARRIED OUT?
- Use the equalization charge function if it is available on your charger, or another

function, but under no circumstances exceed an intensity current greater than 0, 03C5
- Maintain the equalization charge for at least 10 hours.
- Always carry out the equalization charge after a normal charge.
4.7 – FRONT DISK BRAKE :
1 - Brake caliper
2 - Nose
3 - Piston
4 - Piston seal
5 - Piston cap
6 - Nose fixing screw
7 - Brake pad
8 - Pad spring
9 - Pin
10 - Key
11 - Wear indicator
12 - Pin guide locking key
13 - Pin guide
14 - Noise damping seal
15 - Wiper seal
16 - Pin guide cover
17 - Bleed screw
18 - Bleed screw cap
* For nomenclature with references and repair kit, see disk brake diagram
4.7.1 Caliper for series IV disk brake:
4.7.2 Description:
The brake incorporates the sliding caliper, which consists of 2 parts:
- An aluminium hydraulic cylinder, comprising two pin guides.

- A cast iron nose.
4.7.3 Operation :
The translational sliding action is provided by two cylindrical pin guides secured to the
hub carrier, connected by two bored holes in the hydraulic cylinder. It should be noted
that these pin guides replace the so-called plate support in a conventional brake.
4.7.4 Sliding mechanisms :
Construction and protection

4.7.5 Replacing shoes on series IV disk brake:
The shoes are replaced from above, as in a fixed brake, without removing the caliper. On
a brake which does not have a mechanical hand brake control device, this operation does
not require a special tool.
Before removing the pads the pistons must be pushed back as follows:
- Insert a screwdriver between the nose and the pad, lever until the brake slides
outwards. The piston will then be pushed back sufficiently to insert the shoe on
the nose side (Figure 1).
- Remove the pin and slide the key, as indicated (Figure 2). Remove the shoes.
- Fit a shoe on the nose side of brake (spring opposite the key) and slide it by hand
until the shoe comes into contact with the disk. Push the piston back as far as
possible, then fit the second shoe (Figure 3).
Refit the key and pin.
- When the shoes have been installed, actuate the brake pedal several times to
draw the shoes closer to the disk.
Figure 1 Figure 2 Figure 3

4.7.6 The disk :
The disk warping must be as low as possible, particularly for brakes of the « fixed » type.
To determine the value of the maximum permitted warping, refer to the manufacturers
instructions.
However, we can give a mean value which must not be exceeded:
• 0.1 mm in the case of disk brakes of the «fixed » type
• 0.2 mm in the case of disk brakes of the « floating » type
The warping is controlled by means of a comparator. Before measuring it, make sure that
the wheel bearings are correctly tightened (tightening torque established by the
manufacturer).
If the warping is unacceptable the disc must be replaced.
In this case change both disks on the same axle.
A « saw tooth » may be formed on the outer circonference of the disk (1, Figure 4) wich
may be particularly inconvenient when removing or refitting the pads, particularly when
the caliper is provided with an anti-recoil system.
Use a file to remove this, taking advantage of the motor drive if possible.
The braking track must be in good condition. If it is scratched (2, Figure 4) or worn hollow,
straightening may be possible within the limits established by the manufaturer.
If the manufacturer prohibits this operation, the disc must be replaced.
Any work on a disk, whether it be straightening or replacement, must also be carried out
on the other disk on the same axle.
Any disk whose thickness is less than the minimum dimension specified by the
manufacturer must be replaced under the conditions set out above.
Thickness of new disc: 10 mm, minimal thickness of used disc: 8 mm
Figure 4
4.7.7 The caliper:
The centring of the caliper or plate is very important. Wedges are available for certain
vehicles for re-centring. These wedges are supplied by the manufacturer.
The piston or pistons must slide correctly in the bore, an essential condition for ensuring
correct release of brakes.
If the piston is seized or returns poorly, use special grease ref. 499 991 to lubricate it (if
the brake fluid is of the synthetic type).
Carry out the following operations :
- Clean the caliper with a brush (particularly around the cap);
- Compress the piston;
- Release the cap from its groove;
- Pull out the piston, taking care to insert a wooden wedge in order to limit the
distance it is pulled out;
- Apply a little special grease (Figure 5);
- Compress the piston, remove the surplus grease (this could soil the pads);
- Replace the cap after making sure that it is in good condition.
- We generally recommend that this operation be carried out on all the disk brakes
of the vehicle when the pads are replaced for the 2nd or 3rd time. The pads must
slide freely in the caliper or plate. Whenever you replace the pads clean the support
points with a metal brush or soft brush (Figure 6). Compress the piston before this
operation. Dusting must be carried out using a soft brush.
4.7.8 Wearing in :
New pads must be worn in. They must be adapted to the disk and it is normal for the first
applications of the brake not to be as efficient as might be expected. To wear the pads in
properly it is sufficient to brake moderately for the first few kilometers, as brakes must
regain their efficiency progressively.
Figure 5 Figure 6
Figure 5 Figure 6
4.8 - REAR BRAKES:
The rear braking is provided by brake drums and expansion linings activated by a wheel
cylinder, the latter being actuated by the brake pedal.
To replace the linings proceed as follows:
a- Raise and secure the tractor.
b- Remove the rear wheels in order to withdraw the drums.
c- Remove the brake drums (2 FHc screw) to gain access to the brake plates.
d- Inspect the drums wearing dimensions:
Inner diameter of the new drum : 254,5 mm
Maximum grinding diameter drum : 256,13 mm
Maximum diameter of the drum wear : 257 mm
e- Carefully withdraw the lining clamps.
f- Remove the lower spring, the hand brake cable and the two upper springs.
g- Remove the linings by pressing the buttons on the wheel cylinder.
h- Clean and dust the different components of the brake plates.
i- Fit the new linings together with the springs, clamps and brake cables.
j- Replace the drums (2 FHc screw).
k- Adjust the linings to the drum (licking) ensure correct lining/drum contact.
l- Drive the tractor a short distance and check correct operation of the brakes. Adjust
if necessary.
1 - Wheel cylinder
2 - Hand brake rod
3 - Primary segment
4 - Adjustment lever
5 - Adjustment latch
6 - Latch spring
7 - Segment retaining spring
8 - Plate
9 - Segment release spring
10 - Hand brake rod retaining springs
11 - Hand brake lever
12 - Side spring
13 - Secondary segment
14 - Hand brake cable
M8 calibration for removal

of drum
4.9 - LEVEL AND LUBRICATION:
DESIGNATION
CAPACITY CHECK CHANGE
-30°C to+20°C -15°C to+40°C 0°C to +60°C CODE LUBRICATION
(indication) LEVEL OIL NOTE
cold temperate hot
API GL5/GL4 GEAR EP SAE GEAR EP SAE 500 H
DRIVING AXLE 3,5 – 3,6 L
SAE 75W90 80W-90 OIL 80W-90 OIL
250 H
OU 1 AN
2
BRAKING FLUID LOOCKEED 55 1000 H OU

TANK
0,25 L
+(BENDIX)
DOT4 DAY
2 ANS
5
- FRONT AND
DRIVING
SUSPENSION AXIS
-AXIS
- SPHERICS PAIR
GRAISSE
- SEALS RALLYE ISO L
XM2
250 H 4
- FRONT WHEEL HUBS
- FRONT AND REAR

HUB BEARING
- FRONT RUNNER
BELOW STRUCTURE
HYDRAULIC CHAQUE 500 H

CIRCUIT
20 L HYDRO BT HVC46 HVC68
SEMAINE OU 1 AN
1
BELT
MOTOREDUCTEUR
0.7 L OIL PAO ISO VG 460 50H 5000 3
NOTE :
1. With the lifting cylinders completely down.
2. When filling the axle carter, leave enough time for the lubricating fluid to get in the
different cavities and space around parts and components in each sub-asssembly. Add
lubricating fluid until the required level is reached.
3. When filling in the belt moto reducer, leave enough time for the lubricating fluid to get in
the different cavities and space around parts and components in each sub-asssembly.
Add lubricating fluid until the required level is reached.
4. Grease using a greasing pump until the old grease gets out of the component.
5. Empty the tank by aspiration, fill in with new fluid and bleed all wheel cylinders to drain
out old fluid.
REAR BELT
Grease with greasing pump in the union until the old grease
gets out of the component.
REAR BELT
Belt moto rear
On each side of
the belt
FRONT AXLE
On each side of cylinder
BRAKE PEDAL ASSEMBLY
Grease with greasing pump in the

union until the old grease gets out of
the component.
Lubricate with oil or dry type
lubricant.
OPERATOR'S COMPARTMENT
HANDRAILS
Grease with greasing pump in the union until the

old grease gets out of the component.
Lubricate with oil or dry type lubricant
BRAKING SYSTEM
Lubricate with oil or dry type lubricant

REAR AXLE
BATTERY COVER
Penetrating oil
4.10 - ELECTRIC DRIVE MOTOR:

4.10.1 Removal of electric drive motor:
a- Remove and disconnect the motor and axle

b- Note the orientation of the electrical connection box of the motor.
4.10.2 Refitting the electric drive motor:
a- Apply sealing paste to the surface of the front plate to seal it (after cleaning it
correctly).
b- Presentation of the motor (take care not to destroy the gearing of the motor/axle
pinions).
NOTE the orientation of the electrical connection box of the motor.
c- Putting into place of screws and blocking of the motor on the axle
C: 7m/kg
d- Tractor driving tests.
4.11 - BELT DRIVE MOTOR:

Whole assembly dismounting procedure:
CAUTION: Always use security supports when proceeding to maintenance operations below
the belt.
CAUTION: Disconnect the battery before unplugging the motoreducer cables to avoid any
electric shock.
a. Lift the belt structure high enough with the hydraulic command to enable the use of
security supports.
b. Switch off and disconnect the battery plugs to suppress all electric feed to the vehicle.
c. Unscrew and remove the belt motor cover located at the rear right side of the vehicle.
Disconnect and mark up the wiring of the emergency stop mounted on the cover.
d. Unscrew and remove the motor reducer plugboard cover. (1)
e. Untighten the cable clamps. (2)
f. Disconnect and mark up the wirings to the belt motoreducer.
g. Remove the cable clamps and rewire the cables in the belt chassis and leave it on the
rear bridge.
CAUTION: Please make sure to carefully markup wiring to avoid mistakes while putting the
cables back into place, which would cause damage to the motoreducer.
h. While maintaining the belt motor, remove the 4 fixing nuts between motor and reducer.
Separate the two. Keep the key you used to dismount the reducer because you will need
it to remount (3)
2
1
3
4.12 - BELT ADJUSTING

4.12.1 Basic principle of the belt alignment:
- The movement of one of the drums causes the movement of the belt to the least
stretched side.
- The movement of a stretching roller causes the movement of the belt to the less
stretched side. This phenomenon will occur with the tensor rollers even if the front
and rear drums are perfectly aligned.
NOTA : To ajust the belt alignment in forward mode, ajust the crowder roller and the cone-
shape roller (only when belt is operating in forward mode).
To ajust ajust the belt alignment in revere mode, ajust the crowder roller and the
cone-shape roller (only when the belt is operating in reverse mode).
It is necessary to proceed to the adjustments of the 2 ends of the belt at the sae
time, since the adjustment of 1 side will impact on the alignment of the other. During
tests, modify alignment by 1/4 turn, let the belt run for 2 turns each way to realign
it before proceeding to a new adjusmtent.
4.12.2 Adjusting procedure:

Adjust the perpendicularity of the rear drum from the belt chassis using the nuts of the
cylinder screws as follows (same procedure for both drums):
a- Place a longitudinal ruler on the right belt chassis spar and

make sure it is parallel to it.
b- Place a second longitudinal ruler, placed on supports,
above the drum to be adjusted, and perpendicularly to the
first one, checking the angle with a square, placed on the
belt or upper rollers.
c- Please a vertical square on the second ruler and check that
each end of the drum axis is parallel to the transversal
ruler.
d- Adjust if necessary the drum, by turning the cylinder screw
nuts.
e- Retighten the nuts and counter nuts of the cylinder screws

once the adjustment is done.
f. Adjust the rear drum protection plate to have a 4mm distance between the edge of the
plate and the drum, using its adjustment nuts. Tighten the protection plate nuts.
g. Adjust the rear tensor roller so that it is parallel to the hub using the tensor roller nuts.
Adjust the front drum axis position to 115mm from the front end of the belt structure, using
the cylinder screws nuts at the same value, right and left.
Adjust the perpendicularity of the front hub from the belt chassis using the cylinder screw
nuts and repeat former operations to front.
Adjust the belt stretching

- Take 2 align points on the belt chassis, 3m far one from the other.
- Stretch the belt of 1cm and adjust front drum and end with refinement.
- By turning the rear hub cylinder screw nuts of the same value on both right and
left sides in order not to modify the perpendicularity settings. Proper stretching
when the edges of the upper belt can be lifted by hand between 10 and 15 cm
maximum in the middle of the belt length.
4.12.2.1 Align the belt on the rollers
CAUTION : Stop the belt each time you need to adjust the belt or the rollers.
- Rear drum adjustment can be done when the belt is working in revere mode. If the belt
moves to one side, you need to slightly increase the tension on the same side, but turning
1/4 on the rear drum cylinder screw nuts.
- Front drum adjustment can be done when the belt is working in forward mode. If the belt
moves to one side, you need to slightly increase the tension on the same side, but turning
1/4 on the front drum cylinder screw nuts.
- Rear tensor roller adjustment: to refine the belt course in forward mode with the rear hub:
if the belt is deporting on one side, you need to slightly increase the tension on this same side,
by approaching the tensor roller to the rear hub. Repeat this operation until the belt is aligned
on the rear hub (take care and respect a correct tension of the belt).
- Front tensor roller adjustment: to refine the belt course in reverse mode with the front hub:
if the belt is deporting on one side, you need to slightly increase the tension on this same side,
by approaching the tensor roller to the front hub. Repeat this operation until the belt is
aligned on the front hub (take care and respect a correct tension of the belt).
ROLLER ADJUSTING NUTS
HUB PROTECTION HUB ADJUSTING NUTS

ADJUSTING NUT (SCREW-CYLINDER)
4.13 - ADJUSTMENT OF THE FRONT SUSPENSION:

Adjustment of parallelism on front axle:
a- Raise and secure the tractor.

b- Align the two front wheels with the two rear wheels using a rule placed on each side of
the bottom part of the chassis.
c- Align the two front wheels with the rule by acting on the steering rod on the steering
axle as follow:
Slacken the two locking collars of the rod.

Unscrew or screw up the rod, depending on whether you want to “clamp” or
“open” the wheel relative to the rule.
Retighten the collars of the steering rod once the adjustment has been made.
4.14 - BRAKE PEDAL ADJUSTMENT :

a- After having bled the service brakes.
b- Raise and secure the tractor.
c- Remove the lower protective plate in the assembly equipment.
d- Adjust the clearance (1 mm) of the brake pedal as follows :
- Slacken the lock nut on the thrust rod of the brake pedal assembly.
- Adjust the pedal stop by means of the thrust screw, taking care to slacken the lock
screw.
- Tighten the screw flush with the support (pedal approximately 10 mm from the
edge of the support), then retighten the lock nut.
- Unscrew the thrust rod until it is in contact with the bottom of the master cylinder,
then screw up again to obtain a clearance of approximately 1 mm.
- Retighten the lock nut on the thrust rod.
4.15 - PARK BRAKE ADJUSTMENT:

a- After having bled the service brakes.
b- Switch off the truck and disconnect the battery.
c- Release the parking brake lever. Ensuring wheels are safely chocked.
d- Lift and secure the truck to gain access to the cable adjuster located beneath the frame
of the truck in the center.
e- Check that the rotation of the rear wheels is free.
f- Act the cable adjuster to tighten the cables without braking the wheels. The wheels
should easily be moved by hand.
g- If the compensator is angled, adjust the settings on the front ends of the rear brake
cables.
h- After the replacing the rear brake pad, it is necessary to bed in the shoes with the
service brake before making the final adjustment of the parking brake.
4.16 - COMMISSIONING AND MAINTENANCE OF THE HYDRAULIC

ASSEMBLY:
The proper operation of a hydraulic installation is dependent on strict adherence to the
commissioning and maintenance instructions.
Only close adherence to these various instructions will guarantee increased service life
and high reliability of the installation.
It is recommended that maximum care be taken in any operation and measures be taken
to ensure that they are carried out under maximum conditions of cleanliness. No
operation must be carried out on an installation if it is under pressure.
4.16.1 Filling the installation:

Before filling it is advisable to check the cleanliness of the installation, particularly the
tank:
a- Clean it if necessary (woolen rags are banned).

b- Pay particular attention to the cleanliness of the containers used for filling.
c- Do not remove the metal screen from the filler plug (depending on the vehicle
equipment).
d- Fill up to the maximum level (detail see 4.16.3).
e- After filling, carefully re-close the tank.
4.16.2 Commissioning:
Before delivery, our installations are subjected to workshop tests to assure us of their
good design and satisfactory operation of the assembly, and to enable us to detect any
leakages that are visible afterwards.
After acceptance testing, our customers must proceed to carry out the following
operations:
- Visual inspection of the installation to ensure conformity and to check for any
damage in transit, cleanliness, etc...
- Checking for leakages:
Before delivery, our units are subjected to tightness tests:
However, because of vibrations in transit and vibrations peculiar to the installation

itself, leaks from the connections may occur after the first few hours of operation.
Simple retightening will suffice to eliminate these leaks.
4.16.3 Maintenance and inspections:

A detailed and attentive checking will enable you to obtain the best efficiency of
your vehicle. Check oil level in the tank after having put the belt in lower position on
flat ground.
Stop the vehicle: the oil level must reach the graduation below the "MAX" mark on
the plastic tank.
See periodic maintenance for more details.

- The temperature of the fluid must not exceed 60°C.
- In case of overheating establish the cause.
- In the 60° to 100°C range the fluid is consumed twice as quickly.
4.16.4 Description of the hydraulic installation:

This type of modular installation consists of a central base which receives the various
components.
The description of each mechanism will be found in the following chapters.
1 - Base
2 - Electric motor and coupling
3 - Gear pump
4 - Tank and its special CHARLATTE equipment
1 2 3 4
MILLIPAK 4QPM CONTROLLER MANUAL
FOR SYSTEM VERSION V1.50.01
Document History
______________________________________________________________________________
Document History
Author Reviewer
Version Reason for Modification
Initials Date Initials Date
PB 06/03/01 - - 0.01 Original.
DL /
14/09/01 1.01 Document updated for V1.01 software
CEH
PG 19/11/01 - - 1.50.00 Document updated for V1.50.00 software
PG 07/03/02 1.50.01 Document updated for V1.50.01 software
MillipaK 4QPM Controller Manual 11/06/02

Contents
______________________________________________________________________________
CONTENTS
Introduction
Safety
Installation
Mounting
MillipaK 4QPM Power Wiring
MillipaK Light Wiring example
Calibrator
Traction Drive Hours Counter
Calibrator Security Levels
Navigation
Adjustments
Status and Test Information
Configuration
System Configuration
System Voltage
System I/O Configuration
System / Motor Set-up
Contactor chopping
Accelerator Full /Zero Setting
Performance
Acceleration Delay
Deceleration Delay
Control Mode
Regen Braking
Braking Levels
Braking Entry and Exit
Footbraking
Creep Speed
Maximum Speed
Accelerator Characteristics
Features
Standard Controller Features
Power Steer
High Speed Switch and Anti-Tie Down
Seat Switch
Handbrake Switch
Cutback speeds
Traction Drive Hours Meter
Reverse Speed
Pump Soft Start
Reverse Buzzer
Line Contactor Drop out
Safety Features
Start Up Sequence
FS1 Recycle

Contents
______________________________________________________________________________
SRO (Static return to off)
Belly Switch
Anti-Rollback
Anti-Rolloff
Fail-safe
Controller Protection Features
Temperature Monitoring
Safe Operating Area (SOA)
Under-voltage and over-voltage protection
Commissioning Checklist
Personality Record
Fault Finding
Fault Clearance
Fault Reporting Form
Software Version and Serial Number indication
Specifications
Power Configurations
EMC standards
Socket B protection
Contactor drive ratings
Analogue Input Impedance
Digital Input Impedance
EMC Guidelines
Ordering Information

Introduction
______________________________________________________________________________
Introduction
The MillipaK 4QPM (Four Quadrant Permanent Magnet) range of controllers provides a new
range of power frames for 24V-48V, 330A in small, highly efficient packages. This is achieved
using a Sevcon patented power switching scheme and radical new construction techniques, which
enable large powers to be incorporated into very small packages.
The MillipaK provides a completely sealed (IP66) unit containing both power and logic circuitry,
as well as all suppression components and an optional integrated pump soft start/stop chopper.
MillipaK supports Sevcon’s existing MOS90 calibrator for adjustment of vehicle performance
characteristics. MillipaK is ideally suited to applications requiring a single traction controller, for
example walkies, golf cars and basic ride-on trucks.
Controllers are FLASH microprocessor based enabling field re-programming for new features and
have numerous user set-up options. The MillipaK uses high frequency (silent) MOSFET power
switching technology, to control a 4Q power frame bridge. Armature current is monitored. Motor
feedback should not be necessary. Controllers have been designed to satisfy the requirements of
the relevant UL and EC standards.

Safety
______________________________________________________________________________
Safety
The MillipaK controller contains a triple fail-safe system to give a high level of safety. If the
diagnostic LED is not illuminated or flashes, the safety circuit may have tripped and the truck
may not drive.
The controller must be used with a line contactor as indicated in the wiring diagrams.
As blow-out magnets are fitted to contactors (except 24V) ensure that no magnetic particles can
accumulate in the contact gaps and cause malfunction. Ensure that contactors are wired with the
correct polarity to their power terminals as indicated by the + sign on the top molding.
The MillipaK controller may be used with suitable onboard chargers, as supplied by Sevcon.
There are several software features which are intended to prevent inadvertent or unexpected
vehicle movement – SRO, Accelerator power up fault and sequence checking. Some of these
features cannot be disabled and the appropriate signals must be supplied to the controller before
drive will be allowed.

Installation Mounting
______________________________________________________________________________
Installation
The small footprint of the MillipaK controller gives maximum flexibility to the user for mounting
options. The following section gives details of certain criteria that should be considered when
situating the controller on a vehicle.
Mounting
The MillipaK HP unit provides 4 x M6 clearance holes for mounting. The controller should be
mounted onto a metal base plate, as large as possible to provide heat-sinking. The surface finish
should be flat, clean and burr free and thermal compound should be applied to the controller base
before fitting.
Figure 1: MillipaK HP Dimensions
Maximum terminal torque: M8 terminals – 10NM

M6 terminals – 7NM

Installation Wiring/Power
______________________________________________________________________________
MillipaK 4QPM Power Wiring
Figure 2: MillipaK 4QPM Power Wiring
NOTE: The Pump MOSFET’s are optional (soft start versions only).

Installation Wiring/Light
______________________________________________________________________________
MillipaK Light Wiring example
Analog
1
Connector A
0V
2
Calibrator De te ct
3
+ 10.5V
4
Clock
SEL 5
Data
CALIBRATOR
6
Se vcontrol
Batte ry +ve 1
Forw ard (Dig 1)
Fus e Ke y-s w itch 2
Re ve rs e (Dig 2)
3
FS1/ Be lly (Dig 3)
4
Se at / Tille r (Dig 4)
5
Digital Input 5
6
Connector B
Digital Input 6
7
Line Contactor*
8
Auxiliary Contactor*
e .g. 9
Analogue Input 1
Acce l 10
M odule Analogue Input 2**
11
12V Output
12
Extra Suppre s s ion 1***
13
Extra Suppre s s ion 2***
14
Horn Suppre s s ion***
15
Batte ry -ve
16
NOTES:
*Contactor Coil Suppre s s ion fitte d inte rnally.
**Analogue Input 2 can als o be configure d as a digital input.
***Extra Suppre s s ion and Horn Suppre s s ion inputs to be us e d as s how n be low :
Extra Suppre s s ion 1 or 2

Batte ry +ve
or Horn Suppre s s ion
Exte rnal Contactor /

Horn
Batte ry -ve
Figure 3: MillipaK Light Wiring

Installation Wiring/Light
______________________________________________________________________________
NOTES:
The line and auxiliary contactors are wired to B+, on the switched side of the key-switch.
Pin 12 is available for 100mA supply, typically used for (but not limited to) accelerator modules.
Pins 13,14 & 15 are general-purpose suppression connections and may be used to suppress spikes
generated by contactors opening / closing. The internal configuration is shown below:
Pin 16 is used to select FLASH memory program update mode and should normally be left
unconnected.

Calibrator Calibrator/General
______________________________________________________________________________
Calibrator
The Calibrator is a hand-held adjustment unit which can be used to configure and test the system.
The MillipaK is designed to work with the Calibrator currently in use with SEVCON's MOS90
system. See diagram below. The menu structure is shown in the Calibrator Map located near the
end of this manual.
i.8.8.8
+
SELECT
CALIBRATOR
Se vcontrol
Figure 4: MillipaK Calibrator

Calibrator Calibrator/Traction Drive Hours Counter
______________________________________________________________________________
Traction Drive Hours Counter
When the Calibrator is first plugged into the unit after power up, the Calibrator shows the
Traction Drive Hours Counter. Refer to the Traction Drive Hours Counter section for more
information on this function.
With no buttons pressed, the number displayed shows the number of minutes (accurate to 0.5
minutes). Pressing the '-' button displays the number of hours under 1000 and pressing the '-'
button displays the number of 1000 x hours.
For example, if the hours counter was 12, 345 hours, 13 minutes and 40 seconds, with no buttons
pressed, the display would show 13.5. Minutes are only shown to the nearest 0.5 minutes. If the '-'
button was pressed, the display would show 345 (number of hours under 1000) and if the '+'
button was pressed, the display would show 12 (number of 1000 x hours).
This is the only time that the hours counter can be viewed. Once the Select button has been
pressed to enter the normal calibrator menu structure, it is not possible to return to this point. To
view the hours counter again, you must recycle the Keyswitch.
This is also the point at which you can enter a password to enable different levels of access to
personalities. Refer to the section below on Calibrator Security Levels for more details.

Calibrator Calibrator/Security Levels
______________________________________________________________________________
Calibrator Security Levels
Which personalities and status items which can be viewed on the Calibrator is restricted using
passwords. There are three levels of Calibrator access. These are shown in Table 1.
Access Level Text Password Description

Default. This level is selected when no password or an
Service Ser - invalid password is entered. Only items shown in the
Calibrator Map with a thick solid border are displayed.
All items, except those in the Setup menu, can be
Engineering Eng 1645
displayed.
Contact
All Adjust All All items are be displayed, regardless of configuration.
SEVCON
Table 1: Calibrator Security Levels
Note, for Service and Engineering security levels only items appropriate to the current system
configuration are displayed. For example, if none of the switch inputs are configured as a Cutback
1 Speed Switch, then the Cutback 1 Speed personality will not be displayed.
The All Adjust security level allows access to all personalities, including those not required by the
current configuration. The items in the Setup menu can only be accessed at this security level.
The password can only be entered just after power up when the Traction Drive Hours Counter is
displayed. The '+' and '-' buttons are used to enter the password. The first digit is entered by
pressing the '+' button the appropriate number of times (i.e. once to enter 1). The second digit is
entered by pressing the '-' button the appropriate number of times (i.e. 6 times to enter 6). The
third digit is entered using the '+' button again and the final digit is entered using the '-' button
again. Note that when the '+' or '-' buttons are pressed, the display still changes to show hours or
1000 x hours.
When the password has been completely entered press either the '+' button or the SELECT button
to initiate verification. If the password has been entered correctly, the text shown in Table 1
appropriate to the required level will be displayed for 1s indicating the password was accepted. If
the password was incorrect or no password was entered, the system always defaults to Service
mode.
After the Security Level has been displayed, the system enters the normal menu structure shown
in the Calibrator Map. To change the password level, you need to recycle the Keyswitch.

Calibrator Calibrator/Navigation
______________________________________________________________________________
Navigation
The Calibrator uses all three buttons for navigating through the menu structure.
Use the SELECT button to move through the menu structure. When the SELECT button is
pressed the next menu item is displayed. The default direction is from left to right, top to bottom.
If the '+' and '-' buttons are held down together, the ID of the currently displayed menu item is
shown. For example, if the Armature Current Limit personality was selected, then the ID would
be 0.01 (menu 0, item 1). This allows the operator to locate where they are in the map.
If the '+' and '-' buttons are held down together for more than 3 seconds, the direction through the
menu structure is reversed. Now when the SELECT button is pressed the direction is from right to
left, bottom to top. In this mode, the LED on the Calibrator will flash. If the '+' and '-' buttons are
held down together for more than 3 seconds again, the direction reverts back to the first direction
and the Calibrator LED stops flashing.
The SELECT button is used to navigate through most of the menu structure, however, the Test
menu (menu 19) is slightly different. Pressing the SELECT button will take you to the first item
in the Test menu, (item 19.01 - Accelerator Demand). To navigate the Test menu, you need to use
the '+' and '-' buttons. The '+' button moves up the Test menu and the '-' button moves back down.
Pressing the SELECT button at any time exits the Test menu and moves to the first item in the
menu structure (menu item 0.01 - Armature Current Limit).
The items which are displayed depends on the current system configuration and the Security
Level.

Calibrator Calibrator/Adjustments
______________________________________________________________________________
Adjustments
Menus 0 to 12 are primarily used for configuring the system. All the personalities that the system
uses to configure each function are in one of these menus. A brief description of the purpose of
each menu is listed below. For more complete descriptions of each personality refer to the
appropriate section in this manual.
Menu Name Purpose

0 Current Limits Used to setup maximum currents for motor.
1 Braking Levels Used to setup braking strength and performance.
Used to setup acceleration and deceleration performance and to
2 Accelerator
configure the accelerator input voltage range.
3 Creep Speed Used to setup creep speed.
4 Bypass Not Used
5 Maximum Speed Used to setup maximum speeds.
6 Cutback 1 Speed Used to setup the speed for Cutback Speed 1.
7 Cutback 2 Speed Used to setup the speed for Cutback Speed 2.
8 Motor Setup Used to setup motor protection levels.
9 Power Steer Timer Used to setup the Power Steer timer.
10 Seat Delay Used to setup the Seat Switch debounce delay.
Used to setup additional personalities. These are personalities
Additional which do not belong in any of the menus shown above, or they
11
Personalities are deemed to be unsuitable for modification by service
engineers or end users.
Used to configure the system at a high level. Items to configure
the system I/O and performance are located in here. It is
recommended that items in this menu are configured first before
12 System Setup
any of the other personalities. Unlike the personalities in the
other menus, changes to items in this menu do not take affect
until the Keyswitch is recycled.
Table 2: Adjustment Menus

Calibrator Calibrator/Status and Test Information
______________________________________________________________________________
Status and Test Information
Menus 13 to 19 are primarily used for providing information about the system. Every parameter
which the system measures in located in one of these menus. A brief description of the purpose of
each menu is listed below.
Menu Name Purpose

If there is a fault active in the system, this menu provides
13 System Status information about what the fault is. Refer to the Diagnostics
section for more information.
14 - Reserved for future use.
Used to display Battery and Capacitor Voltage measurements.
The Battery Voltage measurement shows the voltage measured
15 System Voltages at the Keyswitch pin (pin 1 on connector B). The Capacitor
Voltage measurement shows the voltage measured at the B+
terminal.
16 Motor Voltages Used to show the voltage measured at the Point A terminals.
17 Motor Currents Used to show the Armature Current Measurement.
Heatsink Used to access the Heatsink Temperature measurement. Refer to
18
Temperature the Temperature Monitoring section.
Used to access items which allow for testing of all the Analogue
and Digital inputs available on connector B. Also displays unit
19 Test Menu information such as the Software Version, Controller Serial
Number and the Personality Checksum. Refer to the appropriate
sections for more information on each of these items.
Table 3: Status and Test Information Menus

Configuration System
______________________________________________________________________________
Configuration
Configuration of the MillipaK controller is split into two categories – system and performance,
which will be discussed in turn.
System Configuration
The MillipaK system configuration items relate to how the MillipaK will interface with connected
hardware such as the system battery, vehicle control switches, accelerator and the traction motor.

Configuration System/Voltage
______________________________________________________________________________
System Voltage
The system voltage usually refers to the main system supply battery voltage. The controller uses
this information to ensure low and high voltage settings are within an appropriate range.
System Voltage Power Up

Calibrator Menu Reference: 12.19
Minimum Maximum Step Size Default
24v 48v 2v 24v

Configuration System/IO Configuration
______________________________________________________________________________
System I/O Configuration
The digital inputs, analogue inputs and contactor drive outputs available on socket B can be
configured in a number of ways to suit various applications. Table 4 shows a range of pre-
determined settings which are available to the user and should cover the majority of applications,
see below:
Digital I/O Description

Value
1 Walkie vehicle with Speed Cutback 1 switch, Pump Trigger switch
and Electromagnetic Brake. Pump Trigger activates Pump Soft Start
function.
2 Walkie vehicle with High Mast switch, Pump Trigger switch and
Pump Contactor.
3 Walkie vehicle with High Mast switch, Pump Trigger switch and
Electromagnetic Brake. Pump Trigger activates Pump Soft Start
function.
4 Walkie vehicle with Speed Cutback 1 switch, Pump Trigger switch
and Pump Contactor.
5 Walkie vehicle with Quick Pick switch, High Speed switch,
Electromagnetic Brake and Hours Counter Drive.
6 Walkie vehicle with Pump Trigger switch, Brake Override switch,
and Electromagnetic Brake.
7 Ride On vehicle with Speed Cutback 1 and 2 switches and external
LED drive.
8 Ride On vehicle with Speed Cutback 1 switch, Handbrake switch
and external LED drive.
9 Ride On vehicle with Handbrake switch, Power Steer Trigger switch
and Power Steer Contactor.
10 Ride On vehicle with Speed Cutback 1 switch, Power Steer Trigger
switch and Power Steer Contactor.
11 Ride On vehicle with Handbrake switch, Pump Trigger switch and
Pump Contactor.
12 Ride On vehicle with Handbrake switch, Pump Trigger switch and
Pump Contactor.
13 Ride On vehicle with Power Steer Trigger switch, Pump Trigger
switch and Power Steer Contactor. Pump Trigger activates Pump
Soft Start function.
14 Ride On vehicle with Traction Motor Overtemperature switch,
Handbrake switch and external LED drive.
15 Ride On vehicle with Power Steer Trigger switch, Footbrake switch
and Power Steer Contactor.
16 Ride On vehicle with Speed Cutback 1 and 2 switches and Alarm
Buzzer drive.
Table 4: Description of each Digital I/O configuration.

______________________________________________________________________________
WARNING: Incorrect configuration could cause a vehicle to move unexpectedly,
for example if FS1 was inadvertently configured as a belly switch.
If your application doesn’t fit any of the above, please contact Sevcon with details of your
requirements.
Each of the above configurations allocates the controller i/o as shown below:
Digital Value of Digital I/O Configuration Item

Function 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Forward B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2 B2
Reverse B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 B3 B3
Belly B4 B4 B4 B4 B4 B4
Tiller B5 B5 B5 B5 B5 B5
FS1 B4 B4 B4 B4 B4 B4 B4 B4 B4 B4
Seat B5 B5 B5 B5 B5 B5 B5 B5 B5 B5
Speed Cutback 1 B6 B6 B6 B6 B6 B6 B6
Speed Cutback 2 B7 B7
Handbrake B7 B7 B7 B7
P. Steer Trigger B6 B7 B6 B7
Pump Trigger B7 B7 B7 B7 B7 B6 B7 B7
High Mast B6 B6
Motor Over Temp B6
High Speed B6
Quick Pick B7
Brk Override Sw B6
Footbrake Sw B6
Line Contactor B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8 B8
P. Steer Contactor B9 B9 B9 B9
Pump Contactor B9 B9 B9 B9
Electro Brake B9 B9 B9
External LED B9 B9 B9
Hours Counter B9
Buzzer B9
Table 5: Digital Functions

Notes:
1. Bx refers to Socket B pin numbers.
2. All vehicles have Forward and Reverse Switches and a Line Contactor.
3. All Walkie vehicles have Belly and Tiller Switches.
4. All Ride On vehicles have FS1 and Seat Switches.
5. Pump Trigger will trigger Pump Soft Start function as well as the Pump Contactor. This is
why some configurations have a Pump Trigger but no corresponding Pump Contactor.

______________________________________________________________________________
Analogue Functions
Analogue Value of Analogue Input Configuration Item

Function 1 2 3
Accelerator B10 B11 B10
Footbrake B11
Table 6: Analogue Functions
Notes:
1. Bx refers to Socket B pin numbers.
2. All vehicles have an Accelerator input.
Table 6 details which analogue functions are configured for each value of the Analogue Input
Configuration Item.
Digital Configuration Power Up

1 16 1 As Required
Analogue Configuration Power Up

1 3 1 As Required

Configuration System/Motor Set-up
______________________________________________________________________________
System / Motor Set-up
There are various settings available to the user to tailor the MillipaK controller to specific motors
and applications.

Configuration System/Armature Current Limit
______________________________________________________________________________
Armature Current Limit
The armature current limit personality is provided to allow the user to limit the maximum current
supplied to the motor to a value lower than the peak rating of the controller.
Armature Current Limit Immediate

Minimum Maximum Step Size Typical Value
50A ABR 10A ABR
ABR – Armature Block Rating refers to the controller maximum peak current.

Configuration System/Contactor Chopping
______________________________________________________________________________
Contactor chopping
This feature allows 24 V contactors to be used at all battery voltages 24V - 48V, by continuously
monitoring the battery voltage and chopping the contactor output pins accordingly, to present an
average voltage suitable for 24V coils. Chopping is selectable by the calibrator. Care must be
taken to ensure that chopping is always selected if 24V contactors are being used on battery
voltages higher than 24V. In applications > 24 volts contactors must be fitted with blow out
magnets. Chopping can reduce the overall dissipation in the coils and allows only one set of
contactors to be stocked for all battery voltages.
Chopping Frequency approx. = 667Hz (Slightly audible).
Typical contactor coil voltage during chopping = 16 volts.

Typical contactor coil voltage during energisation = 24 volts for 1 second.
There are 3 contactor chopping options available via the setup menu: Off, On and 24V. The off
setting is used for nominal battery voltage coils, and the On setting is for 24V coils on higher
voltage vehicles. Setting to 24V provides chopping for 24V coils and lamps without the drop to
16V after 1s.
Chop Select Power Up

Options Default
OFF ON 24V OFF

Configuration System/Accelerator
______________________________________________________________________________
Accelerator Full /Zero Setting
The accelerator/analogue inputs are flexible in the range of signal sources they can accommodate
and can be adjusted to minimise dead-bands and mechanical tolerances. Each analogue input has
2 adjustments associated with it to allow the input voltage range to be determined.
For the Traction Accelerator, for example, the 2 adjustments are called the “Accelerator Zero
Level” and the “Accelerator Full Level”. If these were set to 0.20V and 4.80V then 0% pulsing
would start at 0.20V at the input, increasing to 100% pulsing at 4.80V. For accelerators with
decreasing voltage outputs, the Zero adjustment might be set to 3.5V and the Full adjustment to
0.0V. The Calibrator test menu shows the instantaneous voltage reading, and the equivalent %
“push” for each input.
Accelerator Zero Volts Immediate

0.00V 4.50V 0.02V 0.10V
Accelerator Full Volts Immediate

0.00V 4.50V 0.02V 3.50V
Note that a 6 flash fault will occur if the full and zero levels are set within 0.50V of each other.
The PWM demand will vary between the Creep level and Maximum Speed level as the
accelerator voltage varies between “Accelerator Zero” and “Accelerator Full”.

Configuration Performance/Acceleration
______________________________________________________________________________
Performance
Various parameters may be adjusted to tailor the performance of the vehicle to customer
requirements.
Acceleration Delay
This is an adjustable delay to ramp up the pulsing from 0% on to 100% on, and can be used to
ensure smooth acceleration.
Acceleration Delay Immediate

0.1S 5.0S 0.1S 1.5S
Drive Deceleration Delay
This is an adjustable delay to ramp down the pulsing from 100% on to 0% on when a Drive
direction is selected, and can be used to provide a smooth reduction of power to the motor.
Drive Deceleration Delay Immediate

0.1S 10.0S 0.1S 0.1S
Direction Change Deceleration Delay
This is an adjustable delay to ramp down the pulsing from 100% on to 0% on when a new Drive
direction is selected, and can be used to provide a smooth reduction of power to the motor.
Direction Change Deceleration Delay Immediate

0.1S 10.0S 0.1S 0.1S
Neutral Deceleration Delay
This is an adjustable delay to ramp down the pulsing from 100% on to 0% on when Neutral is
selected, and can be used to provide a smooth reduction of power to the motor.
Neutral Deceleration Delay Immediate

0.1S 10.0S 0.1S 0.1S

Configuration Performance/Control Mode
______________________________________________________________________________
Control Mode
The method of motor control may be switched between Torque and Speed control.
Control Mode Power Up

Options Default
Torque Speed Torque
Currently only torque control mode is available.

Configuration Performance/Braking
______________________________________________________________________________
Regen Braking
All braking types are implemented using regenerative braking in the 4QPM MillipaK.
Braking can be initiated in one of 3 ways:
(i) Direction Braking. Initiated when the direction switch inputs are reversed during drive.
i.e., Reverse is selected when driving in Forward or Forward is selected when driving in
Reverse.
(ii) Footbrake Braking. Initiated when the operator depresses the Footbrake pedal and a
footbrake input is configured. See section below for more information about setting up and
configuring the system for Footbraking.
(iii) Neutral braking. Initiated when the vehicle is put into neutral during drive and neutral
braking level is greater than 0%.
Braking Levels
Each Braking Type has its own personality for setting the required braking level. These are shown
below:
Direction braking level Immediate

5% 100% 1% 75%
Neutral braking level Immediate

0% 100% 1% 10%
Footbrake braking level Immediate

0% 100% 1% 0%
The three braking levels for direction, neutral and footbraking are used to determine the strength
of the braking. Setting the level to 0% disables braking (Note: Direction Braking cannot be
disabled), 1% sets the braking strength to minimum (weakest braking) and 100% sets the braking
strength to maximum (strongest braking).
Footbraking

______________________________________________________________________________
Footbraking can be initiated in one of two ways:
Via an analogue input configured as a Footbrake Pot. Using a potentiometer allows the
operator to vary the amount of braking they want. See below.
Via a digital input configured as a Footbrake switch. When the switch is active, the system
will brake at the footbrake level.
Footbrake Pot
If the system is configured to use a Footbrake Pot, then the system will allow the operator to vary
the amount of footbraking depending on the position of the footbrake pedal. Similar to the
Accelerator input there are 2 personalities which can be used to setup the input voltage range of
the Footbrake Pot.

______________________________________________________________________________
Footbrake Zero Volts Immediate

0.00V 4.50V 0.02V 0.10V
Footbrake Full Volts Immediate

0.00V 4.50V 0.02V 3.50V
As the input voltage varies from the Zero level to the Full level, the footbrake demand varies from
0% to 100%. When the footbrake demand is at 0%, there is no footbraking. As the footbrake
demand increases from 1% to 100%, the braking level applied by the system increases from 50%
of the Footbrake Level personality to 100% of the Footbrake Level personality.
For example, assume the system is configured to have a footbrake pot and the Footbrake Level
personality is set to 60%. If the operator has not depressed the footbrake pedal, then the voltage
into the controller will be outside of the Footbrake Zero Level personality and the footbrake
demand will be 0%. There will be no Footbraking.
If the operator starts to press the footbrake pedal, then the footbrake demand will increase. When
the demand increases above 0% the system will start braking and will set the braking effort
according to the following formula:
§ § footbrake demand · ·
¨¨ ¸ 50 ¸
braking effort ¨ © ¹ ¸ u footbrake level personality
2
¨ 100 ¸
¨ ¸
© ¹
So, for this example, at 1% demand the braking effort would be

§§ 1· ·
¨ ¨ ¸ 50 ¸
braking effort ¨ © ¹ ¸ u 60
2
¨ 100 ¸
¨ ¸
© ¹
30%
and at 75% demand the braking effort would be

§ § 75 · ·
¨¨ ¸ 50 ¸
braking effort ¨ ©
2¹ ¸ u 60
¨ 100 ¸
¨ ¸
© ¹
52.5%

______________________________________________________________________________
Footbrake Priority
Footbrake priority can be set to drive or brake and this determines the controller action in the case
of the accelerator and footbrake pedal both being active at the same time.
Footbrake Priority Power Up

Options Default
Drive Brake Drive

Configuration Performance/Creep Speed
______________________________________________________________________________
Creep Speed
The Creep speed is adjustable and is used to select a minimum pulsing level as soon as drive is
requested, to minimise delays and dead-bands. The motor voltage is rapidly ramped to the creep
level (equivalent to a 100mS acceleration delay).
Creep Speed Immediate

0% 25% 1% 0%

Configuration Performance/Maximum Speed
______________________________________________________________________________
Maximum Speed
Adjustment limits the maximum applied %on to the armature.
Maximum Speed Immediate

0% 100% 1% 100%

Features Performance/Accelerator Characteristics
______________________________________________________________________________
100
90
80
Accelerator Demand
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
Accelerator Push
Linear Curved Dual Slope Crawl
Figure 5: Accelerator Characteristics
Accelerator Characteristics Power Up

Options Default
Linear Curved 2*Slope Crawl Linear
This function is used to vary how much speed is demanded depending on the accelerator position.
Setting either Curved, Dual Slope or Crawl gives a smaller change in speed for large changes in
accelerator position and is useful for low speed maneuvering.
The accelerator push refers to how much the operator has the accelerator depressed. This is the
value which is displayed on item 19.01 in the Test menu on the Calibrator. The Accelerator
Demand refers to how much accelerator demand is requested after the Characteristic function is
applied. This accelerator demand is then used along with the Creep Speed and Maximum Speed
personalities to determine the speed demand for the vehicle.
If a valid direction is selected and the accelerator demand is at 0%, the speed demand will be set
to the Creep Speed personality. As the accelerator demand is increased to 100%, the speed
demand increases linearly to the Maximum Speed personality.

Features Performance/Accelerator Characteristics
______________________________________________________________________________
Examples:
1. The Accelerator Characteristic is set to Dual Slope, the Creep Speed personality is set to 0%
and the Maximum Speed personality is set to 100%. If the accelerator push was at 70%, then
the accelerator demand and the vehicle speed demand would be 35%.
2. Same conditions as (1) but the Creep Speed personality is set to 10% and the Maximum Speed
is set to 75%. The accelerator push is still 70% and the accelerator demand is still 35%, but
now the vehicle speed demand is 32.75%. i.e.:
§ Accelerator Demand ·
Speed Demand Creep Speed ¨ Maximum Speed Creep Speed u ¸
© 100 ¹
§ 35 ·
10 ¨ 75 10 u ¸
© 100 ¹
32.75%

Features Features
______________________________________________________________________________
Features
The MillipaK controller has several features designed to offer the user maximum flexibility,
safety and performance whilst ensuring the controller is protected against adverse or harsh driving
conditions. These features can be split into three categories – standard controller features, safety
features and controller protection features.
Standard Controller Features
The following section details the standard features found on a MillipaK controller.

Features Standard Features/Power Steer
______________________________________________________________________________
Power Steer
A contactor drive is available to control a separate Power Steer motor. An adjustable delay allows
the motor to operate for a set time, after the power steer trigger or power steer demand has been
removed.
The following triggers are available and configurable for power steer:
Power Steer Trigger Triggers

Configuration Item FS1 switch Fwd or Rev switch Seat switch
0 No No No
1 Yes No No
2 No Yes No
3 Yes Yes No
4 No No Yes
5 Yes No Yes
6 No Yes Yes
7 Yes Yes Yes
Table 7: Internal Power Steer Triggers
The software also monitors the motor for movement (if the Anti-Roll-Off feature is enabled) and
activates the power steer driver accordingly.
Power Steer Personalities:
Power Steer Timer Immediate

0S 60S 1S 2S
Power Steer Trigger Power On

0 7 1 0
See also contactor drive output configuration (System/Digital IO).

Features Standard Features/High Speed Switch
______________________________________________________________________________
High Speed Switch and Anti-Tie Down
Vehicles with a High Speed Switch configured will normally drive at the Cutback 1 Speed, but
will allow the maximum speed of the vehicle to increase to 100% in Reverse or the Cutback 2
Speed in Forward when the High Speed Switch is active. This is usually used for a Walkie type
vehicle with a ride on platform where Reverse (Power unit forward, Forks trailing) is the normal
driving direction.
This function has two modes, Normal and Momentary. Normal mode only activates this feature so
long as the switch is active, Momentary mode activates this feature when the switch is active, and
keeps the High Speed Operation active after the switch is released. High Speed Mode is
configurable via the Calibrator.
High Speed Mode Power On

Options Typical Value
Normal (NOR) Latched (LAT) Normal (NOR)
There are two separate options for High Speed Operation:

Normal (Unlatched). High Speed Operation is only active when the switch is active.
Momentary (Latched). High Speed Operation is active as soon as the switch is made active
and remains active after the switch is released until any of the Anti-Tie Down conditions
become true.
High Speed Operation will be activated when the following conditions are TRUE:
Normal mode:
The High Speed Switch is active, and,
Anti-Tie Down is not inhibiting the feature. Anti-Tie Down is used to prevent High Speed
operation under conditions where the operator may not be expecting it.
Momentary mode:
The High Speed Switch has been active at least once to initiate the function, and,
Anti-Tie Down is not inhibiting the feature.
The speed demand in the Reverse direction (Power Unit Forward) is limited to the Cutback Speed
1 configuration item, if High Speed Operation is not active.
The speed demand in the Forward direction (Forks Forward) is limited to one of the following:
The lower of the Cutback Speed 1 configuration item or the Cutback Speed 2 configuration
item, if High Speed Operation is not active.
The Cutback Speed 2 configuration item, if High Speed Operation is active.

Features Standard Features/High Speed Switch
______________________________________________________________________________
Other speed demand limits may be applied whether High Speed Operation is active or not.
Anti-Tie Down inhibiting to the High Speed Switch Feature will be applied if any of the
following conditions are TRUE:
The system has just powered up.
A change in direction has just occurred. i.e. The reverse direction is selected after the forward
direction and vice versa.
The Tiller Switch is inactive.
Anti-Tie Down inhibiting will be kept active until the High Speed Switch is cycled through its
inactive state. Anti-Tie Down is used to prevent High Speed operation under conditions where the
operator may not be expecting it.

Features Standard Features/Quick Pick
______________________________________________________________________________
Quick Pick
The Quick Pick function is used to drive a Walkie vehicle at a set speed in the Reverse direction
(Power Unit First) when a switch is active on the Tiller arm. This feature is usually set up so that
the vehicle will drive at walking speed. This allows the operator to drive the Walkie using one
switch whilst they walk along side it.
Drive in the Reverse direction (Power Unit First) will be applied at a speed demand specified by
the Walk Speed personality, when all the following conditions are TRUE:
The Quick Pick switch is active.
The Tiller switch is active.
All Drive Switches Are Deselected.
No Drive Inhibit or Severe faults are active.
The Walk Speed personality can be adjusted via the calibrator, i.e.
Walk Speed Immediate

0% 100% 1% As required
Quick Pick speed demand will be treated exactly the same way as a normal accelerator demand,
where any cutbacks apply (Cutback Speeds, etc) and the demand will be treated appropriately in
both Torque and Speed Control modes.
The following inputs will be ignored during Quick Pick operation:

Forward Switch.
Reverse Switch.
FS1 Switch.
Accelerator Demand.
Belly operation will still be allowed when the Quick Pick function is active.
Drive will be allowed after the Quick Pick switch is released only if all Drive Switches are
Deselected. For example, if the Forward switch is activated during the Quick Pick operation,
Drive is inhibited when the Quick Pick switch is released until the Forward switch is deactivated.

Features Standard Features/Seat Switch
______________________________________________________________________________
Seat Switch
If the seat switch is opened and the seat switch timer has timed out during drive the controller will
stop pulsing and a seat fault will be indicated. Before drive can be restarted the seat switch must
be closed, and FS1 and the direction switch must be recycled through neutral. Note the start
sequence for drive requires that the seat switch is closed and both the direction and FS1 switches
are in the neutral position simultaneously before drive can be initiated. The time period is
programmed by means of the Calibrator (Seat Switch Delay). As a setup menu option the seat
switch can also inhibit pump operation if required.
Seat Delay Immediate

0.1S 5.0S 0.1S 5.0S
Seat Cuts Pump Power On

Options Typical Value
OFF ON OFF

Features Standard Features/Handbrake Switch
______________________________________________________________________________
Handbrake Switch
An input is provided for the connection of a handbrake switch, which if operated will disable
armature pulsing.

Features Standard Features/Cutback Speeds
______________________________________________________________________________
Cutback speeds
There are 2 cutback switch inputs as standard. Each one has an associated personality to adjust the
maximum % on when the switch is active. When both switches are active together, the lower
speed is selected. The cutback speed inputs are usually normally closed so that a wire off type
fault or bad connection initiates a lower speed.
Cutback Speed 1 Immediate

0% 100% 1% 100%
Cutback Speed 2 Immediate

0% 100% 1% 100%

Features Standard Features/Traction Drive Hours Meter
______________________________________________________________________________
Traction Drive Hours Meter
The MillipaK maintains a log of the number of hours during which the controller is providing
Traction functionality. The Traction Drive Hours Meter runs whenever the vehicle is driving or
braking. The current number of logged Traction hours can be viewed using the Calibrator. Refer
to the Calibrator section for more information.

Features Standard Features/Reverse Speed
______________________________________________________________________________
Reverse Speed
In some instances the maximum reverse speed of the vehicle is required to be slower than the
forward speed. This can be achieved by enabling the reverse speed limit and setting the Maximum
Reverse Speed personality accordingly.
Maximum Reverse Speed Immediate

0% 100% 1% 100%
Reverse Speed Limit Enable Power Up

Options Default
OFF ON OFF

Features Optional Features/Pump Soft Start
______________________________________________________________________________
Pump Soft Start
The MillipaK units may be fitted with a Pump Soft Start feature. This allows a pump motor (up to
120A) to be connected directly to the controller and eliminates the need for a contactor. It also has
the added benefit of providing a ‘soft start’ to the pump motor by gently ramping up the voltage
over a pre-determined period. After triggering the pump will remain active for as long as the
trigger input remains active or the pre-set timer expires, whichever is the shorter.
Pump Soft Start Ramp Up Delay Immediate

0.1S 1.0S 0.1S 0.1S
Pump Soft Start Timer Immediate

0.5S 10.0S 0.1S 2.0S
WARNING: The pump soft start option, when fitted, is NOT current limited and
care should be taken not to exceed the maximum current specified by
the controller rating.

Features Optional Features/Reverse Buzzer
______________________________________________________________________________
Alarm Buzzer
The Alarm Buzzer function is used to drive a warning buzzer when the vehicle moving in
different conditions. The function works by activating the Buzzer output when:
Mode ‘OFF’
1) The buzzer will not sound at any time if the Buzzer contactor drive output is configured.
Mode ‘Rol’
1) The Reverse Switch is active or vehicle is travelling in reverse – continuous output.
2) The vehicle is moving without a direction selected – pulsed output.
Mode ‘All’
1) The Forward Switch is active or vehicle is travelling in forward – continuous output.
2) The Reverse Switch is active or vehicle is travelling in reverse – continuous output.
3) The vehicle is moving without a direction selected – pulsed output.
Alarm Buzzer Power Up

Options Default
Off Rol All Rol

Features Optional Features/Line Contactor Drop Out
______________________________________________________________________________
Line Contactor Drop out

The controller will close the line contactor once a successful power up sequence has been carried
out, after which drive operation can be achieved. The line contactor will remain closed unless it is
opened following a serious fault or power being disconnected.
A further configurable option is available where the line contactor is opened (dropped out) if no
drive activity has occurred for a period exceeding the Line Contactor Dropout Timer personality.
If drive operation is selected once the line has been opened then it will be closed again so that
drive operation can occur. Line contactor dropout operation can be enabled or disabled in the
setup menu.
Line Contactor Drop out Power Up

Options Default
OFF ON OFF
Line Contactor Dropout Timer Immediate

1S 60S 1S 10S

Safety Features Safety Features/Start Up Sequence
______________________________________________________________________________
Safety Features
The features listed in this section are designed with the safety of the operator in mind.
Start Up Sequence
At keyswitch on, the Direction and FS1 switches must be in the neutral condition simultaneously
at least once before drive can be selected. This is a safety feature to help prevent unexpected
movement immediately after power up.
Alternatively, the system may be programmed only to check FS1 at power on. This option is
programmable:
Direction Switch Checking Power Up

Options Default
OFF ON OFF

Safety Features Safety Features/FS1 Recycle
______________________________________________________________________________
FS1 Recycle
On some vehicles, such as Golf Cars it is desirable to force the driver to remove accelerator
demand before allowing the vehicle to drive in the opposite direction than it has been travelling
in. This feature is implemented as an option and is selected in the PERS setup:
FS1 Recycle Power Up

Options Default
OFF ON OFF

Safety Features Safety Features/SRO
______________________________________________________________________________
SRO (Static return to off)
This feature is optional in the setup menu and when specified, forces the following sequences of
switch inputs to be followed before drive is allowed: Keyswitch-Direction-FS1 or Keyswitch-
FS1-Direction (within 2 seconds of FS1). Any other sequence will not allow drive. Drive will be
inhibited if FS1 is active for more than 2 seconds with no direction selected. In this case the FS1
will need to be recycled.
Static Return to Off Power Up

Options Default
OFF ON OFF

Safety Features Safety Features/Belly Switch
______________________________________________________________________________
Belly Switch
A Belly Switch function is available when the controller is used on a walkie type truck. The
feature can be enabled in the setup menu. See this section and wiring diagrams for additional
information. Basic operation is as follows:-
Truck moving in Reverse and activating the Belly Switch, accelerator in reverse position:-
a) The controller applies 100% braking.

b) The vehicle will accelerate in the Forward direction (Forks Forward) at full speed along the
accelerator curve when the vehicle has stopped.
c) All drive will cease after driving for the time given by the Belly Delay personality (See
below).
d) The controller will wait for neutral to be selected before drive will operate. If the Belly Switch
is pressed again however, action starts at b) above.
The Belly operation may be set to NORMAL or CONTINUOUS. When set to NORMAL the
vehicle will activate belly operation for the duration set by the personality Belly Delay (Calibrator
Menu Item 11.03). When set to continuous the belly action will operate for as long as the Belly
switch input is active.
Belly Delay Immediate

0.1S 5.0S 0.1S 1.0S
Belly Style Power Up

Options Default
Normal Continuous Normal

Safety Features Safety Features/Anti-Rollback
______________________________________________________________________________
Anti-Rollback
This is a standard SEVCON feature and is used to help prevent roll back conditions on ramps. If
the driver reselects the previous direction after a neutral condition, braking is not attempted, and
full drive power is available to restart on a hill.

Safety Features Safety Features/Anti-Rolloff
______________________________________________________________________________
Anti-Rolloff
This feature is designed so that if a vehicle is powered up, without its handbrake applied, any non-
drive condition on a gradient results in the vehicle braking slowly, in a controlled way, down a
ramp without running away. The vehicle has to be stationary at least once after power up before
the feature is applied.
The Roll-Off Electro-brake option may be set so that the Electro-brake (if fitted & configured) is
applied (brakes on) when Roll-Off is detected.
The Roll-Off strength is not adjustable but can be enabled and disabled using the Roll-Off Enable
option.
Roll-Off Enable Immediate

Options Default
OFF ON ON
Roll-Off E-Brake Power On

Options Default
OFF ON OFF

Safety Features Fail-safe
______________________________________________________________________________
Fail-safe
The controller’s safety system includes a microprocessor watchdog which can detect software
failure, and a hardware fail-safe system which can prevent dangerous runaway conditions in the
event of certain hardware failures.
Every time the controller is powered-up, the software checks that the fail-safe circuit is able to
switch off the MOSFETs and open the contactors.

Controller Protection Temperature Monitoring
______________________________________________________________________________
Controller Protection Features
There are several in built features which are designed to protect the MillipaK controller from
damage due to excessive load currents, voltages and prolonged periods of high demand.
Temperature Monitoring
If the temperature of either power frame exceeds 75oC its maximum available current will be
reduced. Note, however, that if the set current limit is less than the maximum available current
limit actual cutback will occur at progressively higher temperatures than 75oC. The thermal
cutback ensures that the maximum heatsink temperature is limited to 90oC (See Figure 6). When
cutback occurs the diagnostic LED will flash 8 times. Inspection of the calibrator fault messages
will indicate which unit is in thermal cutback.
Thermal Cutback Characteristic
100
90
Current Limit (%)
80
70
60
50
40
30
20
10
0
70 72 74 76 78 80 82 84 86 88 90
Temperature (DegC)
Figure 6: Armature Thermal Cutback Characteristic

Controller Protection Timed Current Cutback
______________________________________________________________________________
Timed Current Cutback
During periods of high current usage the power components of the controller produce
considerable heat. Under normal circumstances the controller will cutback the maximum current
supplied to the load when the heatsink temperature rises above a safe level for the controller
components. However, when the current supplied is close to the maximum rating of the controller
the temperature rise of the components leads the heatsink temperature by up to 40qC. If this
situation was allowed to arise damage may result in the controller. In order to prevent this
situation a timed current cutback feature is incorporated in the MillipaK controller, which works
as described below:
The controller monitors the load current each second and estimates the junction temperature of the
MOSFETs. If the estimated temperature exceeds 125oC, then the current limit is reduced by 1% of
the Armature Block Rating (ABR). If the temperature is above 100oC and the temperature has
exceeded 125oC without falling below 100oC, then the current limit is reduced by 1% of the ABR.
If the temperature is below 100oC, then the current limit is increased by 1% of the ABR. The
current limit can be reduced to a minimum of 60% of the ABR.
The system will limit the current through the armature to the calculated limit during drive and
braking.

Controller Protection Motor Protection Cutback
______________________________________________________________________________
Motor Protection Cutback
By monitoring the motor current over a period of time, the controller then calculates the total
power dissipation within a typical motor and so estimates the motor temperature rise.
After setting Motor Protection Cutback to ON, the estimated motor temperature can then be used
to set the maximum allowed motor current and thus prevents excessively high motor temperatures
being reached.
The maximum allowed motor current will reduce down to a minimum of 30% of the Armature
Block rating if the estimated Motor Temperature rises to a dangerous level.
If Motor Protection Cutback is set to OFF then there will be no reduction in allowed maximum
motor current due to estimated motor temperature, although any other forms of maximum current
reduction (such as thermal cutback) will still be applied.
The Upper and Lower Limits set the cutback levels. The maximum allowed current is linearly
cutback between the two levels. As the levels are reduced the maximum allowed current will be
cutback earlier.
Motor Protection Cutback Power Up

Options Default
OFF ON OFF
Current Cubed Lower Limit Immediate

0 254 1 25
Current Cubed Upper Limit Immediate

1 255 1 40

Controller Protection Safe Operating Area
______________________________________________________________________________
Safe Operating Area (SOA)
The controller’s current may be limited at high and/or low duty cycles depending on its current
and voltage specification. This is to reduce the thermal stress on the power components in order to
increase long term reliability. See Figure 7.
The “Safe Operating Area” is a characteristic of the MOSFETs and Freewheel Diodes which
make up the power-frame. The MOSFET SOA restricts current at high duty cycles on all
configurations, and the Diode SOA tends to restrict the current at lower duty cycles on lower
voltage applications.
For most applications SOA will have little or no effect on the operation of the controller. Its effect
is more significant in protecting the controller against adverse loads such as damaged motors and
static test rigs.
24-48V Controllers
100
90
80
% of Max. Current
70
60
50
40
30
20
10
0
0 20 40 60 80 100
% On
Figure 7: SOA Characteristic

Controller Protection Under/Over Voltage Protection
______________________________________________________________________________
Under-voltage and over-voltage protection
In order to prevent a sudden loss in power, the controller will begin to linearly ramp down the
current limit, once the average battery voltage falls below a pre-set under-voltage start level. The
current will be ramped down to 0 and a 7 flash fault indicated if the averaged battery voltage falls
below the under-voltage cut-out level.
To protect the controller from over-voltage caused by prolonged regen braking, regen braking will
be reduced when the average battery voltage reaches the over-voltage start level. If the voltage
exceeds the over-voltage cut-out level in braking then the line contactors will open and
freewheeling will occur, requiring the vehicles foundation brakes to be used.
Under any other circumstances if the battery voltage exceeds the over-voltage cut-out level, all
pulsing is stopped and a 7-flash fault is indicated. This protects against incorrect battery
connection.
Nominal Under-voltage Under- Over-voltage Over-voltage

Battery Cutout Voltage Start Start Cut-out
Voltage (adjustable) (adjustable)
24 V 14.5V Under Voltage System V up to 30.0V
36 V 14.5V Cut-out up to Over Voltage 45.0V
48 V 14.5V System V Cut-out 57.0 V
Table 8: Under and Over-Voltage Cutback Levels
The following calibrator menu items are used to set these values.
Low Voltage Start Immediate

Low V System 0.5V 18.0V
Cutout Voltage
Low Voltage Cutout Immediate

14.5V Low V Start 0.5V 16.0V
High Voltage Start Immediate

System High V 0.5V High V Cutout
Voltage Cutout

Controller Protection Under/Over Voltage Protection
______________________________________________________________________________
High Voltage Cutout Immediate

High V 50.0V or 0.5V 50.0V or 58.0V
Start 58.0V
The maximum High Voltage Cutout depends on the level of the System Voltage item. If the
System Voltage is set to 36V or lower, then the maximum is 50.0V. If the System Voltage is set
greater than 36V, then the maximum is 58.0V.

Calibrator Map
Calibrat o r 1 2 (18) 3 (19) 4 (20) 5 (21) 6 7

Reference
Map for 4Q Controller System Version 1.50.01 - 7th March, 2002
Descript ion T OP x xx Service Level Access
Navigation
Current T he o perat or m o ves t hrough t he Calibrat or M ap by pressin g t he SE LECT key. T he solid lin e sho ws t h e p at h t h e
0 I.M AX Arm I Limit x xx E n gin eering Level Access
L im it s t h rough t h e m enu st ruct ure when t he SEL ECT key is pressed.
Brakin g In Serv ice M ode (no P asswo rd ent ered) on ly t he it em s sh own wit h a t h ick so lid border are displayed. W h en t he
x xx All Adjust Level Access
1 P LUG Dir Change Neutral Foo t brak e next it em is hidden (Engineering o r All adjust access o nly ), t he calibrat o r m o ves on t he nex t displayable it em .
L ev els
It em s wh ich are not con figured will also be h idden, ie t h e by pass it em s will n ot be displayed if t he byp ass
cont act or is n ot con figured.
2 ACCEL. Accelerat or Accel Delay Drive Decel Dir Decel Neut. Decel Accel Zero V Accel Full V
In Engineering M o de (P asswo rd ent ered) t h e it em s sh own wit h a so lid border are display ed. W hen t he n ex t it em
8 9 10 is h idden (All adjust access on ly ), t he calibrat or m ov es on t he n ext displayable it em . It em s which are n ot
Creep configured will also be hidden.
3 CREE P Creep Speed
Sp eed
In All Adjust M o de (P assword ent ered) all t he it em s (solid and dashed bo rders) are disp lay ed.
4 BYP ASS Byp ass Direction

By default , t h e Calibrat o r m oves from left t o right t h ro ugh t he m en u st ruct ure. If t he operat or p resses and holds
t h e '+' an d '-' keys for m ore t han 1 seco nd t he n av igat ion direct ion chan ges and t h e Calibrat or will m o ve from
M axim um righ t t o left t hrough t h e m enu st ruct ure. T he direct io n can be rest o red by ho ldin g t he '+' and '-' keys for 1 seco n d
5 SP E ED Max. Speed Rev Sp eed again .
Speed
T he direct ion is indicat ed by t he L ED on t h e Bar Graph. If t he LE D is lit st eadily, t he direct ion is from left t o
Cut back righ t , else if t h e L ED is flashing t h e direct io n is from righ t t o left .
6 SP E ED1 Cut Sp d 1
Speed 1
Information Items
Cut back T he T est m enu on ly shows inform at ion it em s t hat can no t be m odified. T h e op erat or can m ov e up
7 SP E ED2 Cut Sp d 2 and down t he m enu using t he '+' and '-' keys. As befo re, it em s wit h a dash ed bo rder are on ly displayed in All
Speed 2
Adjust M ode. If t he Operat or p resses t he SE LECT key t he Calibrat o r m oves t o t h e nex t m enu.
M ot or I Cubed I Cubed
8 F.W E AK Lower Limit Upper Limit
Item Identification
Set up
T he o perat or can ident ify t he curren t it em by holdin g do wn t he '+' and '-' keys. Fo r ex am ple, h olding down t he
'+' an d '-' key s o n t he High V Cut out person alit y will disp lay 1 1.09 (M enu 11 (I.M AX is m enu 0 ), It em 9). T h e
P ower St eer op erat or will use t h e User M anual t o ident ify t he personalit y from t he ID.
9 T IM ER P. Steer Timer
T im er 11 12 13 14 15 16 17
Seat Swit ch
10 SEAT Seat Delay
Delay
11 X2 Addit ion al Roll-off W alk Speed Belly Delay P SS Ramp Up P SS T im er

Line Dropout
L o w V St art
Low V
High V St art
High V
FBrake Zero FBrake Full
Timer Cutout Cutout
P ersonalit ies
Sy st em Seat Cuts High Speed Power Steer FBrak e

12 X3 Ch op Select SRO E nable Control Mode Roll-Off Brae Rev Sp d FS1 Recy c. Seq Dir SW M ot or P rot Line Dropout Accel Ch ar. Belly St y le Buzzer Alarm Digit al I/O
Set up Pump Mode T rigger Priority
An alo gue System

Inputs Voltage
13 X4 Fault L og System Status
Sp eed
14 X5
E st im at e
Syst em
15 BAT T Vo lt ages
Battery Voltage Cap. Voltage
Motor P oin t A1 P o int A2

16 M OT OR (V) Arm. Voltage Q2 FET Voltage Q4 FET Voltage
Vo lt ages Voltage Voltage
Motor
17 M OT OR (A) Arm. Current
Current s
Heat sink Max Clear Max

18 T EM P T emperature
T em perat ure T emperature T emperature
19 T EST T est M enu AccelDem Accel Voltage Aux. Demand Aux . Voltage Digital 1 Switch Digital 2 Switch Digital 3 Switch Digital 4 Switch Digital 5 Switch Digital 6 Switch S/W Version S/W Revision Ser No. Date Ser No. ID1 Ser No. ID2 Pers Checksum
T OP

______________________________________________________________________________
Controller Mounted on suitable flat heatsink with appropriate heatsink compound?
Power wiring checked, shortest routes taken where possible?
Light wiring checked; use calibrator to verify controller correct switch operation.
Accelerator set-up and checked 0 – 100%?
Personalities are all set, checked and record filled out?

Commissioning Personalities Record
______________________________________________________________________________
Personality Record
New Range
Personality
Setting Minimum Maximum
0.01 Armature Current Limit 50A ABR1
1.01 Direction Change Braking Level 5% 100%
1.02 Neutral Braking Level 0% 100%
1.03 Foot-brake Braking Level 0% 100%
2.01 Acceleration Delay 0.1s 5.0s
2.02 Drive Deceleration Delay 0.1s 10.0s
2.03 Direction Change Decel Delay 0.1s 10.0s
2.04 Neutral Deceleration Delay 0.1s 10.0s
2.05 Accelerator Zero V2 0.00V 4.50V
2.06 Accelerator Full V2,3 0.00V 4.50V
3.01 Creep Speed 0% 25%
5.01 Maximum Speed 0% 100%
5.02 Maximum Reverse Speed 0% 100%
6.01 Cutback Speed 1 0% 100%
7.01 Cutback Speed 2 0% 100%
8.01 I Cubed Lower Limit 0 254
8.02 I Cubed Upper Limit 1 255
9.01 Power Steer Timer 0s 60s
10.01 Seat Delay 0.1s 5.0s
11.01 Roll-Off Enable OFF/ON
11.02 Walk Speed 0% 100%
11.03 Belly Delay 0.1s 5.0s
11.04 PSS Ramp Up Delay 0.1s 1.0s
11.05 PSS Timer 0.5s 10.0s
11.06 Line Contactor Dropout Timer 1s 60s
11.07 Low Voltage Start Low V Cutout System Voltage
11.08 Low Voltage Cutout 14.5V Low V Start
11.09 High Voltage Start System Voltage High V Cutout
11.10 High Voltage Cutout High V Start 50.0V or 58.0V4
11.11 Foot Brake Zero Volts 0.00V 4.50V
11.12 Foot Brake Full Volts 0.00V 4.50V
12.01 Chop Select OFF/ON/24V
12.02 SRO Enable OFF/ON
12.03 Control Mode TORQUE/SPEED
12.04 Seat Cuts Pump OFF/ON
12.05 Roll-Off Electro brake OFF/ON
12.06 Reverse Speed Limit OFF/ON
12.07 FS1 recycle on Dir Change OFF/ON
12.08 Dir Sw Seq Checking OFF/ON
12.09 Motor Thermal Protection OFF/ON

Commissioning Personalities Record
______________________________________________________________________________
Range
Personality New Setting
Minimum Maximum
12.10 Line Contactor Drop out OFF/ON
12.11 Accelerator Characteristics LINEAR/CURVED/2*SLOPE/CRAWL
12.12 High Speed Mode NORMAL/MOMENTARY
12.13 Belly Style NORMAL/CONTINUOUS
12.14 Power Steer Trigger FS1/SEAT/DIRECTION/
12.15 Foot-brake Priority DRIVE/FOOTBRAKE
12.16 Buzzer Alarm Off/REVERSE+ROLLOFF/ALL
12.17 Digital I/O 1 16
12.18 Analogue I/P 1 3
12.19 System Voltage 24V 48V
Table 9: Personality Record

Fault Finding
______________________________________________________________________________
Fault Finding
The MillipaK controller includes a number of features designed to help the user track down
operational faults, wiring faults or internal controller faults.
The Diagnostic LED mounted next to the calibrator connectors on the front of the controller
serves as a simple diagnostic tool as explained below:
ON No fault, normal condition

OFF Internal controller fault
1 flash Personality out of range
2 flashes Illegal start condition (Traction)
3 flashes MOSFET Short Circuit
4 flashes Contactor fault or Motor Open Circuit
5 flashes Not used
6 flashes Accelerator wire off fault
7 flashes Low or High battery voltage or BDI cutout operating
8 flashes Over temperature or timed cutback
10 flashes Power Up Autozero has not yet been completed
Table 10: Flash Fault Descriptions
In addition to the LED indication a more detailed description of any faults detected may be found
by using the calibrator. Menu item number 13.01 gives a code which corresponds to the following
detected faults:
ID Fault Description Flash Fault

0 System OK On
Maximum power available to the motor has
1 Thermal Cutback been reduced due to excessive Heatsink 8
temperature.
Maximum power available to the motor has
Timed Current Limit
2 been reduced by the Timed Current Limit 8
Cutback
Cutback function.
Input wire from accelerator has been
3 Accelerator Wire Off 6
disconnected.
Accelerator Pressed at
4 Accelerator pedal pressed at power up 6
Power Up
5 Belly Fault The Belly switch function has occurred 2
6 Seat Fault Drive selected and no seat switch closed. 2
No drive allowed until power up autozero has
7 Autozero Not Taken 10
been taken
FS1 switch remained closed during a direction
8 FS1 Recycle 2
change
Direction switch selected for greater than 2
9 SRO Fault 2
seconds with FS1 open.

Fault Finding
______________________________________________________________________________
ID Fault Description Flash Fault

10 Two Direction Fault Two directions selected together. 2
11 Sequence Fault Direction or FS1 switch closed at power up. 2
12 Low Battery Fault Battery voltage is too low. 7
13 High Battery Fault Battery voltage is too high. 7
High Battery Fault with Battery voltage is too high before the line
14 7
Line Contactor Open contactor is closed
Configuration Range
15 A personality is out of range. 1
Fault
Configuration CRC
16 The personality CRC is incorrect 1
Fault
Line Contactor Welded
17 Line contactor is welded. 4
Fault
Line Contactor did not
18 Line contactor is open circuit. 4
Close Fault
Lower MOSFETs Short Short circuit on Q2/Q4 Armature MOSFETs
19 3
Circuit detected.
20 - Reserved for future use -
MOSFETs did not pulse during power on
21 MOSFET Off 0
failsafe checks (failsafe circuit enabled).
MOSFETs pulsed during power on failsafe
22 MOSFET On 0
checks (failsafe circuit disabled).
Upper MOSFETs Short Short circuit Q1/Q3 Armature MOSFETs
23 3
Circuit detected.
Contactor 2 did not pulse during power on
24 Drive 2 Off 0
Contactor 2 pulsed during power on failsafe
25 Drive 2 On 0
Contactor 1 did not pulse during power on
26 Drive 1 Off 0
Contactor 1 pulsed during power on failsafe
27 Drive 1 On 0
Table 11: Fault Numbers and Descriptions
Fault Clearance
Any fault indication will be cleared by re-initiating the start sequence after the cause of the fault
has been removed.

Fault Finding
______________________________________________________________________________
Fault Reporting Form
Sevcon is committed to improving the quality if all of its products. Please help us by using this
form to report faults to Sevcon. Please give as much detail as possible. Use extra sheets if
required. Fax this form to +44 191 482 4223.
Your Name Telephone Number

Your Company email address
Vehicle Vehicle Type
Manufacturer
Controller Type Part number
Serial Number Software Version
Date / Time that fault
first occurred.
Exact Fault Message
(calibrator or display)
When did the fault during drive / when the vehicle stopped / in neutral / after a keyswitch off-on
message appear? (delete as applicable)
How did the fault
occur?
Please describe:
The vehicle speed.
The approximate
gradient (up or down
hill)
Pedal and switch
changes by the driver
What happened to
the vehicle when the
fault occurred
What is the status of

the vehicle now?
Is there a fault
message at key-
switch on?
Can it be driven?
Table 12: Fault Reporting Form

Fault Finding
______________________________________________________________________________
Software Version and Serial Number indication
For identification purposes and to assist in queries, the software version, and the controller serial
number are indicated in the calibrator Test Menu.
The software version and revision are shown in the Test menu. When giving the software version
and revision, the entire number should be quoted (i.e. MM.mm.rr).
The Serial Number is shown across three items in the Test menu. The first item is the date code
and the next two are the identifier. All these items need to be used to get the complete serial
number. The format is:
Test Item: Ser No. Date Ser No. ID1 Ser No. ID2
Serial Number: MMYY AA BB
Table 13: Serial Number Format
MMYY gives the month and year when the controller was manufactured. (e.g. 0701 indicates
July, 2001). AABB are combined to give a 4 digit identifier which is simply a number from 0001
to 9999. When giving the Serial Number, the entire number should be quoted (i.e.
MMYYAABB).
The MillipaK range of controllers use the latest FLASH technology to allow In System
Reprogramming. This is achieved without having to remove the controller from its installation –
all that is needed is connection to the 6-way calibrator socket.

Specifications
______________________________________________________________________________
Specifications
The following specifications apply to all MillipaK controllers.
Power Configurations
At present the MillipaK 4Q controller is available in the following power configurations:
Housing Armature Soft Start Option

HP Large 180A 100A Soft Start
HP Large 330A 100A Soft Start
Table 14: Power Configurations
All the MillipaK 4Q range of controllers operate from 24-48v batteries.
WARNING: The pump soft start option, when fitted, is NOT current limited and
care should be taken not to exceed the maximum current specified by
the controller rating.
EMC standards
All MillipaK variants are tested to and conform to EN12895.
Socket B protection
All user connections on socket B are protected against indefinite short circuit to battery minus and
battery positive.
Contactor drive ratings
All contactor drives are rated at 3A peak (10s) and 1.5A continuous. All the drives have reverse
battery connection protection, inbuilt freewheel diode and are internally protected against short
circuit.
Analogue Input Impedance
The two analogue inputs are internally pulled up to +12v via a 12k resistor. This is primarily
designed for use with 5k potentiometers, but may also be used with suitable voltage sources.
Digital Input Impedance
The digital inputs are internally pulled up and are active LOW. They therefore must be connected
to battery minus to operate a function. Maximum resistance to battery minus to operate is
500ohms.

EMC Guidelines
______________________________________________________________________________
EMC Guidelines
The following guidelines are intended to help vehicle manufacturers to meet the requirements of
the EC directive 89/336/EEC for Electromagnetic Compatibility.
Any high speed switch is capable of generating harmonics at frequencies that are many multiples
of its basic operating frequency. It is the objective of a good installation to contain or absorb the
resultant emissions.
All wiring is capable of acting as a receiving or transmitting antenna. Wiring should be arranged
to take maximum advantage of the structural metal work inherent in most vehicles. Vehicle
metalwork should be electrically linked with conductive braids.
Power Cables
All cables should be routed within the vehicle framework and kept as low in the structure as is
practical - a cable run within a main chassis member is better screened from the environment than
one routed through or adjacent to an overhead guard.
Power cables should be kept short to minimize emitting and receiving surfaces
Shielding by the structure may not always be sufficient - cables run through metal shrouds may be
required to contain emissions.
Parallel runs of cables in common circuits can serve to cancel emissions - the battery positive and
negative cables following similar paths is an example.
Tie all cables into a fixed layout and do not deviate from the approved layout in production
vehicles. A re-routed battery cable could negate any approvals obtained.
Signal Cables
All wiring harnesses should be kept short.

Wiring should be routed close to vehicle metalwork.
All signal wires should be kept clear of power cables or made from screened cable
Control wiring should be kept clear of power cables when it carries analogue information - for
example, accelerator wiring.
Tie all wiring securely and ensure wiring always follows the same layout.
Controller
Thermal and EMC (emissive) requirements tend to be in opposition.

Additional insulation between the controller assembly and the vehicle framework reduce
capacitive coupling and hence emissions but tend to reduce thermal ratings. A working balance
needs to be established by experiment.
The complete installation should be documented, in detail, and faithfully reproduced on all
production vehicles. When making changes, consider their effect on compliance ahead of any
consideration of cost reduction or other “improvement”.

Ordering Information Part Numbers
______________________________________________________________________________
Ordering Information
The controllers and contactor panels are allocated 633 numbers as shown. The lettering section
gives the full listing of item types.
item description voltage current logic Customer Code
A= 2= 24 1= 100-199 1= SEM plug XX

B= 3= 36 2= 200-299 2= SEM plug s/start
C= Controller only 4= 48 3= 300-399 3= SEM regen
D= Traction panel 7= 72 4= 400-499 4= SEM regen s/start
E= Traction + Pump Panel 8= 80 5= 500-599 5= Series Pump
F= Twin Traction Panel 9= 96 6= 600-699 6=BPM
G= Twin Traction + Pump Panel 7= 700-799 7=BPM s/start
H= 8= 800-899 8= 4QPM
J= 9= 900 + 9= 4QPM s/start
K=
L=
M=
N=
P=
R=
S=
T= HP Controller only
W= HP Traction panel
X= HP Traction + Pump Panel
Y= HP Twin Traction Panel
Z= HP Twin Traction + Pump Panel
HP = High Power
For panels then the voltage, current and logic numbers should be used to describe the traction
controller.
Examples:
330A 4QPM controller 633T43801
330A 4QPM controller with Soft Start 633T43901

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TECHNICAL MANUAL

CBL 150 48V

Sce Commercial France : Tél. 03 86 43 04 54

1.1 – WARRANTY PROCEDURE

1.3 - VARIATEUR DE TRACTION / DRIVE AND BELT CONTROLLER

1.1.1 Trac Pers IMAX 500A

Erreur ! Liaison incorrecte.

2.1.3 Electrical circuit:

2.1.7.1 Service brake

2 front disc brakes:

2.1.7.2 Parking brake

2.1.7.3 Electric braking

2.1.8 Front suspension:

2.1.9 Drive Sytem

2.1.10 Driving suspension:

2.1.11 Front wheels:

2.1.12 Rear wheels:

2.2.1 General description:

Belt inching devices

2.2.3 Belt structure:

Rear lifting arm

Main welded chassis assembly

2.2.4 Front axle:

2.2.5 Front brakes:

2.2.6 Front suspension:

2.2.7 Steering system:

2.2.8 Rear axle:

2.2.9 Rear brakes:

2.2.10 Rear suspension:

2.2.11 Parking brake:

2.2.13 Main drive motor:

2.2.14 Belt motor:

2.2.15 Hydraulic pump motor:

2.2.16 Drive/belt controller:

2.2.18 Lighting system:

2.2.19 Belt comm

Hydraulic pump lever

2.2.20 Operator's compartment commands:

2.2.20.1 Screwed to ground:

• Deadman pedal (activated by left foot)

2.2.20.2 Dashboard is equipped of :

(1) an ignition switch (standard) or a key switch or smart key switch;

3.1.1 Precautions and recommendations:

Recommendation: in the bends, the speed must be reduced.

Recommendation: the elements of the battery must never be exposed to superior

Recommendation: for maintenance, if the vehicle must be lifted to work underneath, it is

Recommendation: Do never throw hot water or steam on battery element(s)

Recommendation: never use cleaning products, solvents or grease removers containing

3.1.3 Before starting the unit:

CAUTION: Do NEVER try and adjust the seat while driving.

d- Fasten seat belt

h- Push the brake pedal to ground and maintain it.

d- Put the forward/reverse lever to neutral position;

THE EMERGENCY STOP MUST ONLY BE USED IN EXCEPTIONAL

3.1.6 Belt use instructions:

1st case: Mode selector traction/belt is on traction position.

2nd case: Mode selector traction/belt is on belt position.

a- Handbrake lever applied, forward/reverse lever in neutral and selector on belt

THE EMERGENCY STOP MUST ONLY BE USED IN EXCEPTIONAL

3.1.7 Belt hydraulic handpump lever in case of emergency :

1) Open the door.

4) Close the valve.