Contents Introduction ...................................................................................................................................................................2 FB10-15KRT PAC.....................................................................................................................................................2 Market focus .................................................................................................................................................................3 Opportunity................................................................................................................................................................3 Industry .....................................................................................................................................................................3 Market segmentation ................................................................................................................................................4 Product presentation ....................................................................................................................................................6 Standard configuration..............................................................................................................................................6 Product specs ...........................................................................................................................................................6 Introduction 5 steps presentation..............................................................................................................................7 Optional...................................................................................................................................................................13 CSM............................................................................................................................................................................15 CSM ........................................................................................................................................................................15 Operator comfort.........................................................................................................................................................17 Display ....................................................................................................................................................................18 Operator Controls ...................................................................................................................................................20 Brake system ..........................................................................................................................................................20 Frame and body..........................................................................................................................................................21 Frame and Battery compartment ............................................................................................................................21 Overhead Guard (OHG)..........................................................................................................................................21 Length and Turning Radius.....................................................................................................................................21 Control system............................................................................................................................................................23 PM-1000 AC controller............................................................................................................................................23 PM-1000 AC controller system ...............................................................................................................................23 Controller functions .................................................................................................................................................24 CAN-bus electrical system......................................................................................................................................27 Drive train ...................................................................................................................................................................28 Drive train assembly ...............................................................................................................................................28 AC motors ...............................................................................................................................................................28 Hydrostatic Steering................................................................................................................................................30 Steer and drive Axle................................................................................................................................................30 Mast ............................................................................................................................................................................31 Operation Features .................................................................................................................................................31 Mast Tilt Angles.......................................................................................................................................................31 Serviceability...............................................................................................................................................................32 Standards ...................................................................................................................................................................33 Appendix I...................................................................................................................................................................34 Truck specifications FB10-15KRT PAC..................................................................................................................34 Appendix II..................................................................................................................................................................36 Mast Charts FBKRT PAC .......................................................................................................................................36 Appendix III.................................................................................................................................................................45 Battery drawing FB10-15KRT PAC ........................................................................................................................45 Appendix IV ................................................................................................................................................................46 PM-1000 AC Controller Pre-settings ......................................................................................................................46 Introduction FB10-15KRT PAC Mitsubishi Forklift Trucks introduces an improved 24V 3-wheel model product line with AC technology. This model update provides you with the latest market and safety requirements. 3-Wheel 24V Electric models Nomenclature: Nomenclature FB10KRT PAC FB12KRT PAC FB15KRT PAC Nominal capacity 1000 kg @ 500 mm L.C. 1250 kg @ 500 mm L.C. 1500 kg @ 500 mm L.C. FB10-15KRT PAC series Operator comfort A comfortable operator compartment with a low footstep and well placed grab handle allows easy on/off access. The compartment has a tilting steering column and carefully placed hydraulic control levers for improved comfort and reduced fatigue. The functional display keeps the driver informed of truck, traction and hydraulic hours and the state of the battery charge. Adaptability Low emissions and low noise means these series is suitable for indoor use. Advanced electronics means truck can be customized to meet the precise needs of each application, load and driver. In addition to 5 pre-set modes: - Normal - High performance - Economy - Long distance - Short shuttle Performance The truck has the latest AC technology. Drive and lift speeds, acceleration and regenerative braking functions can all be programmed, allowing optimal performance and efficiency to be achieved in each application Serviceability Minimal service requirements are achieved through the use of an active protection system that monitors motors, controller and battery for safe operation. The service interval is improved to 500 hours. 2 CEOM0924 Market focus Opportunity The figure below represents the 3-wheel electric sales volume in Europe for the year 2005, split by load capacity and voltage. The majority of the sales are in the range of 1.5 - 1.6 ton. Although in this capacity range both 24-volt and 48-volt machines are offered, there is a clear difference in performance specifications. European total market figures 3- wheel 24V – 48V models Industry Typically you will find these lift trucks in: Retail Applications: Here lift trucks are used for maximum 2 hours at intermittent shifts. The performance specifications are typically low. Therefore the low usage does not justify an expensive machine. Mostly, the drivers are inexperienced. The type of applications includes grocery stores, do-it-yourself centers, garden centers and wholesale & retail food distribution. Production Applications: The compact dimensions result in high maneuverability. The customer will accept the lower performance specs in the case that productivity is not the key issue. Typical application examples are small engineering & manufacturing companies, agriculture, food processing, and printing. Warehouse Applications: A combination of compact dimensions and flexibility are the key characteristic of this model when used in narrow aisle applications. This model can be used as the gateway into the warehouse segment. Usually experienced drivers are assigned to the truck. Typical narrow aisle applications are warehouses, distribution centers, wholesale & retail beverage distribution and container stuffing 3 CEOM0924 Market focus Market segmentation Within the 3-wheel 24V electric lift truck segment the 1500kg capacity is the most popular range. 4 CEOM0924 Market focus Maneuverability Compact overall chassis dimensions contribute to exceptional maneuverability in narrow aisles and in block stacking or drive-in racking applications. The low overall truck height provides generous clearance for operation in containers or trailers. Our engineers have focused on the following issues to improve the 24V series. Bullet points - Improved gradeability and acceleration New generation Mitsubishi AC controller Integrated Presence System (IPS) features (includes, park brake alarm; seat belt reminder and lift & tilt interlock) Standard high overhead guard 500hrs service interval, to improve Total Cost of Ownership CAN-bus electrical network system Diagnostics and performance programmable by Laptop/PC and GSE Reduced energy consumption Reduced noise levels Improved regenerative braking Back-up alarm supplied as standard New improved display Steering on demand system 5 performance application settings Improved backwards visibility 5 CEOM0924 Product presentation Standard configuration 3 - Wheel Chassis, 24 Volt Tiltable steering column PM-1000 AC Traction control system Manual hydraulic levers 5 kW AC Traction motor 2-way hydraulic valve PM-1000 AC Hydraulic control system Battery compartment side covers 6,5 kW AC Hydraulic motor EEC name plates Hydrostatic power steering (Single hydraulic) English Language Markings Operations and Maintenance Manual Display: * Battery Discharge Indicator [BDI] with Lift Interrupt * Truck / drive motor / hydraulic motor hour reading * Indicators for Brake Fluid and Park Brake * Fasten seat-belt reminder Electronic backup alarm Integrated Presence System (IPS)* Regenerative Braking High over head guard (truck height = 2015 mm) Working Lights, 2 Front/ 1 rear * Fault indicator Super Elastic tires Integrated Presence System (IPS) SBE Connectors for frame Rubber floor mat * Integrated Presence System (IPS): Seat belt indicator, park brake alarm, Lift & Tilt interlocks Product specs Manufacturer’s model designation Lifting capacity At load centre Length to forkface Overall width Working aisle width 1000 x 1200mm pallets Working aisle width 800 x 1200mm pallets Travel speed, with/without load Lift speed, with/without load Lowering speed, with/without load Gradeability, with/without load Max. gradeability, with/without load Battery voltage/capacity at 5-hour discharge FB10KRT PAC 1.0 500 1700 997 FB12KRT PAC 1.2 500 1700 997 FB15KRT PAC 1.5 500 1775 997 3030 3030 3104 km/h m/s m/s % 2850 11,5/13,5 0,29/0,48 0,52/0,50 9.6/15.1 2850 11,2/13 0,27/0,48 0,52/0,50 8.1/13.6 2925 11/12,5 0,26/0,48 0,52/0,50 6.9/12.3 % 16.4/25.1 14.0/22.6 12.2/20.6 V/Ah 24V 720Ah 24V 720Ah 24V 840Ah Q (t) c (mm) l2 (mm) b1 (mm) Ast (mm) Ast (mm) Truck spec sheet See the truck spec sheet in Appendix I, mast capacity charts in Appendix II and the battery drawing in Appendix lll. 6 CEOM0924 Product presentation Introduction 5 steps presentation The product presentation is a summary of all the features and benefits that the new FB10-15KRT PAC trucks have. It describes an easy walk around presentation in 5 steps. The bullet points are to help sales people during a demonstration. The complete truck can be easily demonstrated in the following 5 steps Position 1 Front of the truck Mast The mast channels are designed with narrow flanges and wide webs to increase the inside “window opening” for good visibility without sacrificing mast strength. Unique cross member design provides good torsion strength and rigidity with the mast raised at full lifting height. Hose and chain routings on the Duplex and Triplex mast have been positioned behind the mast channels at 45 degrees angles contributing to good visibility. Square fork bars increase the opening area between the upper and lower fork bars allowing good fork tip visibility through the carriage. The mast is interchangeable with the DC model and with the 48V N series. The mast has standard load backrest and an integral or hook on side shifter is optional. The working lights are applied as a standard on this truck. Standard working lights 500 hours service interval The service interval of the truck is now 500 hours. This is reached by updating the front axle point where the mast is mounted and the dust seals in the tilt cylinder socket. 7 CEOM0924 Product presentation Position 2 Right hand side of the truck All the three models in this 24V-series share the same chassis. The difference in lifting capacity is achieved by the use of three different counterweights Compact overall chassis dimensions and low overall truck height The compact overall chassis dimensions contribute to exceptional maneuverability in narrow aisles and in block stacking or drive-in racking applications. The low overall truck height provides generous clearance for operation in containers or trailers. This truck fills the gap between the warehouse trucks and the larger counterbalance trucks. The battery hood is opened by moving the manual control box forward and releasing 2 locks. The battery hood has a gas spring to hold it safely open while you check out the battery compartment. It has a wide opening, which gives easy access to the battery and other components. This easy access speeds up removal and exchange of batteries. The connection for the PC or Laptop can be found on the left hand side under the floor plate. With this connection the service engineer can adjust each setting in detail. Controlled roll down One of the control system’s functions that you particularly should mention is the controlled roll down. The controlled roll down function works with the regenerative braking system to keep the truck moving slowly and safely when it’s allowed to roll forward or backwards on a gradient. 8 CEOM0924 Product presentation Position 3 Rear of the truck This model is driven by one AC drive motor on the rear wheel; this construction is typical for the low-duty 24V-models. The traction motor is a 5 kW AC motor. The advantages of an AC motor is it provides high torque for rapid acceleration, better ramp performance and smooth, quiet, controlled operation and an AC motor is maintenance free. Turn within its own dimensions Hydrostatic power steering Steering on demand This truck has a very small turning radius due to his compact dimensions and the possibility to make a turn within its own dimensions. The rear-wheel is both the drive and steering wheel. The hydrostatic steering operates by sensing the current of the pump motor. This means that when the operator turns the steering system, increasing oil pressure changes the current of the pump motor and the main hydraulic system will increase duty for smooth cut-in to steering power. It’s a lowmaintenance system and it allows smooth, precise, effortless maneuvering. The steering wheel is very light and goes from lock to lock in just five turns. Whatever the truck’s speed, the amount of pressure needed to turn the wheel remains constant. The truck features a steering on demand system, which senses the need for steering power and delivers it smoothly from the main hydraulic motor. This means there is no need for a separate power steering motor and having no separate steering motor means less noise, fewer parts and lower maintenance costs. The drive motor is easy to reach; you only have to remove the cover on the rear. The rear cover can be removed without any tools. Also under this cover you will find the contactors and the inverters. The emergency button is located on the right hand side at the back of the truck, just behind the operator. This way the operator can reach the emergency very fast when driving backwards. 9 CEOM0924 Product presentation Position 4 Left hand side of the truck To get on board the truck has a grab bar and a low-height, anti slip step. DRS switch Under the floor plate, which is easily to remove without any tools, you will find the hydraulic tank, motor and pump. Also the DRS switch is here at the left hand side of the truck. This switch allows you to set the truck up and the service engineer performs a diagnostic on the truck. Either the owner can select one of the five pre-set modes or the service engineer can adjust the performance settings to match the application. In either case, it’s very quick to do and it requires no special tools. Not only is the drive motor on the truck quiet, but so is the AC-powered hydraulic motor, there is no separate steering motor to add extra noise. Which means the driver will be very comfortable. Wide tread option The solid pneumatic tyres are fitted as standard on the truck but the non-marking tyres are available if needed. Also a wide tread option is available. This will mean the total width of the truck will increase from 997mm to 1067mm. Because of the increased width the total stability of the truck increases and the residual capacity will increase. Regenerative braking There are three braking systems on these trucks. 1. Operator brake 2. Parking brake 3. Regenerative braking 10 CEOM0924 Product presentation Position 5 Sit on the driver seat of the truck The seat is standard a static seat you can move it forward and backward. The seat is fitted with both hip restraints and an inertia-reel safety belt. The seat belt warning will flash when the belt is not fastened. There is also an important safety feature within the seat; it’s a safety switch that automatically prevents all travel or fork movement if the driver isn’t securely seated. Good visibility From the driver seat you have great visibility. The truck has an automotive style pedal lay-out. There are two pedals, for the accelerator and brake. They’re mounted through the floor. That’s very important, because throughthe-floor pedals cause a lot less leg strain than hanging pedals. Their height and angle have been set for maximum comfort. The truck has a compact steering wheel. It takes you effortlessly from lock to lock in just five turns. The steering wheel can be adjusted in infinite number of positions. To the left of the steering column there’s a directional lever. You can choose between forward, neutral and reverse. If the truck is parked in forward or reverse mode, the lever must be returned to neutral and the direction must be re-selected before the truck will move again. This is a safety feature to prevent the truck from starting off in the wrong direction. Clear display The display consists of a clear, easy-to-read LCD display. The icons are displayed by universal graphic symbols for ease of understanding. The display monitors the trucks performance levels and operational indicators, such as truck hours, drive motor hours and hydraulic motor hours. In addition a battery discharge indicator is displayed. (See page 18) 11 CEOM0924 Product presentation The hydraulic functions; lifting, tilting and auxiliary functions are controlled by short levers that are positioned next to the operator on the battery cover, for a comfortable operation. The handgrips are ergonomic shaped with in mould symbols. 12 CEOM0924 Product presentation Optional Full suspension seat This seat has full suspension and you can move it forward and backward. You can also adjust the suspension to suit the weight of the driver. The seat is fitted with both hip restraints and an inertia-reel safety belt. An alarm flashes when the belt is not fastened. Also this seat has a safety switch that automatically prevents all travel or fork movement if the driver isn’t securely seated. Amber Strobe light A 24V voltage amber strobe light is available through the price list. (Integrated) Side shifter Over the last few years the side shifter has become a very popular option. At least 80% of the electric forklift trucks are fitted with a side shifter. The main advantage of the hook-on side shifter is easy replacement in case of damage or if other attachments are required. The advantages of the integral side shifter are: - Increased residual capacity in relation to the hook-on model (see mast charts) - Reduced aisle width due to the smaller x-dimension: - Standard Carriage x = 330mm - Integral Side Shifter x = 353mm - Hook-on Side Shifter x = 390mm The mast charts of can be found in the Appendix. Tyres There are several tyre options available in order to choose the most suitable configuration for each truck. Super elastic tyres (US/US) Solid pneumatic tyres or Super elastic tyres are standard on all trucks, providing the good traction, stability and good residual capacity. Non-marking tyres are also available in solid pneumatic profile. These types of tires are used in combination with an earth strap from frame to floor (not supplied). Wide tread super elastic tyres (US/US/WT) Wide tread option With the wide tread option the residual capacity will increase. Especially with higher lift heights. This is because the whole truck width will increase from 997mm to 1067mm. Because of the increased width the total stability of the truck increases and the residual capacity will increase. Normal tyre Wide tread tyre 13 CEOM0924 Product presentation Road light kit The Road light kit option contains out of two brake lights, rear lights and direction indicators. Standard front work lights are mounted on the most practical location. The rear combination lights (24V) are placed on the rear leg of the overhead guard. Putting the lights at this location is stylish, safe and also less vulnerable to damage. Low overhead guard With the standard overhead guard height of 2015mm (h6) you will be able to drive into containers and other applications with restricted overhead clearance. But if that height is still too high you can order a low overhead guard as option. The overhead guard height will be reduced to 1965mm. Note: with a low overhead guard it is not possible to order a full suspension seat because of the torso clearance. A static seat will replace the full suspension seat. 14 CEOM0924 CSM CSM Galvanized chassis Galvanizing is the process of coating iron or steel with molten zinc. This coating is bonded to the iron or steel and protects the metal. The advantages are: 1. 2. It shields the base metal from the atmosphere Zinc is more electronegative than iron or steel. It is ’sacrificed’ to iron or steel and therefore offers perfect protection. Even if the zinc topcoat becomes scratched and the iron or steel is exposed, it will still be protected from corrosion because the zinc is slowly consumed by iron or steel. These treatments extend the lifetime of the truck and the mast and protect their surface against rust and several aggressive chemicals. A galvanized lift truck is therefore perfectly suited for the fishing, food, port and chemical industry. Note: The rear wheel drive is not suitable for fishing industry and cold store applications, this because you will loose traction when a load is on the forks. The galvanized option includes the complete chassis including fenders, head guard, floorplate, front and engine cover. On request other parts can also be galvanized. For more detailed information a mailer is available on the dealer support site. Galvanized mast Same procedure as with chassis. Food grade hydraulic oil When a truck is driving in an environment where they handle food or other products that cannot handle normal hydraulic oil, food grade hydraulic oil can be ordered. Special colours Chassis parts normally painted original colour will be painted in the special RAL colour. Rims will not be painted and overhead guard will be standard black. It is also possible to paint the overhead guard in special colour. Dual tone is also available on request. Foot directional control A foot directional control is also available. The Foot directional control consists of an accelerator pedal that incorporates 2 micro switches controlling the direction of the truck and a neutral reset switch. There is no standard directional lever on the left hand side of the steering column. Foot directional control is preferred in certain applications to enhance productivity. 15 CEOM0924 CSM Swivel seat The swivel seat plate has big advantages for on/off access of truck and for reverse driving. It features a ball bearing and a locking collar design which guarantee no “free play”. The swivel plate is designed to handle all driver weights. The swivel is available with standard locking position at -20°, 0° and 20°. The swivel can be locked in accordance with the following method: Mechanical locking, using a front hand lever. A special design which raises the driver seat by only 18 mm. Explosion-proof lift trucks The explosion-proof lift trucks may be a small segment of the total material handling business, but it is an essential part because it ensures lift trucks do not spark, during operating and cause disastrous workplace incidents. MCFE research based on industry sources indicates that this segment is around 2% of the total lift truck market. Lift truck that work in hazardous locations can be dangerous. The equipments’ ignition sources, like sparking components such as motors, switches and controllers, and hot surfaces from motors, brake and engine exhaust systems, when exposed to flammable gases, vapours, liquids and combustible powders and dust, can cause fires or explosions. EX lift truck users are industries involved in manufacturing, handling, processing or storing explosive or hazardous materials. Examples of materials are perfumes, cosmetics, paints, varnishes, printing ink, flour, confectionery, medical chemicals, botanical products, alkalis and chlorine, and synthetic rubber. Other EX lift truck users includes facilities where combustible dusts are produced from handling materials like dried hay, starches and pastes, potatoes and grain. Locations where there are drying rooms for evaporating flammable solvents and spray or paint booths also require EX lift trucks, and so do sewage treatment facilities that create flammable gas by products and refrigerators that store volatile and flammable materials. Classifications hazardous location The classifications of hazardous locations depend on the types of materials being handled. The European classification system is – also followed by many other non EU countries – where workplaces are classified into zones. According to European directive ATEX 1999/92/EC, hazards associated with gases or vapours are classed either in zones 0, 1 or 2. Hazards associated with powders or dust particles are categorized as zones 20, 21 or 22. EX lift trucks are constructed from the ground up or converted from standard lift trucks. Pyroban, a leading European EX system provider, converts about 600 lift trucks a year to a recognized EX standard. The company is the exclusive and approved EX conversion supplier to lift truck manufactures like Toyota, Jungheinrich, Hyster and BT for conversions in accordance with European standards and directives. It takes 8 to 12 weeks to convert a standard lift truck to an EX truck, depending on the size and specification of the truck. The proces involves establishing the parameters of the truck that is converted, manufacturing materials, installing materials, testing the truck and certification. 16 CEOM0924 Operator comfort Hydraulic control levers The hydraulic functions are controlled by short levers that are positioned next to the operator on the battery cover. This will give a comfortable operation position for the operator. The handgrips on top of the levers are ergonomic shaped with in mould symbols on the lift and tilt levers. The system allows operator to control the hydraulics smooth and precisely with a minimum rd th operating effort. There are standard 2 valves equipped on the truck; optional is a 3 and 4 valve. Entry and Exit Open step frame on both sides of the truck and will allow entry and exit from either side if required. A step height of 450 mm and floor height of 520 mm ensures a natural entrance and exit from the truck. Note: It is recommended to get on and off the truck via the left hand side. Tilt steering column The steering column is tiltable allowing the operator to set it in the most comfortable position suitable. By using the knob on the right hand side of the steering column the operator can set the lock into infinite number of positions 17 CEOM0924 Operator comfort Display The display consists of a clear, easy-to-read LCD display. The icons are displayed by universal graphic symbols for ease of understanding. The display monitors the trucks performance levels and operational indicators, such as truck hours, drive and hydraulic motor hours. In addition a battery discharge indicator is displayed. Item BDI (Battery discharge indicator) level Seat belt warning Brake fluid warning Parking brake operation Situation when lamp will illuminate or flash The 10 segments BDI display the present battery state of charge. At the last segment the battery warning indicator start flashing. After the last segment is off the truck will slow down to 5km/hr and the warning indicator will illuminate continuously. The BDI will not reset until the battery is changed or charged over 7 segments. Will illuminate as a reminder when the operator is seated and the seat belt is not used. Brake fluid illuminates when the brake fluid bottle is low. This ensures on time service and protection of the investment. When the Parking brake is engaged, the travel power will be reduced to 35% of the maximum current of the motors and the travel speed is restricted to 4 km/h. 18 CEOM0924 Operator comfort Service indicator Warning LED Vehicle hour meter / warning codes The service indicator can be programmed to illuminate at a prescribed number of hours to alert the user of the need for maintenance. This setting is done via the controller. This setting is adjustable from 100hrs in steps of 50hrs to 1000hrs (std service interval is 500hrs). The indicator will flash 20 hours before time is due. Additional option to this is a speed limitation of 5km/h can be set when this illuminates. This function is default 0. Should a fault occur in any of the truck circuit, this indicator flashes and the error code appears on the display and the main line contactor will open. Truck/Traction/Hydraulic motor hours are showed when key switch is turned “ON”. After this it shows the truck hours during operation. When an error occurs in the truck the display will indicate an error code which corresponds with the trouble shoot list of the service engineer. 19 CEOM0924 Operator comfort Operator Controls Pedal System The pedals are ergonomically placed and located in the automotive style in order to provide easy operation for every operator. The pedals are positioned at an ergonomic height and angle in relation to the floor area. Brake system Manual braking The operator brake is a foot operated hydraulic drum brake with asbestos free linings. The brake system contains duo servo drum brakes mounted to the front wheels. The strong regen braking that the AC motors provide reduce excessive brake wear. This drum brake is the same type that is used on IC trucks: reliable design and excellent braking control both in forward and backward direction. The drum brakes are self-energizing meaning that the shape of the shoes is such that the braking force is increased and selfadjusting meaning that the shoes are automatically adjusted during wear. Parking brake The parking brake is a hand operated cable brake. The hand actuated parking brake is activated mechanically, not hydraulically. When the operator leaves his seat without the park brake activated a continuous alarm will sound until the park brake is applied. Regen braking The regenerative braking can be done in two ways: - Directional regen braking - Auto regen braking When the operator uses the direction control (directional regen braking) or release the accelerator pedal (auto regen braking), the electronic circuit changes the drive motor into a generator and this is called regenerative braking. The braking force can be set in the controller software. There are a number of advantages for electric braking: • Extends life of the brake drums and shoes/linings • Extends life of the motor • Returns power to the battery When the operator uses the direction control or releases the accelerator pedal, the electronic circuit changes the drive motor into a generator, this is called ‘regenerative braking’. This function reduces the battery consumption and prevents unwanted heat. The regenerative braking function is to prevent brake wear and heat build up in the motor and extends the life time of the components. Operators should be trained to use this function in their operation. AC motors are not limited by the use of carbon brushes or a commutator, so unlike a DC motor there is strong regenerative (electro magnetic) braking at high speed. When the regenerative braking is activated the motor will work like a generator and slow the truck down. It is the same feeling like in your car, when you release the accelerator pedal your car will slow down by the power of the motor. The powerful regenerative braking of the AC motors reduces the wear of the brakes and transfers some energy back into the battery. In a normal truck operation the regen braking will be sufficient to slow down the truck. The regeneration function is standard on all the electric models. 20 CEOM0924 Frame and body Frame and Battery compartment This truck is made for light applications and small shifts. The maximum battery capacities for these models are: Cat Lift Trucks model Voltage / Capacity Battery container dimensions Length Width Height 1 Height 2 FB10KRT PAC FB12KRT PAC 830 380 612 627 24V/720Ah/5h FB15KRT PAC 830 438 612 627 24V/840Ah/5h The batteries are the same dimensions as the previous series and this makes it possible to replace or add trucks to an existing fleet without new investments in batteries. The maximum weight for the battery is: FB10KRT PAC FB12KRT PAC FB15KRT PAC Minimum weight Maximum weigth 445 kg 524 kg 524 kg 600 kg Overhead Guard (OHG) When using this truck for stuffing containers, loading Lorries or train carriages, the entrance height is the critical factor. For load handling in these confined spaces, the standard overhead guard height of 2015mm is sufficient enough. But even for applications where a lower height is required we can offer an optional low overhead guard of 1965mm. The height of the overhead guard is also determined by the seat index point and the torso clearance. This is the reason why we change the OHG height when different seat is ordered. Length and Turning Radius The dimensions of a forklift truck are always a compromise between maximum battery capacity, spacious compartment, high residual capacity and optimal maneuverability. In comparison with the 48-Volt models, this type of 3-wheel models has relatively small battery compartment. Together with the rear-wheel drive construction, this result in a truck design that can easily operate in narrow aisles. The Mitsubishi design uses a fixed wheelbase. The characteristics of the fixed wheelbase are summoned on the next page in comparison to the extending wheelbase that most competitors (Still, Toyota and Hyster) use. 21 CEOM0924 Frame and body - - The extending wheelbase feels unstable when braking and tilting the mast, because the load moves relative to the truck. Competitors claim a better residual capacity, because of the extended wheelbase, but the mast is put straight when lifting to large heights. Competitors claim better maneuverability, but the wheel base is longest when driving. Thus the effect is opposite to what the operator needs when turning in a narrow aisle. The thin and fragile single tilt cylinder is located at the bottom of the truck, at a very vulnerable position. Objects from the ground will easily damage the cylinder. Think about the tremendous mess when there is a leak in the hydraulic system. (e.g. food industry) The two tilt cylinders are mounted higher and less exposed to objects from the ground In addition, using a mast design with only one tilt cylinder will result in more stress in the mast and an increased risk of torsion. An additional advantage for dealers is the mast commonality with the 48V models; the masts of the Mitsubishi series are completely interchangeable. This will reduce the required stock of masts. 22 CEOM0924 Control system PM-1000 AC controller Mitsubishi Forklift Trucks developed a completely new generation of AC controllers. With the latest MOSFET and heat dissipation technology these controllers provide maximum performance and energy efficiency. The in-house developed controllers are proven to be easy to service, provide high performance with great reliability. PM-1000 AC controller system The truck designers have implemented the well proven intelligent, interactive monitoring and diagnostics system. This system immediately pinpoints faults, reducing the potential for major service expenses. Since this system is ‘built-in’ there is no need for expensive external test equipment. It monitors the truck functions continuously. By a switch which can be set to Diagnostics, Run or Set-up of the truck (DRS-switch) the system can be easily monitored and adapted. This makes it possible to service or ‘set-up’ the performance of the truck without any external tool. The DRS switch is located underneath the floor plate at the left hand side. This location makes it possible to use this switch while checking the display on a short distance. ‘Diagnostics’ gives access to the integrated diagnostics tool, ‘Run’ is the neutral position and is used when the truck is in operation and ‘Set-up’ is used when changing the performance parameters 23 CEOM0924 Control system Controller functions Drive functions. a) Changes in drive characteristics These affect the acceleration, maximum output and battery consumption efficiency. The following two parameters can be set: Acceleration rate: sets the acceleration Traveling power: select a maximum output to change the battery consumption. The acceleration with load is affected. (See appendix 4) Regenerative braking power and mode for regenerative brake can be selected. The individual brake performance of the following two regenerative modes can be set: b) Automatic regeneration Normal deceleration where the running and direction lever are the same when releasing the accelerator pedal. c) Regeneration by direction lever Deceleration by reverse operation where the drive direction and direction lever directions are opposite and where the accelerator pedal angle affects the braking force. d) Regeneration by brake pedal When (b) and (c) are not selected, regeneration by brake can be considered to prevent excessive brake wear. Regenerative braking is applied when the brake pedal is pressed. e) Controlled roll down function The controlled roll down movement helps the operator in both forward and reverse direction, to slowly go down a sloping road or ramp, instead of a free roll. The controlled roll down speed is depending on the angle of the ramp/gradient, the weight of the truck (1.0, 1.2 or 1.5 ton), the weight of the load on the forks and the auto-regeneration level that is set. f) Boost function If the truck does not move because of a bump and the operator steppes on the accelerator pedal the driving force is boosted. This provides a better driving operation when for instance driving into a warehouse or starting on a ramp. g) Limit maximum speed Like on our electric models with our controller, maximum speed can be easily limited by changing the top travel speed limit setting in the controller between 5 and 14 km/hr using the DRS-switch. Top travel speed limitation can be useful when a speed restriction exists in the application where the truck is operational. There are 3 additional travel speed limiters in this truck which can be used by Auxiliary switches or sensors (for instance remote controlled when driving into a warehouse). h) Other related drive settings The tires size can be adjusted to compensate tire wear. A stall timer stops the traction motor when the truck is not moving for an amount of time, this to prevent overheating and damage to the traction motor when the accelerator pedal is pressed and it also reduces battery consumption. 24 CEOM0924 Control system Forklift functions a) Setting and limiting the forklift hydraulic speed Like all our electric models the speed can be easily changed by the DRS-switch (See appendix 4). Items that can be changed: Start lift speed Auxiliary 1 speed Top lift speed Auxiliary 2 speed Tilt speed General functions a) Diagnostics / Run / Setup (DRS) mode This controller has three main setup modes, with: Diagnostic : Self diagnostics Run time diagnostics Run : Normal truck operation Setup : Group 1 data set-up (basic performance) Group 2 data set-up (advanced functions) Group 3 data set-up (model set-up) b) Integrated Presence System (IPS) set-up features This controller includes a protection to be activated when the operator is not seated. For the controller this function includes: Seat switch: when the operator leaves his seat during driving the truck will slow down and stop Mast interlock: when the truck is not operational the hydraulic lifting function is disabled. c) BDI display function From the current battery voltage, the remaining battery life is indicated in a BDI indicator which is divided in 10 segments. The battery type can be selected. Truck history folder The diagnostic system has a built-in truck history folder that enables accurate analyses of faults. If a fault occurs, the LED fault indicator illuminates and a numeric code appears on the LCD display in place of the hours. The truck history folder records the following information: - Error code Vehicle hours at time of fault Battery charge level at time of fault This information provides a precise operating history. The history folder captures the latest thirty-two generated fault codes and stores them in a protected memory. This memory is not affected by unplugging the battery or turning off the key switch. The history folder information can be accessed very easily by the service department and the memory can be cleared if required. By knowing the vehicle hours and the battery discharge level at the time of each fault, a pattern of misuse or abuse can be traced to a specific operator and/or shift. Such a system allows the service technician to easily diagnose problems and isolate causes, and suggest operator training for better operation in the future. 25 CEOM0924 Control system Application settings As each application is different, this truck can be set to perform in five different types of applications, simply by choosing the applicable pre-set mode. Each mode contains up to seven performance specifications to be set. It is very easy to select one of the preprogrammed settings. This is convenient, as each truck may be used in one of several applications. Application A is the factory default setting. This is based on a normal warehouse setting. Here, about 60% of the work cycle is drive-related and about 40% is hydraulic related. Most applications fit under this setting. Application B is a high performance setting, where short cycle time is very important. Application C is an economy/congested setting. As a balance between performance and low energy use, this is also the most appropriate setting for congested works areas. Travel speed, acceleration rate, lift and tilt speeds are reduced. However, the truck still maintains a high degree of functionality. Application D is designed for long travel. Here, top speed is maximized, while hydraulic speeds are set at moderate levels and acceleration is soft, while auto regen is set at midrange. Application E is designed for short shuttle or dock work. In this demanding setting, tilt speeds are set at fast while lift speeds are moderate. Auto regen is set at a high limit to extend brake life - the energy returned to the battery is at maximum level. In certain cases where the five application settings don’t optimize truck performance, each of the settings can be individually adjusted to customize the truck for specific needs: Title of function Top Travel Speed Acceleration Rate Travelling Power Regen Adjustment Start Lift Speed Max Lift Speed Tilt Speed Range 5-14km/hr 1-5 Economy/Standard/High 1-5 1-10 1-10 1-10 Default 13 or 14 2 2 3 7 10 1 26 CEOM0924 Control system The control system also incorporates several settings that enable the customer to have the truck performance suit to specific requirements. There are 5 settings for this option: high power; standard power; economy power. High power allows the truck to maintain its current limit for a longer period of time and at higher speeds. Mode A Lift Fast B High power Fast Fast D Long distance Fast Tilt Medium Medium Medium Medium Medium Fast Fast Medium Fast Medium Acceleration Medium Fast Slow Medium Fast Power Standard Powerful Economy Regen Medium Medium Medium Medium Medium Standard Vehicle speed C Economy E short shuttle Fast Option number #1 Start lift speed 7 7 7 7 7 2 Top lift speed 10 10 7 7 10 3 1 13 or 14*¹ 1 13 or 14*¹ 1 1 4 10 1 13 or 14*¹ 9 7 Acceleration rate 2 5 1 2 5 8 Travelling power 2 3 1 3 2 9 Automatic regen 3 4 2 3 4 23 Tilt speed Max vehicle speed CAN-bus electrical system The data transmission is handled via a CAN-Bus system. CAN-bus ensures quick and reliable control and at the same time the CAN bus simplifies the wiring harness in the vehicle as well as the diagnostic troubleshooting should anything go wrong. This makes maintenance easier and fewer components are required. The controller is the centre of the forklift control system, but with a CAN-BUS system, these are more than one independent controller on the Controller AREA Network (CAN). The system units that are located in this network are - Logics unit Traction inverter - Pump inverter Display unit 27 CEOM0924 Drive train Drive train assembly The 24V model is driven by one drive motor on the rear-wheel, this construction is typical for the low-duty 24V-models (Exception is Linde, who uses two traction motors on the front wheels, also on the 24V model). The traction motor is a 5 kW AC motor. AC motors The 5kW AC motor offers faster acceleration, better gradeability, and quicker deceleration by regen braking than ordinary DC motors. Direction change will go more smoothly and seamlessly when torque and speed is tightly controlled. This means higher reliability of the components, higher up time for the owner of the truck and a higher productivity rating. 3-phase AC technology DC (direct current) motors uses the fact that two similar magnetic poles repel each other. On the outer side of the motor (armature) there are two fixed magnets, on the inner side (rotor) there is a current that flows through a coil that creates an electromagnetic field. The magnet on the outer side repels the electromagnetic field and this is what makes the DC motor turn. At the moment the electromagnetic field is almost attracted to the other magnetic side, the commutator changes the direction of the current and the electromagnetic field changes into the opposite electro magnetic pole. By continuing this, the motor keeps on turning. Brushes power the commutator and supply the current from the armature side to the rotor side. These brushes need to be replaced after they have worn out, and limits the motor in its performance. AC (alternated current) motors make use of induction. By powering coils on the outside of the motor (which creates an electromagnetic field) and let the current ‘walk’ around the rotor, by switching various coils on and off in a smooth way, it is possible to create a magnetic field inside the coil of the rotor by induction. Induction is created when a coil is moving through a magnetic field. These two magnetic fields repel each other so the motor starts turning. Because the AC current switches the coils in the armature on and off in a smooth way, the rotor keeps on rotating just behind the activated coils. 28 CEOM0924 Drive train The more coils are used the smoother the motor runs. So by using 3 phases (equals 6 coils) of AC current it is possible to turn the motor in a smoother and more controlled way. The controller constantly calculates three phases of AC current so the motor is controlled at high speed on a gradient, or on low speed on a flat surface. By doing this the energy of the battery is used in the most energy efficient way. By manipulating the power and frequency of the AC current in the coils of the armature of the motor, it is possible to change the power and speed of the motor accordingly. This makes it possible to turn the motor in a very controlled and smooth way and to supplies the motor with exactly the right amount of speed and power to the operator needs. This improves the control over the truck and saves energy. AC motors do not use any kind of brushes; these brushes supply current to the rotor but limit the DC motors from running at very high speed and limit the force that is needed to use regenerative braking at high speed. Brushes have to be replaced approximately every 3000hrs, so the maintenance that is needed on a DC motor is not required on an AC motor. So no brush wear and no carbon dust in AC motors, which reduces the service cost over the lifetime of a truck. The space that is taken by the commutator and brushes in DC motor can now be used for a complete armature in the same space. That gives the possibility to have an increase of performance with an AC motor within the same space of a DC motor. The increase of performance can be up to 33% with the same dimensions of an AC motor referred to a DC motor. An AC motor controls the torque and the speed of the motor separately, variations are possible for low speed - low torque to high speed - high torque. This provides optimum performance balance in every application. Due to less heat build up in the motors (no brushes, no commutator and therefore less friction in the motor) it is possible to seal the motor to protect it against dust and water. The traction motor is an IP-54 rated motor, which means it, is splash waterproof. AC-DC motor speed time diagram 29 CEOM0924 Drive train Hydrostatic Steering The low maintenance, full hydrostatic steering system provides exceptional operator control and maneuverability. In a fully hydrostatic system, steering is accomplished by hydraulic oil flow – thus eliminating kickback from the steer wheels into the steering wheel. Because there are few mechanical linkage points, precise steering control is maintained. The same minimum amount of steering wheel effort is required to the truck regardless of truck speed. This system has become the accepted “standard” design in the forklift industry. Stability Many people assume that a 4-wheel truck is more stable than a 3wheel truck. In practice, there are many factors that determine a truck’s stability, and whether a truck has 3 or 4-wheels is of minor significance. Drive axle width, location of centre of gravity, wheelbase, and truck travel speed are all important factors that affect truck stability. The steer axle on a 4-wheel truck is usually mounted with a trunnion or sprunnion to allow steer axle oscillation on uneven surfaces. This, essentially, makes a 4-wheel truck the same as a 3-wheel truck in the initial stages of stability, because they both have a stability triangle. A 4-wheel truck is usually equipped with axle stops. However, the outside rear corner of the frame of a 3-wheel truck plays the same. Optional Wide tread tires can be mounted to improve its stability and therefore also its residual capacity. Steering on Demand A pressure switch in the steering unit detects the increase of hydraulic flow and indicates the need for steering pressure. This means that when the operator turns the steering system, the main hydraulic system will increase duty for smooth cut-in to steering power. This reduces the requirement for an additional power steering motor and reduces noise levels. Steer and drive Axle The 3-wheel electric 24 volt truck has an AC drive motor that is vertically installed for providing the drive wheel of the truck with driving power. The 3-wheel electric truck offers standard power steering. The rear axle is a so called COMBI axle. This means that the axle is used for both driving and steering. This makes the system a simple and low cost construction. This truck has a one-tire system, this means that the weight of an empty truck is concentrated in a very small area; this has influence on the ground pressure of the truck. The full power steering includes no mechanical connections between the steering wheel and the steering axle. Hydraulic flow is provided by the main hydraulic pump. Thus, along with ease in steer effort, if the truck loses power, the operator still has steering control. This truck doesn’t need a wheel angle sensor as the 48V 3-wheel model. This because there is only 1 traction motor on the rear wheel instead of 2 traction motors on the front wheel of a 48V model. (The control system uses wheel angle signals to operate the inside drive motor during a turn. The sensor signal informs the panels to adjust the inside drive motor speed, to match the angle of the steer wheels. As the steer wheels turn, the inside drive motor is progressively slowed down with respect to the outside drive motor until it is essentially in neutral. At this point the inside drive motor reverse and progressively increased as the cramp angle increased until, at maximum steer wheel cramp angle, it is turning in reverse as fast as the outside motor is turning forward.) 30 CEOM0924 Mast Operation Features Spherical bearings For reliability, each lift cylinder has an external drain that permits a controlled amount of hydraulic oil to flow above the piston and thus prevents corrosion of the cylinder rod. Mast tilt angles For further enhanced reliability, great care has been taken in the design of the mast and carriage to ensure proper alignment and distribution of operating forces. For example, the tilt cylinder rod ends mount to the mast using spherical bushings thereby preventing misalignment of the tilt cylinders. If a cylinder is not properly aligned it will eventually leak and possibly fail. The tilt socket is equipped with a seal resulting in less maintenance and more durable. Optional lifting eyes for mast FEM class II, 1 & 2 ton There are six load rollers that support the forwards and backwards loading of the rollers. Specially shaped channels allow for two-point load roller contact even though the rollers are not canted. The two-point contact enables the rollers to handle side thrust forces between the mast channels. The carriage has two side thrust rollers to help maintain its alignment in the mast. They are in addition to the six load rollers that support the fore and aft loading. The 1 and 2 ton size trucks use a FEM class 2A carriage. All masts have “mast cushioning” and “internal bleeding”. Mast cushioning provides less shock on the operator when the mast is lowered. The internal bleeding reduces hoses and increase visibility. Mast Tilt Angles The forward tilt angle is 5 degrees for all masts, while the backward tilt angle depends on the mast model and mast height. The correct mast tilt angles can be found in the mast charts in Appendix ll. 31 CEOM0924 Serviceability The floor plate provides easy access to all the components from the top of the truck. Service interval of the truck is 500hrs for most working conditions (see Operation & Maintenance Manual for details). The controllers cover behind the battery hood gives access to the controllers and fuses. This controller cover can be removed for easy access to the controllers. Easy Service Diagnostics and performance settings can be done via de DRS-switch and the display. An external service tool can also be used to do this service. Like on all our N-series models also this models has diagnostics and performance programmable by PC and GSE program for the laptop. The Service interval on this model has increased to 500hrs for most applications. This reduces the total service cost over the life time of the truck by approximately 50%. Less visits of the service engineer are required. Ground support Equipment (GSE) Ground support equipment is software used by a laptop or PC to read out data stored in the controller, and reduces the down time of the truck. GSE software will mainly be used by your service engineers, to see on-line which switches and sensors are working, read out what the settings of the truck are, read out it’s error code history folder (max. 32 error codes) and upload new software with it when required. Less down time for the truck while the Service engineer is finding the problem or analyses the data of the truck. 32 CEOM0924 Standards Standards EN1726-1 Safety of industrial trucks – self propelled trucks up to and including10000 kg capacity and industrial tractors with a draw bar up to and including 20000 N. EN13564 Visibility 2 EN13059 Vibrations < 1,4 m/s (for more information about vibration, please look in the newsletter 11-06C “Vibrations 2002 44 EC” about vibrations on the dealer support site) EN12895 Electromagnetic Compatibility Noise levels according EN 12053: 60,7dB (A) VDI energy consumption: [45 cycles /h] [FB15KRT PAC] 4,75 kWh/h 33 CEOM0924 Appendix I Truck specifications FB10-15KRT PAC Characteristics 1,1 Manufacturer (abbreviation) Mitsubishi FB10KRT PAC Mitsubishi FB12KRT PAC Mitsubishi FB15KRT PAC 1,2 Manufacturer's model designation 1,3 Power source: (battery, diesel, LP gas, petrol) Battery Battery Battery 1,4 Operator type: pedestrian, (operator)-standing, -seated Seated Seated Seated 1,5 Load capacity Q (kg) 1.0 1,25 1,5 1,6 At load centre c (mm) 500 500 500 1,8 Load distance x (mm) 330 330 330 1,9 Wheelbase y (mm) 1125 1125 1200 kg 2354 2569 2775 kg 2857/497 3195/574 3731/544 kg 1119/1235 1109/1460 1194/1581 2,1 2,2 2,3 Weight Truck weight, without load / including battery (simplex mast, lowest lift height) Axle loading with rated load, front/rear (simplex mast, lowest lift height) Axle loading without load, front/rear (simplex mast, lowest lift height) Wheels, Drive Train 3,1 Tyre type: V=solid, L=pneumatic, SE=solid pneumatic - front/rear SE/SE SE/SE SE/SE 3,2 Tyre dimensions, front 18x7-8 18x7-8 18x7-8 3,3 Tyre dimensions, rear 18x7-8 18x7-8 18x7-8 3,5 Number of wheels, front/rear (x=driven) 2/1x 2/1x 2/1x 3,6 Distance between centreline of tyres, front b10 (mm) 840 840 840 3,7 Distance between centreline of tyres, rear b11 (mm) - - - Dimensions 4,1 Mast tilt, forwards/backwards ∂/ß ° 4,2 Height with mast lowered h1 (mm) 5/7 5/7 5/7 2110 2110 2110 4,3 Standard free lift h2 (mm) 120 120 120 4,4 Standard lift height h3 (mm) 3300 3300 3300 4,5 Overall height with mast raised h4 (mm) 3895 3895 3895 4,7 Height to top of overhead guard h6 (mm) 2015(1965) 2015(1965) 2015(1965) 4,8 Seat height h7 (mm) 928 928 928 4,12 Tow coupling height h10 (mm) 410 410 410 4,19 Overall length l1 (mm) 2500 2500 2575 4,20 Length to fork face (includes fork thickness) l2 (mm) 1700 1700 1775 4,21 Overall width b1/b2 (mm) 4,22 Fork dimensions (thickness, width, lenght) s/e/l (mm) 4,23 Fork carriage to DIN 15 173 A/B/no 4,24 Fork carriage width b3 (mm) 997 997 997 35x80x800 35x80x800 35x80x800 2A 2A 2A 920 920 920 4,31 Ground clearance under mast, with load m1 (mm) 80 80 80 4,32 Ground clearance centre of wheelbase, with load (forks lowered) m2 (mm) 100 100 100 4,33 Working aisle width with 1000 x1200 mm pallets, crosswise Ast (mm) 3030 3030 3104 4,34 Working aisle width with 800 x1200 mm pallets, crosswise Ast (mm) 2850 2850 2925 4,35 Turning circle radius Wa (mm) 1370 1370 1445 4,36 Minimum distance between centres of rotation b13 (mm) - - - Appendix I Performance 5,1 Travel speed, with/without load km/h 11.5/13.5 11.2/13 11/12.5 5,2 Lifting speed, with/without load m/s 0.29/0.48 0.27/0.48 0.26/0.48 5,3 Lowering speed, with/without load m/s 0.52/0.50 0.52/0.50 0.52/0.50 5,5 Rated drawbar pull, with/without load (60 min short duty) N 1706/1991 1569/1937 1435/1876 5,6 Maximum drawbar pull, with/without load (5 min short duty) N 5327/5621 5190/5558 5056/5497 5,7 Gradeability, with/without load (30 min) % 9.6/15.1 8.1/13.6 6.9/12.3 5,8 Maximum gradeability, with/without load (5 min short duty) % 16.4/25.1 14.0/22.6 12.2/20.6 5,9 Acceleration time, with/without load (0 -10 m) s 5.9/5.6 6.0/5.7 6.1/5.7 5,10 Service brakes (mechanical/hydraulic/electric/pneumatic) Hydraulic Hydraulic Hydraulic Electric motors 6,1 Drive motor capacity (60 min. short duty) kW 5 5 5 6,2 Lift motor output at 15% duty factor kW 6.5 6.5 6.5 6,3 Battery according to DIN 43 531/35/36 A/B/C/no 43 535A 43 535A 43 535A 6,4 Battery, voltage/capacity at 5-hour discharge V /Ah 24 / 720 24 / 720 24 / 840 6,5 Battery, weight kg 524 524 600 Energy consumption according to VDI cycle kWh/h - - - Impuls / AC Impuls / AC Impuls / AC 143 143 143 6,6 Miscellaneous 8,1 Type of drive control 8,2 Maximum Operating pressure for attachments 8,3 Oil flow for attachments l/min - - - 8,4 Noise level, mean value at operator’s ear dB(A) 60.7 60.7 60.7 8,5 Towing coupling design / DIN type, ref. - - - bar 35 CEOM0924 Appendix II Mast Charts FBKRT PAC FB10KRT PAC SE / Std Carriage Simplex Tilt [F/B] deg 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/5 5/5 Duplex Back Tilt deg 5/5 5/5 5/5 5/5 Triplex Back Tilt deg 5/5 5/5 5/5 5/5 5/5 5/5 5/3 5/3 5/3 h3 mm h1 mm 2000 2560 2760 3000 3290 3720 4090 4480 5000 5500 6000 h3 mm 1460 1740 1840 1960 2105 2365 2550 2755 3015 3265 3515 h1 mm 3000 3295 3700 4030 h3 mm 1960 2105 2365 2550 h1 mm 3710 4010 4310 4750 5090 5490 5990 6490 7000 1760 1860 1960 2105 2225 2365 2550 2810 3015 h4 mm 1) 3045 3605 3805 4045 4335 4765 5135 5525 6045 6545 7045 h4 mm 1) h2 mm 80 80 80 80 80 80 80 80 80 80 80 h2 mm 4045 4340 4745 5075 h4 mm 1) 4755 5055 5355 5795 6135 6535 7035 7535 8045 h5 mm h5 mm h2 mm Q,@500 kg 1000 1000 1000 1000 1000 1000 950 950 850 850 450 800 3) 2) Q,@500 kg 915 1060 1320 1505 h5 mm - 2) Q,@600 kg 1000 1000 1000 1000 950 950 900 850 800 750 450 750 3) Q,@600 kg 1000 1000 1000 950 Q,@500 kg 715 815 915 1060 1180 1320 1505 1765 1970 1000 950 950 900 850 800 800 550 750 3) 300 600 3) 1000 950 950 900 Q,@600 kg 900 900 850 850 800 750 700 550 300 700 3) 600 3) 1) The h4 dimension without Load Backrest will decrease with 442 mm The h5 dimension without Load Backrest will increase with 442 mm 3) The capacity with the Wide Tread Option: the overall width changes from 997mm to 1067mm 2) h1 - Height with mast lowered h2 - Standard free lift h3 - Standard lift height h4 - Height with mast raised h5 - Full free lift Q - Lifting capacity, rated load Tyres: Solid Pneumatic (SE) Front Rear 10KRT PAC 12KRT PAC 15KRT PAC 18x7-8 18x7-8 18x7-8 18x7-8 18x7-8 18x7-8 36 CEOM0924 Appendix II FB12KRT PAC SE / Std Carriage Simplex Tilt [F/B] deg 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/5 5/5 Duplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 Triplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 5/5 5/5 5/3 5/3 5/3 1) 2) 3) h3 mm h1 mm 2000 2560 2760 3000 3290 3720 4090 4480 5000 5500 6000 h3 mm 1460 1740 1840 1960 2105 2365 2550 2755 3015 3265 3515 h1 mm 3000 3295 3700 4030 h3 mm 1960 2105 2365 2550 h1 mm 3710 4010 4310 4750 5090 5490 5990 6490 7000 1760 1860 1960 2105 2225 2365 2550 2810 3015 h4 mm 1) 3045 3605 3805 4045 4335 4765 5135 5525 6045 6545 7045 h4 mm 1) h2 mm 80 80 80 80 80 80 80 80 80 80 80 h2 mm 4045 4340 4745 5075 h4 mm 1) 4755 5055 5355 5795 6135 6535 7035 7535 8045 h5 mm h5 mm h2 mm Q,@500 kg 1250 1250 1250 1250 1250 1250 1200 1150 900 11003) 850 10503) 500 850 3) 2) Q,@500 kg 915 1060 1320 1505 h5 Mm - 2) 1250 1250 1250 1200 Q,@500 kg 715 815 915 1060 1180 1320 1505 1765 1970 1250 1200 1150 1100 1100 850 10503) 850 10003) 550 900 3) 350 600 3) Q,@600 kg 1250 1250 1250 1200 1200 1150 1100 1050 900 10003) 900 950 3) 500 850 3) Q,@600 kg 1200 1200 1150 1100 Q,@600 kg 1150 1100 1050 1050 1000 900 950 3) 900 900 3) 600 850 3) 350 650 3) The h4 dimension without Load Backrest will decrease with 442 mm The h5 dimension without Load Backrest will increase with 442 mm The capacity with the Wide Tread Option: the overall width changes from 997mm to 1067mm h1 - Height with mast lowered h2 - Standard free lift h3 - Standard lift height h4 - Height with mast raised h5 - Full free lift Q - Lifting capacity, rated load Tyres: Solid Pneumatic (SE) Front Rear 10KRT PAC 12KRT PAC 15KRT PAC 18x7-8 18x7-8 18x7-8 18x7-8 18x7-8 18x7-8 37 CEOM0924 Appendix II FB15KRT PAC SE / Std Carriage Simplex Tilt [F/B] deg 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/5 5/5 Duplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 Triplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 5/5 5/5 5/3 5/3 5/3 h3 mm h1 mm 2000 2560 2760 3000 3290 3720 4090 4480 5000 5500 6000 h3 mm 1460 1740 1840 1960 2105 2365 2550 2755 3015 3265 3515 h1 mm 3000 3295 3700 4030 h3 mm 1960 2105 2365 2550 h1 mm 3710 4010 4310 4750 5090 5490 5990 6490 7000 1760 1860 1960 2105 2225 2365 2550 2810 3015 h4 mm 1) 3045 3605 3805 4045 4335 4765 5135 5525 6045 6545 7045 h4 mm 1) h2 mm 80 80 80 80 80 80 80 80 80 80 80 h2 mm 4045 4340 4745 5075 h4 mm 1) 4755 5055 5355 5795 6135 6535 7035 7535 8045 h5 mm h5 mm h2 mm Q,@500 kg 1500 1500 1500 1500 1500 1500 1450 1400 1000 13503) 950 12503) 600 950 3) 2) Q,@500 kg 915 1060 1320 1505 h5 mm - 2) 715 815 915 1060 1180 1320 1505 1765 1970 1500 1500 1500 1450 Q,@500 kg 1500 1450 1400 1350 1300 950 12503) 1000 12003) 650 10503) 400 700 3) Q,@600 kg 1500 1500 1500 1450 1450 1400 1350 1300 1000 12003) 950 11503) 600 950 3) Q,@600 kg 1450 1450 1400 1350 Q,@600 kg 1350 1350 1300 1250 1200 950 11503) 1000 11003) 650 10503) 400 700 3) 1) The h4 dimension without Load Backrest will decrease with 442 mm The h5 dimension without Load Backrest will increase with 442 mm 3) The capacity with the Wide Tread Option: the overall width changes from 997mm to 1067mm 2) h1 - Height with mast lowered h2 - Standard free lift h3 - Standard lift height h4 - Height with mast raised h5 - Full free lift Q - Lifting capacity, rated load Tyres: Solid Pneumatic (SE) Front Rear 10KRT PAC 12KRT PAC 15KRT PAC 18x7-8 18x7-8 18x7-8 18x7-8 18x7-8 18x7-8 38 CEOM0924 Appendix II FB10KRT PAC SE / Hook-on SS Simplex Tilt [F/B] deg 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/5 5/5 Duplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 Triplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 5/5 5/5 5/3 5/3 5/3 1) 2) 3) h3 mm h1 mm 2000 2560 2760 3000 3290 3720 4090 4480 5000 5500 6000 h3 mm 1460 1740 1840 1960 2105 2365 2550 2755 3015 3265 3515 h1 mm 3000 3295 3700 4030 h3 mm 1960 2105 2365 2550 h1 mm 3710 4010 4310 4750 5090 5490 5990 6490 7000 1760 1860 1960 2105 2225 2365 2550 2810 3015 h4 mm 1) 3045 3605 3805 4045 4335 4765 5135 5525 6045 6545 7045 h4 mm 1) h2 mm 80 80 80 80 80 80 80 80 80 80 80 h2 mm 4045 4340 4745 5075 h4 mm 1) 4755 5055 5355 5795 6135 6535 7035 7535 8045 h5 mm h5 mm h2 mm Q,@600 kg 1000 1000 1000 1000 1000 950 900 850 800 750 450 700 3) 2) Q,@500 kg 915 1060 1320 1505 h5 mm - Q,@500 kg 2) 715 815 915 1060 1180 1320 1505 1765 1970 1000 950 950 900 900 850 800 800 750 700 450 650 3) Q,@600 kg 1000 1000 950 900 Q,@500 kg 900 900 850 800 800 750 700 500 200 900 900 850 800 Q,@600 kg 650 3) 550 3) 850 800 800 750 750 700 650 500 200 650 3) 550 3) The h4 dimension without Load Backrest will decrease with 442 mm The h5 dimension without Load Backrest will increase with 442 mm The capacity with the Wide Tread Option: the overall width changes from 997mm to 1067mm h1 - Height with mast lowered h2 - Standard free lift h3 - Standard lift height h4 - Height with mast raised h5 - Full free lift Q - Lifting capacity, rated load 39 CEOM0924 Appendix II FB12KRT PAC SE / Hook-on SS Simplex Tilt [F/B] deg 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/5 5/5 Duplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 Triplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 5/5 5/5 5/3 5/3 5/3 1) 2) 3) h3 mm h1 mm 2000 2560 2760 3000 3290 3720 4090 4480 5000 5500 6000 h3 mm 1460 1740 1840 1960 2105 2365 2550 2755 3015 3265 3515 h1 mm 3000 3295 3700 4030 h3 mm 1960 2105 2365 2550 h1 mm 3710 4010 4310 4750 5090 5490 5990 6490 7000 1760 1860 1960 2105 2225 2365 2550 2810 3015 h4 mm 1) 3045 3605 3805 4045 4335 4765 5135 5525 6045 6545 7045 h4 mm 1) h2 mm 80 80 80 80 80 80 80 80 80 80 80 h2 mm 4045 4340 4745 5075 h4 mm 1) 4755 5055 5355 5795 6135 6535 7035 7535 8045 h5 mm h5 mm h2 mm 1250 1250 1250 1250 1200 1150 1100 1050 950 10003) 900 950 3) 500 900 3) 2) 915 1060 1320 1505 h5 mm - Q,@500 kg 2) 715 815 915 1060 1180 1320 1505 1765 1970 Q,@500 kg 1250 1200 1150 1100 Q,@500 kg 1150 1100 1100 1050 1000 900 950 3) 900 900 3) 550 850 3) 300 600 3) Q,@600 kg 1250 1200 1150 1150 1100 1050 1000 1000 950 950 3) 900 900 3) 500 850 3) Q,@600 kg 1150 1100 1050 1000 Q,@600 kg 1050 1000 1000 950 900 900 950 3) 850 850 3) 550 800 3) 300 600 3) The h4 dimension without Load Backrest will decrease with 442 mm The h5 dimension without Load Backrest will increase with 442 mm The capacity with the Wide Tread Option: the overall width changes from 997mm to 1067mm h1 - Height with mast lowered h2 - Standard free lift h3 - Standard lift height h4 - Height with mast raised h5 - Full free lift Q - Lifting capacity, rated load 40 CEOM0924 Appendix II FB15KRT PAC SE / Hook-on SS Simplex Tilt [F/B] deg 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/5 5/5 Duplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 Triplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 5/5 5/5 5/3 5/3 5/3 1) 2) 3) h3 mm h1 mm 2000 2560 2760 3000 3290 3720 4090 4480 5000 5500 6000 h3 mm 1460 1740 1840 1960 2105 2365 2550 2755 3015 3265 3515 h1 mm 3000 3295 3700 4030 h3 mm 1960 2105 2365 2550 h1 mm 3710 4010 4310 4750 5090 5490 5990 6490 7000 1760 1860 1960 2105 2225 2365 2550 2810 3015 h4 mm 1) 3045 3605 3805 4045 4335 4765 5135 5525 6045 6545 7045 h4 mm 1) h2 mm 80 80 80 80 80 80 80 80 80 80 80 h2 mm 4045 4340 4745 5075 h4 mm 1) 4755 5055 5355 5795 6135 6535 7035 7535 8045 h5 mm h5 mm h2 mm 1500 1500 1500 1500 1450 1400 1350 1300 1050 12503) 950 11503) 550 950 3) 2) 915 1060 1320 1505 h5 mm - Q,@500 kg 2) 715 815 915 1060 1180 1320 1505 1765 1970 Q,@500 kg 1500 1450 1400 1350 Q,@500 kg 1400 1350 1300 1250 1200 950 11503) 1000 11003) 600 10503) 350 650 3) Q,@600 kg 1500 1400 1400 1350 1350 1300 1250 1200 1050 11503) 950 11003) 550 950 3) Q,@600 kg 1350 1350 1300 1250 Q,@600 kg 1250 1250 1200 1150 1150 1100 1050 600 10003) 350 650 3) The h4 dimension without Load Backrest will decrease with 442 mm The h5 dimension without Load Backrest will increase with 442 mm The capacity with the Wide Tread Option: the overall width changes from 997mm to 1067mm h1 - Height with mast lowered h2 - Standard free lift h3 - Standard lift height h4 - Height with mast raised h5 - Full free lift Q - Lifting capacity, rated load 41 CEOM0924 Appendix II FB10KRT PAC SE / Integral SS Simplex Tilt [F/B] deg 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/5 5/5 Duplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 Triplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 5/5 5/5 5/3 5/3 5/3 1) 2) 3) h3 mm h1 mm 2000 2560 2760 3000 3290 3720 4090 4480 5000 5500 6000 h3 mm 1460 1740 1840 1960 2105 2365 2550 2755 3015 3265 3515 h1 mm 3000 3295 3700 4030 h3 mm 1960 2105 2365 2550 h1 mm 3710 4010 4310 4750 5090 5490 5990 6490 7000 1760 1860 1960 2105 2225 2365 2550 2810 3015 h4 mm 1) 3045 3605 3805 4045 4335 4765 5135 5525 6045 6545 7045 h4 mm 1) h2 mm 80 80 80 80 80 80 80 80 80 80 80 h2 mm 4045 4340 4745 5075 h4 mm 1) 4755 5055 5355 5795 6135 6535 7035 7535 8045 h5 mm h5 mm h2 mm Q,@600 kg 1000 1000 1000 1000 1000 1000 950 900 850 800 450 750 3) 2) Q,@500 kg 915 1060 1320 1505 h5 mm - Q,@500 kg 2) 715 815 915 1060 1180 1320 1505 1765 1970 1000 1000 1000 950 950 900 850 850 800 750 450 700 3) Q,@600 kg 1000 1000 1000 950 Q,@500 kg 950 950 900 850 850 800 750 500 250 950 950 900 850 Q,@600 kg 700 3) 550 3) 900 850 850 800 750 750 700 500 250 650 3) 550 3) The h4 dimension without Load Backrest will decrease with 442 mm The h5 dimension without Load Backrest will increase with 442 mm The capacity with the Wide Tread Option: the overall width changes from 997mm to 1067mm h1 - Height with mast lowered h2 - Standard free lift h3 - Standard lift height h4 - Height with mast raised h5 - Full free lift Q - Lifting capacity, rated load 42 CEOM0924 Appendix II FB12KRT PAC SE / Integral SS Simplex Tilt [F/B] deg 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/5 5/5 Duplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 Triplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 5/5 5/5 5/3 5/3 5/3 1) 2) 3) h3 mm h1 mm 2000 2560 2760 3000 3290 3720 4090 4480 5000 5500 6000 h3 mm 1460 1740 1840 1960 2105 2365 2550 2755 3015 3265 3515 h1 mm 3000 3295 3700 4030 h3 mm 1960 2105 2365 2550 h1 mm 3710 4010 4310 4750 5090 5490 5990 6490 7000 1760 1860 1960 2105 2225 2365 2550 2810 3015 h4 mm 1) 3045 3605 3805 4045 4335 4765 5135 5525 6045 6545 7045 h4 mm 1) h2 mm 80 80 80 80 80 80 80 80 80 80 80 h2 mm 4045 4340 4745 5075 h4 mm 1) 4755 5055 5355 5795 6135 6535 7035 7535 8045 h5 mm h5 mm h2 mm 1250 1250 1250 1250 1250 1200 1150 1100 900 10503) 850 10003) 500 850 3) 2) 915 1060 1320 1505 h5 mm - Q,@500 kg 2) 715 815 915 1060 1180 1320 1505 1765 1970 Q,@500 kg 1250 1250 1200 1150 Q,@500 kg 1200 1150 1150 1100 1050 850 10003) 900 950 3) 550 900 3) 300 600 3) Q,@600 kg 1250 1250 1200 1200 1150 1100 1050 1050 900 950 3) 850 950 3) 500 850 3) Q,@600 kg 1200 1150 1100 1050 Q,@600 kg 1100 1050 1050 1000 950 850 900 3) 900 900 3) 550 850 3) 300 600 3) The h4 dimension without Load Backrest will decrease with 442 mm The h5 dimension without Load Backrest will increase with 442 mm The capacity with the Wide Tread Option: the overall width changes from 997mm to 1067mm h1 - Height with mast lowered h2 - Standard free lift h3 - Standard lift height h4 - Height with mast raised h5 - Full free lift Q - Lifting capacity, rated load 43 CEOM0924 Appendix II FB15KRT PAC SE / Integral SS Simplex Tilt [F/B] deg 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/7 5/5 5/5 Duplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 Triplex Tilt [F/B] deg 5/5 5/5 5/5 5/5 5/5 5/5 5/3 5/3 5/3 1) 2) 3) h3 mm h1 mm 2000 2560 2760 3000 3290 3720 4090 4480 5000 5500 6000 h3 mm 1460 1740 1840 1960 2105 2365 2550 2755 3015 3265 3515 h1 mm 3000 3295 3700 4030 h3 mm 1960 2105 2365 2550 h1 mm 3710 4010 4310 4750 5090 5490 5990 6490 7000 1760 1860 1960 2105 2225 2365 2550 2810 3015 h4 mm 1) 3045 3605 3805 4045 4335 4765 5135 5525 6045 6545 7045 h4 mm 1) h2 mm 80 80 80 80 80 80 80 80 80 80 80 h2 mm 4045 4340 4745 5075 h4 mm 1) 4755 5055 5355 5795 6135 6535 7035 7535 8045 h5 mm h5 mm h2 mm 1500 1500 1500 1500 1500 1450 1400 1350 1000 13003) 950 12503) 550 950 3) 2) 915 1060 1320 1505 h5 mm - Q,@500 kg 2) 715 815 915 1060 1180 1320 1505 1765 1970 Q,@500 kg 1500 1500 1450 1400 Q,@500 kg 1450 1400 1350 1300 1250 950 12003) 950 11503) 600 10503) 350 650 3) Q,@600 kg 1500 1500 1450 1400 1400 1350 1300 1250 1000 12003) 950 11503) 550 950 3) Q,@600 kg 1400 1400 1350 1300 Q,@600 kg 1350 1300 1250 1200 1200 950 11503) 950 11003) 600 10003) 350 650 3) The h4 dimension without Load Backrest will decrease with 442 mm The h5 dimension without Load Backrest will increase with 442 mm The capacity with the Wide Tread Option: the overall width changes from 997mm to 1067mm h1 - Height with mast lowered h2 - Standard free lift h3 - Standard lift height h4 - Height with mast raised h5 - Full free lift Q - Lifting capacity, rated load 44 CEOM0924 Appendix III Battery drawing FB10-15KRT PAC 45 CEOM0924 Appendix IV PM-1000 AC Controller Pre-settings Setting Var. Standard (Factory setting or default) Long distance Short shuttle High power Economy A B C D E 1 Start lift speed 1-10 7 7 7 7 7 2 Top lift speed 1-10 10 10 10 10 10 3 Tilt speed 1-10 5 7 5 7 7 4 Max. vehicle speed 5-14 13 or 14 13 or 14 10 13 or 14 9 7 Acceleration rate 1-5 2 5 1 2 5 8 Travelling power 1-3 2 3 1 3 2 9 Automatic regeneration 1-5 3 4 2 3 4 23 Application SUO# SUO#: Individual option no. PM-1000 AC Controller Set-up options First group Option 1 Title of Option Application Pre-Sets Range A-E Default A 2 Start Lift Speed 1 to 10 7 3 Top Lift Speed 1 to 10 10 4 Tilt Speed 1 to 10 5 5 Auxiliary 1 Speed 1 to 10 3 6 Auxiliary 2 Speed 1 to 10 1 7 Top Travel Speed Limit 5 to 14 [km/h] or 5 to 13 [km/h] 13 or 14 8 Acceleration Rate 1 to 5 2 9 Travelling Power 1,2,3 2 10 Service Indicator 0 = disable 0.1 = for sales demo only 100-500, with 50 hours increments 0 46 CEOM0924 Appendix IV Second group Option Title of Option Range Default 11 Auxiliary input for lift 1 Not used (0 to 2) 0 14 Auxiliary input for lift 2 same as #11 0 20 Stall timer (preventing overheating of the traction motors when torque is too high) 2 to 10 [sec] 5 21 Regen function 0:accelerator regen ("auto regen") 1 to 5 : brake regen (accel must be off) 0 22 Regen adjustment for lever regen 1 to 5 4 23 Regen adjustment for auto regen 1 to 5 3 27 Tire size adjustment 0 to 40 20 0: disable 1: travel speed limit (switch closed) 2: power reduction (switch closed) 3: travel speed limit (switch opened) 4: power reduction (switch opened) 30 Auxiliary input for travel speed 0 31 Auxiliary maximum travel speed setting 5 to 14 [km/h] or 5 to 13 [km/h] 8 32 Auxiliary output power limit 0 to 100 [%] 70 47 CEOM0924 Appendix IV To change set-up options There is no tooling needed for changing the set-up options. You have to remove the floor plate for access to the DRS switch. The DRS switch is installed under the floor plate at the left hand side of the truck. Turning on the key switch allows you to enter one of the modes in each setup group and show as the figure. You can not transfer to another mode unless the source power is turned off. DRS switch Seat Direct. lever Accel. Pedal Lift lever Tilt lever Attachment 1 lever Sets default data of group 1 and 2 S not sit R on off off off Checks and sets basic function (#1 to #10) S not sit N off off off off Function Description Default data set Group 1 data In the display you can see which group you are in: The set value change procedure consists of selecting the desire SUO # using the DRS switch, change the set value by moving the direction lever, and registering the new value. Cycle the DRS swicth S -> R -> S. The set value displayed on the screen is registered. The SUO # on the screen then advances to the next SUO #. Changing the set value is now possible for the SUO #. The first half of the DRS switch operation (S -> R) is for overwritting the previous value with the value on the screen (registering). When the value is registered, a set of three dotted lines appears on the screen as shown in the illustration on the next page. The second half of the operation (R -> S) is for advancing the SUO #. Every time the DRS switch is cycled S -> R -> S, the SUO # increments. When advancing the SUO # without changing the set value, simply repeat by cycling the switch as many times as necessary. When the last SUO # is reached, “donE” appears in the set value display area. 48 CEOM0924 Appendix IV Use the direction lever to change the set value. The value increases when the lever is cycled N -> F -> N; it decreases when the lever is cycled N -> R -> N. In either case, by increasing or decreasing direction, the value returns to the first or last value in the available value range. Example When changing setting of SUO #7 (top travel speed limit) from default 13 km/h to 11 km/h: Step 1. Since the SUO #7 belongs to group 1 setup options, cause the first SUO #”01” of the group to appear on the screen using the operation procedure on page 48. Step 2. Move the DRS switch as follows to change the current setting for the SUO #7. Move the DRS switch S -> R. the display changes as shown bellow. The set value (A) for the SUO #01 is overwritten simultaneously. Move the DRS switch R -> S. The display shows the current setting for the next SUO #02. Cycle the DRS switch S -> R -> S 4 times to cause the SUO #07 to appear on the screen. You can see that the default value is on “5”. Step 3. Change the set value from 13 to 11 by moving the direction lever N -> R twice. Step 4. Register the new value by cycling the DRS switch S -> R -> S. The current value is overwritten with the new value. The screen shows the next SUO #08. 49 CEOM0924