NPP Service Manual

9 Electric system adjustments and measurements

The basis for calibrations is that all of the parameters are correctly set according to the
truck parameter list and settings. Before you start adjusting the calibration parameters,
make sure that the rest of the parameters are in order.

9.1 Calibrating the accelerator

If the accelerator or the traction controller is changed, the accelerator must be

calibrated. Also if the truck does not drive smoothly, it is recommended that you always
first perform this calibration.

9.1.1 Acquiring the VACC with TruckTool

1. Connect TruckTool to the truck.

2. In TruckTool, go to the Wizards view.
3. Select the Accelerator calibration option and press the Start wizard button next
to it.

4. Make sure that the truck’s

accelerator lever is in the middle
position.

5. In TruckTool, press Start in the Wizard popup window.

6. Pull the truck’s tiller to the driving

position and turn the accelerator
lever to one end position and then to
the other end position.

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NPP Service Manual

7. In TruckTool, check that the displayed values are acceptable and press Stop.

If the process fails, update the firmware on the controller and try again.

9.1.2 Acquiring the VACC without TruckTool

1. During key-on, lower the forks and turn the accelerator forward at the same time
and hold the buttons down for 15 seconds.
The truck enters the accelerator teach-in mode.
2. Release all the buttons.
3. Teach the accelerator by turning it first fully forward, then fully backward.
4. Release the accelerator.
5. Press the safety button to save the settings.
6. Restart the truck.

9.2 Calibrating the motor resistance

If the traction motor or the traction controller is changed, the motor resistance must be
calibrated. Also if the truck does not drive smoothly, it is recommended that you always
first perform this calibration.

9.2.1 Acquiring the motor resistance with TruckTool

1. Connect TruckTool to the truck.

2. In TruckTool, go to the Wizards view.
3. In the Execute model specific wizard menu, select the Motor resistance option
and press the Start wizard button next to it.
4. Follow the instructions on TruckTool to calibrate the motor resistance.

9.2.2 Acquiring the motor resistance without TruckTool

1. Hold the tiller arm in the driving position and press and hold down the brake release
button and the safety button.
2. While holding the buttons down, switch the truck’s power on.
3. Hold the buttons down for 15 seconds.
The contactor closes and reopens.
4. Release the buttons.
5. Restart the truck.
The new motor resistance is acquired and saved.
6. Make a test drive to make sure that the truck is working normally.

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NPP Service Manual

9.3 Insulation resistance test

9.3.1 Test voltage

The insulation resistance of the truck and the traction battery is checked separately. The
test voltage is greater than the nominal voltage but no more than 100 V or three times
the nominal voltage:

NOMINAL VOLTAGE TEST VOLTAGE

Up to 24 V 50 V

Over 36 V 100 V

9.3.2 Checking the insulation tester

Connect the test probe to the frame of the truck (for example, to a non-painted bolt or
bracket) and the other test probe to another bolt or bracket. The tester should show a
zero value.

Figure 78. Checking the insulation tester

9.3.3 Measuring the insulation resistance

The test is performed with the battery disconnected from the truck. All the electrical
components must be in place.

1. Release the emergency stop and turn the key switch to the ON position.
2. Connect the test probe to the frame of the truck (for example, to a non-painted bolt
or bracket) and the other test probe to the plus terminal of the battery connector.
3. Read the resistance value.
4. Measure and read the minus terminal of the battery connector in the same way.

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NPP Service Manual

9.3.3.1 Insulation resistance of the truck

Figure 79. Measuring the insulation resistance of the truck

The insulation resistance between the live parts of all the electric components and the
frame of the industrial truck with the exception of the battery is at least 1000 Ω
multiplied by the nominal voltage of the truck system.

NOMINAL VOLTAGE MINIMUM INSULATION RESISTANCE

24 V 24,000 Ω

36 V 36,000 Ω

48 V 48,000 Ω

80 V 80,000 Ω

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NPP Service Manual

9.3.3.2 Insulation resistance of the battery

Figure 80. Measuring the insulation resistance of the battery

The insulation resistance of the disconnected, filled and charged traction battery
mounted on the truck is at least 50 Ω multiplied by the nominal voltage of the truck
system between the live parts and the frame of the truck. If the battery is fitted into more
than one container, this test is carried out with the electrically-connected sections
(including metal battery containers).

NOMINAL VOLTAGE MINIMUM INSULATION RESISTANCE

24 V 1,200 Ω

36 V 1,800 Ω

48 V 2,400 Ω

80 V 4,000 Ω

Copyright© 2013 by MCFE. All rights reserved. Revision: A Document ID: 618021 126 (206)