VNA-AC

Truck Overview.

Technical Training
Introduction
 Course Overview

 General Information
 Truck- Installation
 Component Information &
Component Identification &
Location
 Driver cabin
 Controller
 Mast and Attachment
 Hydraulic system.
 Brake system
 Pantograph
 CAN Bus & Sensors
 Adjustments & Parameter
 Diagrams
 Steering + EPS-AC + Wire
guiding
 7 Modele. C1.0 / MTC 10/ C1.3 /MTC13 /
C1.3 80V / MTC 13 80V/ C1.3L / MTC
LWB / C1.5S /MTC13 SWB/ C1.5M /MTC
15 MWB / C1.5L / MTC 15 LWB
 5 Chassis configuration.
 AC Technology.
 CANbus Technology.
 Tri-Lateral Front Mast
 Lifting height 16.1 Meter
 Mini-Mast up to 3 Meter (STD 1980mm).
 Pantograph.
 Tilting Option
 Forkpositioner Option
 Loadwheel brake Frame 4 & 5.
 Multifunction Hydraulics.
 No Micro switches.
 Cabin Option
 Configuration Option
 On Line Help & Technically Support
 Stabiliser Option
 Important
 This training submit detailed information about Service
work / Troubleshooting / Dissambling / Assembling of
components and adjustments about the 7 Models :-

 C1.0 / C1.3 / C1.3 (80v) / C1.3L / C1.5S / C1.5M / C1.5L.

 MTC10 / 13 / 13 (80v) / 13LWB / 15SWB / 15MWB / 15LWB

 The procedures described in the literature is an integral

part of the use and maintenance manual and does not
replace it.

 The procedures given on this training course and within

the literature require specific technical knowledge and
must only be carried out by qualified and trained staff.

 Modifications of any type can only be done after written

permission has been obtained from Factory Engineering
department.
 Truck Selection.

C1.0 / MTC10 C1.3 / MTC13 C1.5 / MTC15

 General

 5 Chassis Frames Sizes, 7 Models. (See Manual).

 Frame Sizes 1 / 2 / 3  48 Volt.

 Frame Sizes 4/5  80 Volt.

 Truck Overview.

 Model line-up.
 Cabin.
 Controls.
 Display.
 Turret Attachment.
 Mast.
 Motors.
 Hydraulics.
 Options.
 General

 The Mast Is Basically The

Same.

 The Hoist Cylinders Are

Now Mounted On the Mast,
Not The Frame.

 Lift heights Of Up To 16.1

Metres Are Possible.
 General

 New Tri-Lateral Front End.

 General

 New Tri-Lateral Front End.

 Pantograph.
 General

 New Tri-Lateral Front End.

 Pantograph.
 Elimination Of Micro
Switch’s.
 General

ENC 3.
Cabin Height Encoder.
 New Tri-Lateral Front End.
 Pantograph.
 Elimination Of Micro
Switch’s.
 Encoders Are Used.

SW 16.
Cab Height Encoder Reset
Sensor.

ENC 1.
Redundant Encoder.
 General

 New Tri-Lateral Front End.

 Pantograph.
 Elimination Of Micro Switch’s.
 3 Phase Traction.
 General

 New Tri-Lateral Front End.

 Pantograph.
 Elimination Of Micro Switch’s.
 3 Phase Traction.
 3 Phase Hydraulics.
 General

 New Tri-Lateral Front End.

 Pantograph.
 Elimination Of Micro Switch’s.
 3 Phase Traction.
 3 Phase Hydraulics.
 3 Phase EPS - AC
 General

 New Tri-Lateral Front End.

 Pantograph.
 Elimination Of Micro Switch’s.
 3 Phase Ac Traction.
 3 Phase Ac Hydraulics.
 3 Phase EPS - AC
 3 x Mhyrio Controllers.

MHYRIO
Multifunction, Hydraulic, Remote, Input,
Output.
 General

 New Tri-Lateral Front End.

 Pantograph.
 Elimination Of Micro Switch’s.
 3 Phase Traction.
 3 Phase Hydraulics.
 3 Phase EPS - AC
 3 x Mhyrio Controllers.
 Electronic Control Hydraulic
Valves.
 General
Optional Cab Layouts.

Joystick Control.

Stepper Motor Steering.

NOTE: -
Version Shown Is American
Specification. No Front Screen.
 General
Dash Version Shown.
 General
Dash Version Shown.
Lift Lower Cabin Tiller.
 General
Dash Version Shown.
Lift Lower Tiller.
Fwd Rev Tiller.
 General
Dash Version Shown.
Lift Lower Tiller.
Fwd Rev Tiller.
Aux. Hydraulic Controls.
 General
Dash Version Shown.
Lift Lower Tiller.
Fwd Rev Tiller.
Aux. Hydraulic Controls.
Function Select Switch’s.
 General
Dash Version Shown.
Lift Lower Tiller.
Fwd Rev Tiller.
Aux. Hydraulic Controls.
Function Select Switch’s.
Wire Guidance Select.
 General
Dash Version Shown.
Lift Lower Tiller.
Fwd Rev Tiller.
Aux. Hydraulic Controls.
Function Select Switch’s.
Wire Guidance Select.
Emergency.
 General

Dash Version Shown.

Lift Lower Tiller.
Fwd Rev Tiller.
Aux. Hydraulic Controls.
Function Select Switch’s.
Wire Guidance Select.
Emergency. RTC
Stepper Motor or RTC Steering.
(RTC is Standard).

Stepper Motor
 General
Dash Version Shown.
Lift Lower Tiller.
Fwd Rev Tiller.
Aux. Hydraulic Controls.
Function Select Switch’s.
Wire Guidance Select.
Emergency.
Stepper Motor Steering.
Sicos Unit.

SICOS
System, Interface, Control, Operator,
Station
 K3 is the supply
contactor the coil is
supplied from the key
switch.

Alarm contactor.
Main Contactor.K1.
In the event of any alarms K2 will
Contactor closes after key-on and
switch off, shutting down traction /
relay K3 (Supply Contactor) is
hydraulics etc.
energized. Battery voltage is
supplied.
Note! K1 remains energized allowing
The feed to K1 can be broken via
steering to still operate.
SW2 Batt Dsc switch.
K4 is the Aux 24 volt output from the dc-dc
converter.
The coil is supplied + from the output of the
dc dc converter, the negative comes from
MHYRIO 2.
This supplies, MHYRIOS, sensors etc.
 MHYRIO 3
SV11 Rotation.

Pot 2.
SV13 Panto
Retract’.

SV14 Panto’
Extend. .
SV12 Rotation.
Renew Hydraulic Filters Every 1000
Hours.
Torque Value = 110NM.
Top Tri -Lateral Mounting.
Allowing Mini - Mast Lift Heights To 9
mt.
Pantograph End
Of Stroke
Sensor.

Pot 3,
Pantograph
Position
Transducer.
 Cabin.

 Low step height.

425mm

 Generous
headroom.
2050mm
 Cabin.

 Extended cabin
depth 200mm for
more leg / knee
room.

 Generous shoulder
room for the larger
sized operators.
 Cabin.

 4 Cabin Widths.
 1200mm,
 1400mm,
 1550mm,
 1700mm,
 Traverse frame the same width as
the cabin.
 Overhead guard provides full
protection across the cab width.
 Cabin.

 Large rear window.

 Flat cables replaced with
a single round cable.
 3 spare wires…….

 Path of the cables and

hydraulic hoses moved
to the centre spine of
mast.
 Cabin.

 Soft floor mat, grooved slip resistant

rubber.

 Large operator presence foot

sensors are mounted under the floor
mat.

 Floor texture on edges

provide additional grip.
 Cabin.

 Gate Arms;
 Spring assisted swing up action.
 Fully open after 45 degrees.
 Self close below 45 degrees.
 Spring loaded toe board.
 Durable rubber padding.
 Provides additional comfort when
picking in the aisle.
 Cabin.

 Premium Comfort Seat.

 Adjustable seat height 150mm.
 Gas spring assisted.
 Seat swivels 0°, 10° or 20°.
 Automatic return to centre.
 Centre index.
 Lockable.
 Contoured to improve ventilation.
 Cabin.

 Premium Comfort
Seat.
 Cushion on the under
side to provide lean
support when standing.
 Increased operator
weight range up to
165kg.
 Cabin.
 Fluorescent Lighting Is Standard.
 1 cabin (dome) light.
 2 work lights.

 2 Automotive style cooling fans.

 Rear View Mirrors (optional).

 Cabin.
 Dual Seat Side Joystick
Controls.
 Cabin.

 Forward Mounted
Control Console.
 Cabin.

 Display.
 Black character on green background.
 Travel Direction.
 Hydraulic function engaged.
 Total lift height.
 Steer wheel position indicator.
 Travel direction.
 Drive mode selected.
 Service code.
 Anomaly i.e. turret head not fully
nested.
 Guidance status.
 Operator password entry. (option)
 Load weight.
 Cabin.
 Drive Modes.
 Driver can select drive mode suited to personal
preference, load handling requirement, learner training.
Slow. Soft. Standard. Hard.
Travel speed 50% 80% 90% 100%
Lift speed 50% 80% 90% 100%
Acceleration 50% 80% 90% 100%
Braking 50% 80% 90% 100%

 Up to 20 driver passwords linked to performance

settings possible. (option)
 Cabin.

 Pre Height Selector (optional)

 Cabin.
 Summary;
 Large cabin.
 Soft floor mat, no trip points.
 Comfortable seat with the ability to
rotate.
 Rear visibility.
 Ergonomic forward mounted controls.
 Optional seat side controls.
 Driver modes and password.
 Turret Head.
 Top and Bottom Mounted Turret
Head.
 Improved load stability on forks.
 Unrestricted visibility of forks, load,
aisle entry. ( empty)
 Greater support.
 Turret Head.

 Pin Type
Forks.
 Less unwanted
movement of the
forks.
 Turret Head.

 4 Auxiliary Mast Heights

Available.
 1980mm. (Standard)
 2140mm.
 2720mm.
 3000mm.
 Turret Head.

 Inverted Cylinder.
 Outer shell is always being
held stable while also
protecting the chrome rod.
 Turret Head.

 Manual Override.
 Remove cover to
manual crank the
turret head across.
 Turret Head.
 210mm Turret Head Thickness.
 Provides additional side clearance.
 Allow smaller operating aisles.
 Turret Head.

 Automatic Pantograph Extension.

 Forks extended up to an additional
250mm beyond the turret head.
 Position is programmed to suit the
application.

 Warning!
 Do Not Exceed Factory Settings.
 Turret Head.

 Additional Pantograph Stroke via By-pass.

 The by pass button allows full 250mm pantograph
when the forks are below 1500mm. *
 Turret Head.

 Fork Positioner.
 Optional integrated zero
thickness fork positioner.
 Turret Head.
 Different Rotation Centres
Available.
 670mm is the standard.
 Other dimensions are available to
suit application.
 Turret Head.

 Sealed Bearings ( x 9).

 Ensure durability and minimise
movement.
 Turret Head.

 Rotation via Hydraulic Actuator.

 No chains, gears or cylinders.
 Turret Head.
 Eccentric Bearings.
 Allow quick, simple and fast
adjustment of the bearings on the
attachment.
 Turret Head.

 Electronic Control End of Stroke

Dampening.
 Automatic slowdown at end of
stroke dampening gives greater
controllability and increased
productivity.
 Turret Head.

 Summary.
 Unrestricted visibility.
 Automatic pantograph extension.
 4 different heights.
 210mm head thickness.
 Main Mast.

 20% Regen’ on mast lowering.

 Cables routed inside column.
 Bolt-on load rollers.
 Cylinders jointed directly to
the mast.
 Slack chain detector.
 Chain anchor load cells detect
slack chain condition.
 Main Mast.

 Triform mast for lifts up to

13400mm.

 I beam channels with

vertical tube reinforcement
and single tube column and
cross members.
 Main Mast.

 Quadform masts
for lifts up to
16100mm.

 I beam channels
with dual tube
column and tube
cross members.
 Main Mast.

 Industry leading design.

 Minimum mast / cabin sway.
 Mast rigidity increased by 15% by mast mounting
structure.
 Encoders provide continuous height sensing over
main and aux lift.
 eliminates speed interlock microswitches.
 Continuous height sensing.
 progressive speed adjustment at heights versus stepped
speed slowdown.
 Chassis.

 5 Chassis Sizes. 7 Models.

Model Voltage Battery Capacity
 C1.0 / MTC10 48 560 Ah – 700 Ah
 C1.3 / MTC13 48 700 Ah – 840 Ah
 C1.3L / MTC13L 48 875 Ah – 1000 Ah
 C1.3 80 / MTC13 80 80 420 Ah
 C1.5S / MTC15S 80 560 Ah
 C1.5M / MTC15M 80 700 Ah
 C1.5L / MTC15L 80 840 Ah
 Chassis.
 Fully robot-welded frame with
solid plate underside.
 Prevents chassis twisting and
early fatigue.
 10% more rigidity over previous
design.
 Chassis.

 4 Width over Load Wheels

Dimensions.
 1220mm.
 1425mm.
 1575mm.
 1725mm.
 Welded box section between load
wheels increases rigidity by 25%.
 Chassis.

 Steel Battery Lid .

 doubles as a storage
tray.
 Chassis.
 Sloping Top Plate Overhead
Guard.
 improves visibility over rear of truck.
 Chassis.

 Battery Retention
System.
 Quick and easy
battery removal.

 Rem: Min, Max

 Battery Mass.
 Chassis.

 Eccentric Stub
Shafts.
 Allow adjustment
to align very tall
masts to vertical.
 Chassis.
 Rear Cover.
 Single steel cover.
 Reinforced ribbing.
 Rubber seal about drive unit.
 Dual gas spring assisted for
lift.
 Locking latch.
 Allows full access in the aisle.
 Pull down handle.
 The Rear Compartment .
 Easy Accessibility to all Components.
 Drive unit.
 Motor and gearbox.
 Steering unit.
 Hydraulics.
 Pump motors and valve.
 Electromagnetic brake.
 CANbus.
 Controllers.
 Emergency cabin lowering and forks traverse.
 Fan Cooled.
 The Rear Compartment.

 Motors.
 AC Brushless.
 Sealed.
 Active monitoring
system.
 Thermal feedback.
 The Rear Compartment.

 Traction Motor.
 48 volt 6.5 kW
 80 volt 8.0 kW
 AC technology.
 Powerful acceleration and braking.
 Optimum performance laden / unladen.
 Reduced maintenance.
 no brushes / commutator.
 Protection against overheating.
 Fixed – no flexing of power cables.
 The Rear Compartment.
 Steering Unit
 AC motor technology.
 Reduced maintenance.
 no brushes / commutator.
 High torque.
 Gear on gear linkage.
 no chain adjustment/maintenance.
 Electronic rotational stops.

 Automatic Straight Ahead Positioning

of Steer Wheel on Start-up.
 The Rear Compartment.
 Pump Motors.
 AC Technology.
 2 x 12 kW 48 V
 2 x 14 kW 80 V
 25% intermittent rating.
 High capacity performance for simultaneous
operation of hydraulic functions.
 Reduced maintenance.
 no brushes / commutator to wear.
 Protection against overheating.
 Regen on lowering.
 Isolated mounting points.
 The Rear Compartment.

 AC Controllers.
 1 x Traction.
 2 x Hydraulic.
 1 x Steering.

 Conversion of DC power from the

battery to AC power.
 The Rear Compartment.

 Electromagnetic Brake.
 Powerful magnetically released / spring applied brake.
 Controlled by.
 throttle position.
 foot presence switch.
 When throttle/ foot presence switch released,
 phase 1 autoregen braking.
 phase 2 brake closes at 40 hz.
 Load wheel proportional braking

 Manual Release Ability.

 The Rear Compartment.
 CANbus.
 Simplified wiring complexity.
 Error free transmission of data.
 Allows truck systems to talk with one another.
 Traction.
 Hydraulics.
 Steering.
 Display.
 Facilitates trouble shooting.
 Single point diagnostic service
point access.
 ETACC.
 The Rear Compartment.

 Sealed Electrical Connectors

 Automotive style IP67
 The Rear Compartment.

 40% Reduction in
Wiring.

 75% Reduction in
Electrical
Connections.
 The Rear Compartment.
 Emergency Forks Traverse.
 Allows forks / load to be
extracted from racking to
permit lowering of the cabin.
 Emergency Lowering.
 Allows cabin to be lowered to
the ground in event operator
has become incapacitated.
 The Rear Compartment.

 Speed to Height (adjustments).

 Speed to Height to Weight.
 The Rear Compartment.

 High Performance.

 Up to 12 km/h travel
speed (application
specific).

 90% of maximum
speed in 5 seconds.
 The Rear Compartment.

 Removable Bumper Plate.

 Choice of 2 gearboxes
 GK30.
 GK40.
 The Rear Compartment.

 Long Life O-ring

Flat Face Seal
Hydraulic Fittings.
 The Rear Compartment.

 Filtration.
 Pressure inline high performance
filters.
 10 micron high efficiency.
 Filters oil before components.
 The Rear Compartment.

 Quick and Easy Oil Level

Check.
 The Rear Compartment.

 Drop Forward Valve Block.

 The Rear Compartment.

 Diagnostics.
 Dash Display.
 Handset.
 PC Laptop.
 The Rear Compartment.

 Summary:
 VSM CANbus system.
 O ring Flat Face Seals.
 AC Brushless sealed motors.
 Sealed connectors.
 Pressure side filtration.
 Easy access.
 High performance.
 Options.
 Wire Guidance.
 Frequencies 5.2 kHz
6.25 kHz
7 kHz
10 kHz
 Wireguidance steering module.
 Continuously adjusts position of the truck over the wire.
 + 25 mm deviation from centerline truck will slow down.
 + 50 mm deviation truck will stop.
 Options.

 Wire Guidance Installation

Guidelines.
 Floor depth.
 Position of rebar.
 Options.

 Wire Guidance.
 Acquisition of wire.
 Angles.
 Options.

 Line Driver.

 1 x generator drives 1000 m of wire

at 6.25 kHz.
 4-6 hour emergency back-up std.

 Warning light.
 off normal operation.
 flashing red malfunction.
 Options.
 Rail Guidance.
 Aisle recognition; ( via infrared photocell)
 Drive wheel centres in the straight ahead
position.
 High rail 100mm.
 Low profile rail 40mm.
 Optional Front Guide Rollers.
 facilitate aisle entry.
 Options.

 Battery Table.
 Battery rollers.
 Welded box frame.
 Options.

 Lift Limit with Override.

 2 Programmable Stop points with over

ride.

 1 Programmable Stop point with no over

ride.
 Options.

 End of Aisle Control Interlocks.

 Protects against.
 truck entering main transfer aisles into other traffic at
speed.
 truck running into wall at end of dead end aisle.

 On Board Truck Sensors.

 read magnets buried in
the floor.
 Options.
 End of Aisle Control Options.
 Slow Down.
 Truck slows to creep speed as it enters transfer aisle.
 Stop.
 Truck slows to stop before it enters the transfer aisle -
 The Operator must recycle via footswitch to restart.
 Slow down and stop with override.
 Truck slows to a stop at end of aisle -
 Operator must recycle to via footswitch to restart.
Note
 With end of aisle control an incremental encoder reads direction
of travel – if truck changes direction after passing over slow down
or stop magnet it will automatically gain top speed.
 Options.
 Cover Screens.
 Lexan cover for overhead guard.
 Wire mesh cover for overhead
guard.
 Full cabin width front lexan screen.
 Options.
 Fork Positioners.
 Spread 20 – 28 in.
 Does not increase rotator head width.
 For handling different width loads.

 Fork Tilt.
 SPED.
 2 ° forward / 4 ° back.
 For push back and flow rack applications.
 Options.
 Cold Store.
 Protection package - 40°C.

 Cold Store Cabin (SPED).

 Heater.
 Double glazing.
 Carpet.
 Intercom.
 Thermostat control.
 Emergency exit.
 Defroster (optional).
 Rearview mirrors. Options.

 Beverage holder and trash holder.

 Clipboard with horizontal prop
support.
 Universal support bracket for radio
terminal.
 Universal support bracket for scanner.
 Prewired for RFDT terminal ( included
with universal support bracket).
 Shuttle Table Options.
(SPED).
 Achieves minimum
aisle width.
 Requires raised P
and D station.
 Lowered top of fork
height 310mm.
 Shuttle table with aux
lift.
 Aux lift 850mm.
 Facilitates
orderpicking.
 Comparison New Models vs Old Models.
 Front end attachment mounting Top+bottom Forward
 Fork extension Pantograph (std) Telescopic (option)
 Fork carriage Pin type Hook on
 Simultaneous functions all travel+main
lift/lower
travel+main/aux
lower
 Speed over aux lift Full up to 600mm
 Driver select performance modes yes no
 Motor technology AC DC
 Truck system management CANbus PLC
 Height sensing Continuous Stepped
 Synchronised traverse/rotate Yes No
 Height speed interlock Encoder Microswitch
 Direction sensing Std Option
 Load sensing Standard N/A
 Steering Gears Chain
 Rear cover Lift up Open out
 Seat Swivel Fixed
 Foot presence switch Under floormat Raised
 Display Yes No
 Password access Yes (option) No
 Load wheel brakes 80V No