Preliminary Monitor

Tiller arm

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Content

Introduction 3 Styling & Shape 4 Functions

1. Driving 5 2. Main lift & lower 5 3. Proportional lift & lower 6 4. Belly button 6 5. Horn 6 6. Tiller arm lock bypass & Creepspeed 7 7. Steering 7

Material 8

1. Shaft 8 2. Tiller head 8 3. Hand grips 9 4. Buttons and levers 9 5. Base block 9

Ergonomics 10 Tiller arm lock 12 Service 14 Improvements 15

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Introduction

A tiller arm is the main point of contact between the driver and the truck. This means that the tiller arm is a very important part of smaller warehouse trucks. The tiller should be comfortable and easy to use. It should also make a good first impression, both for ergonomics and styling. If these objectives are reached the user will regard the whole truck as easy to use and will rate the truck higher. Durability is an important aspect in warehouse trucks. This is especially true for the tiller arm as it also has to protect the driver’s hands. The tiller should be able to resist shocks and large forces in order to keep the driver safe. These aspects were all taken into account when designing the tiller arm. In this Monitor/ Sales Manual the features and benefits will be described and explained.

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Styling & shape

The styling of the new arm matches that of the latest warehouse products and trends in the automobile industry. The materials used are meant to make the tiller stronger and more rugged and at the same time have a modern look. The shape of the crossbars is designed so that obstacles will be deflected away from the tiller head and the driver’s hand. This increases both durability and safety. The buttons on the tiller head do not stick out of the frame so they cannot get caught behind an obstacle.

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Functions

All operating functions of the truck are located on the tiller head.

1. Driving forward and backwards 2. Main Lift / Lower 3. Proportional lift / lower (when available) or 1 speed up, 2

speed down 4. Belly button 5. Horn 6. Creep speed / Tiller arm lock bypass button 7. Steering (not shown)

1. Driving forward and backwards The forward and reverse driving switch is operated with the thumb or index finger. It can be operated with the left or right hand. The shape is designed for optimal grip and comfort. When released, it will return to the neutral position which brings the truck to a gradual stop. When the lever is reversed while driving forward active regenerative braking (plug braking) is applied. The button turns lightly. This is a benefit especially when the driver has to work long shifts. Ergonomic studies show that pressing a lever continuously is very tiring for a person.

2. Main lift & Lower This button activates the fork lift on powered pallet trucks and initial lift on stackers. If there is no initial lift fitted it also works as main lift and lower, but only 1 full speed up and full speed down. It is shaped

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so that it can be reached with the index finger or thumb of both hands. The lifting function is placed closest to the driver, while lowering is placed on the load side. This is a change from the previous tiller arm making the operation more intuitive.

3. Proportional lift & lower This lever is only fitted on stackers models and can be activated with the index finger of both hands. The function is different for trucks with or without proportional lift:

• With proportional lift it gives the driver control over the lift speed. When the lever is touched lightly the lift- or lowering speed will be low. When it is pushed (or pulled) to the limit maximum lift- or lower speeds are reached.

• Without proportional lift the lever works as “1 speed up, 2 speeds down”. When pulled, the stacker will lift with full speed. When pushed, it will lower with half the maximum speed. When pushed further a second hydraulic valve will open, increasing lowering speed to the maximum. This helps the driver position the forks at the correct height without proportional lift.

4. Belly button Safety switch to prevent injury to the driver when he gets trapped between the truck and an obstacle while reversing. When this happens the belly button will touch the driver. The truck’s controller will get a signal to reverse the driving direction to avoid crushing the driver. The strength of the function is programmable. There are two microswitches that activate the function. One acts as a backup system for the other, make the system more secure. The belly button function is partially disabled on trucks that have a platform. When the platform is down, the signal from the belly button is ignored by the truck. This is possible because the safety function is not longer needed when the platform is down: the driver is protected by the platform itself.

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5. Horn The horn is obligatory on all powered trucks and is used to make people aware of the approaching truck. It will keep sounding as long as the button is pushed. On most trucks a flashing beacon is available as an option.

6. Tiller arm lock bypass and creep speed button

This button has two functions: 1. It will reduce the trucks’ speed to 2,5 km/h 2. It will make it possible to drive the truck with the tiller arm in

the vertical position. Creep speed may be required when working in very confined spaces or crowded area’s to prevent accidents. Working with the tiller arm vertical is also important in confined areas. It makes the turning radius of the combination of truck and driver smaller. In order for the functions to work, the button has to be pushed continuously. As soon as it is released the truck will return to normal operation. The only exception is trucks with a Zapi combi AC controller where the button acts as an on/off switch.

7. Steering The tiller arm is also used to steer the truck. The force needed to steer the truck depends on the drive speed and the load. The length of the tiller arm also influences the force needed. On some models electrical power steering is available as an option. The steering angle is 95 degrees to each side. This makes it possible to reverse the truck slightly while manoeuvring. It makes working in tight spaces easier and prevents damage to the trucks and the load.

95 degrees steering angle

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Material

Shaft The shaft is made of aluminium. This makes the tiller arm light and durable. It also matches the styling of the latest generation of warehouse trucks. It is made in one piece and has reinforcement strips to increase the strength. The shaft can be cut to length easily. This is important because the length of the tiller arm is shorter for trucks with a platform.

Cut through section of the shaft

Tiller head The body of the tiller head is also made of cast aluminium. Its resistance to a dynamic force is three times as high as that of the previous tiller head. It can resist an impact force of 3 kN. (+/- 300 Kg) without bending or breaking.

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Hand grips The hand grips are aluminium, covered with rubber. This makes the grip more comfortable for the driver, and prevents his hands slipping off the tiller head. The handgrips are grooved to improve grip in wet circumstances.

Buttons and levers All other parts, such as buttons and switches are made of plastics, reinforced with glass fibre to improve strength.

Base block The base of the tiller arm is made of cast iron. In this part of the tiller arm the forces are biggest, so strength is very important here. The base of the tiller arm is equal to that of the previous series, making them interchangeable.

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Ergonomics

When designing the tiller arm, ergonomics were considered a very high priority. An extensive study was done by an ergonomics expert, resulting in various improvements to the design.

• The shape of the rubber handgrips is such that the pressure of the hand is distributed evenly. This means that the grip is comfortable and does not irritate.

• The shape of the handles forces the driver to position his hand correctly so the lifting and lowering buttons are also with easy reach.

• The handgrips are placed under an angle relative to the tiller arm. This reduces the strain in wrist, elbow and shoulder of the driver.

• The handgrips are covered in grooved rubber. This ensures a good grip, even in wet circumstances or when wearing gloves.

• The length of the tiller arm is such that short and tall drivers can find a comfortable driving position both walking and on the platform.

• The accelerator button turns very lightly. Because of this the physical force needed to drive the truck is very small. This is important because the driver has to push the button continuously to drive the truck and a continuous force is very tiring for the driver.

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• The angle to which the driver button has to be pushed before full acceleration is reached has been reduced to only 40 degrees (see α in drawing below). This also helps to make driving easier. Reversing is also limited to 40 degrees.

α

Neutral Full acceleration

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Tiller arm lock

When the tiller arm is released, it will return to the vertical position. When the vertical position is reached, the parking brake will be applied. This has two effects:

1. This mechanism acts as an emergency brake. When the driver looses grip or control over the truck and lets go of the tiller, the truck will automatically come to a full stop

2. It also acts as a fully automatic parking brake. When the truck is parked on a ramp it will not roll back, even though the motor is not running.

This function can be bypassed by pushing the Tiller arm lock bypass button. In that case the truck will drive with the tiller arm in the vertical position, making in possible to manoeuvre in very tight areas (for example inside a lorry). In this mode the truck’s speed is also reduced to 2, 5 km/h (creep speed). This makes working in confined spaces safer. The creep speed mode can also be used in other applications where lower speed is required, for example when the truck is operating in a crowded area (shops & stores). The truck will also brake when the tiller arm is the horizontal position. This is a safety mechanism to stop the truck when it moves too far away from the driver. For short people this can be a problem, because for them the angle under which the brake is activated is reached relatively fast.

Drive

Brake

Brake

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To prevent unintended activation of the brake an extra spring is fitted to the gas spring that balances the weight of the tiller arm. The brake is now only activated when the tiller arm is forced downwards.

Extra spring

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Service

The tiller head is modular, which means that it is basically equal for all trucks. Stackers have an extra module fitted for the lift and lowering lever. Wiring is also easy to replace. The harnesses are also modular. The tiller head is easy to disassemble. The head can be taken out of the shaft by removing the screw that connects the tiller head to the shaft. All microswitches (6 in total) can easily be reached and replaced if necessary. The belly button has two microswitches to increase safety. All microswitches are numbered corresponding with the wiring diagram. Wiring diagrams can be found at the remote service centre (www.catlifttruckportal.com)

The tiller arm is interchangeable with the previous tiller arm. The base mounting is equal. Old tiller arms can be replaced by new ones with a special kit. For cold store applications the tiller head should be heated to prevent condensation and freezing. This is included in the “cold store modification” option.

Heating element for cold store applications

Extra module for

stackers

Module for drive and

main lift

Connection to wiring

harness

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Improvements

• Stronger materials, resistance to impact tripled

• Tiller arm lock bypass a standard function

• Serviceability and service access improved

• Horizontal tiller arm lock improved by adding spring

• Ergonomics improved o Shape of the handles o Grip o Placement of lift lever on stackers o Angle and force needed for the accelerator reduced

• Attractive styling

• Double microswitch on belly button for improved reliability

• Shaped to prevent damage, obstacles are deflected

• Tools needed to remove buttons, not possible anymore to accidentally remove covers

• Gas spring mechanism improved to improve durability

• Proximityswitch instead of microswitch activates horizontal lock, improved reliability

• Modularity between stackers and powered pallet trucks

• Positioning of lifting and lowering buttons changed to a more intuitive position.