HI there
This trucks is a dc truck which uses the 2 zapi traction and pump controllers and the zapi EPS steering controller.
The truck works drive hydraulics and steer, the only problem is that when you drive the truck fast and turn the steering the steer wheel does not turn fast enough.
We changed the Zapi EPS steer controller, tried adjusting the steer sensitivity settings to max along with steer speed setting to max.
We then tried changing the steering unit the tacho sensor.
We checked the motor brushes all fine. Any suggestions would be appreciated as it looks like we are at a dead end with this one. Perhaps a setting in the steer unit but I cant see this as tried a different controller also off the same type of truck.
Showing items 1 - 20 of 23 results.
Hi Electrodrive
Have you had chance to check the interface board yet, have you checked the jumpers on the board , j2 should be set left of centre,
Have you checked the cut back speed in the traction unit,
I can't think of any thing else at the moment that might affect the steering performance
Regards Titus
It is a Dc truck so I dont think slip is the issue, but the sensors actually stop the steering from what I can see as it comes to its lock. You can see the sensor LEDs light up as it comes to its end lock.
Hopefully will get to the bottom of it most likely by chance :)
Is there not a sensor on that truck that slow's the steering went it gets near um full lock left or right to take any shock off the chain.maybe your getting a signal from one of the sensors
Slip is relevant to ac motors is it not.
HI Ed
Where can i find the slip setting?
You need to make the battery setting in the ESP controler and the traction controler the same which is 48v.
Regards Titus
what is slip set for in the eps settings?
Next week I am going to have a look at this interface relay board on the truck incase it somehow goes through that.
I could not find any ramp settings, but will look at all the possible options and let you know how i get on. Thanks for all the advice greatly appreciated.
HI Titus
Yes I did read this and thats why I asked the customer to charge the battery. Then once fully charged went out to it and tried changing the setting from 48 to 40 then 24 in the EPS controller. Should this be set in this unit or the main traction controller?
So my truck being a 48v truck, I have it set to 48v then played with speed increase and sensitivity, still no difference. Am i adjusting wrong battery settings?
Hi Electrodrive,
I've been looking at my notes , and they tell me that the maximum speed in proportion, can only be adjusted after setting the battery voltage with ( Set Battery type) this parameter increases the speed as a percentage of the set battery voltage, you have to do this before you set the rotation of the speed of steering wheel, levels between 0-9. 9 is high for maximum speed of rotation,
I hope this info helps. Regards Titus
Hi Electrodrive,
I've been looking at my notes , and they tell me that the maximum speed in proportion, can only be adjusted after setting the battery voltage with ( Set Battery type) this parameter increases the speed as a percentage of the set battery voltage, you have to do this before you set the rotation of the speed of steering wheel, levels between 0-9. 9 is high for maximum speed of rotation,
I hope this info helps. Regards Titus
the tach generator may run a different voltage than the rest of the system, the eps controller may only use 24v signal
have you tried checking the output of the new tach generator?
and on another note there may be a ramp setting in the truck setup for the steering gain (steering speed) and possibly a diode board it goes through, thats the way they had it on the OSO orderpickers, this being a reach truck may be different of course :o)
Thank You
Received. Still dont know what else to try :(
Come next week will try a few other checks and then may have to call it a day.
Please check your email I send material
Thanks for all the advice everyone.
I read through the manual and could not find anything additional, so went back to it this morning. Had the battery fully charged, cleaned the power steer motor out, tested the truck off the floor without any load on the drive motor, which connects to the power steer motor through the chain mechanism.
I tried changing voltage settings on the Zapi EPS system.
Still no joy, the customer (being a forklift engineer himself) is adamant its nothing mechanical as he has already checked all other aspects.
I noticed when I repalced the tacho generator it had 24v sticker on it, could it be this tacho should be 48v? Im just ready to try anything now :)
Hi Electrodrive,
It may be a mechanical fault, looking back at the experience I've had with thistruck in the past it may be the steering ring bearing that is partially seized I've had them seized before I have a workshop manual for this truck I will have look see if anything else comes to mind, I've had steer chains broken tach generator gearboxes worn, steer pots worn out, steer motors falling apart
Regards Titus
hello elektrodrive !
material if you need this machine I can send you
add me on skype: hyster.brasil
elektro,
as far as i can remember (on the EPSII) systems
the only communication the steering controller had with the drive controller was more or less a 'go no-go' signal and there may have been a setting to set the truck to either manual steer or wire guided steering, if all was ok and no errors were detected in the steering unit the truck would run fine, if there were errors generated from the EPS then it would shut the truck down. I think (if i remember correctly)all the steering settings were done on the EPS controller itself using trim-pots.
Now as for this system on that truck you have, it MAY be like this or it may be different.
If it is zapi then I'm sure it is different.
having the service manual for the truck and the EPS steering would be a great help. from my recollection Yale was always good about having ample information in those manuals, and if there were any discrepancies the engineers at nacco were always more than willing to help.
Usually you have parameter like set steer left,set steer right and central zero position you must to see when connect and do Vacc pedal accelerator when finish that also know to be stupid problem.Look and tell as what are you do.good Luck
Hi Thanks for the Info
As I am not a mechanical engineer I thought perhaps it was a mechanical issue but the engineer has assured me its not hence why he has called me in.
Its the tacho generator on the steering, which I thought was the culprit, but not in this case. The steer sensor pot is or might also be
Any info on the traction controller settings which affect the steer speed would be appreciated. I will read through the manual to see if i can find such settings however if you can direct me to it would be easier :)
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