25b9 Hyundai

GROUP 3 ELECTRIC COMPONENTS
1. FUNCTIONS OF BATTERY FORKLIFT TRUCK AND ELECTRIC COMPONENTS

The major functions of forklift truck can be divided into DRIVING FUNCTION and LOADING and
UNLOADING FUNCTION.
All the components that work DRIVING and LOADING & UNLOADING functions are driven by AC
motors. And as the BATTERY works as power source of these motors, a charging device is needed.
To drive the fork lift truck, a DRIVING CONTROL SYSTEM and some electric components such as
direction change lever (forward/reverse section switch) and accelerator are required to select the
driving direction and to control the speed of driving motor.
The CONTROL SYSTEM includes some protective circuits that protect the equipment and
components from malfunctioning.
A MONITORING SYSTEM is installed in the monitor panel, which monitors the equipment and
working condition, and let the operator take proper action. For the monitoring system, there are many
sensors such as current sensors, potentiometer sensors, and temperature sensors. The HYUNDAI
Battery forklift trucks are equipped with the most advanced DRIVING CONTROL SYSTEM currently
available world-widely. The operator friendliness features enable him to set the truck conditions
properly according to each working circumstance easily on his seat, and the SELF-DIAGNOSTIC
function displays current status of truck in working.
7-3
2. BATTERY
1) STRUCTURE
4 4
1
2
8 12
8 12
10 6
11
22/25B-9 30/32/35B-9
22B9EL03
1 Cells 6 Cable connector

2 Steel box 8 Negative leading cable
3 Cell connector 10 Handle (red)
4 Row connector 11 Plug
5 Terminal connector 12 Positive leading cable
7-4
2) GENERAL
As in the battery forklift, the battery is an
energy source, the handling of the battery
is very important.
The life and performance of the battery
greatly depend on the ordinary handling
and maintenance. Therefore, be sure to
check and maintain the battery so that it
may be kept best. 35B7EL04
3) SPECIFICATION AND SERVICE DATA

Item Unit 22B-9 25B-9 30/32/35B-9
Type - Lead Acid

Rated voltage V 48
Capacity AH/hr 660 715 740
Electrolyte - WET
Dimension (W×D×H) mm 1030×796×537 1030×990×537
Connector - SB 350 or SR 350 (SBE 320 BLUE)
Weight kg 970/1300 970/1300 1090/1495
Fully charged specific gravity 1.280 (25°C)

End of discharge specific gravity 1.120 (25°C)
Discharge end voltage 48V
Electrolyte Refined dilute sulfuric
Replenishment fluid Refined (pure) water
Insulation resistance 1MΩ
7-5
4) SAFETY PRECAUTIONS
(1) When sulfuric acid contact with skin
For acid contact with skin, eye or clothing, flush with water immediately. If swallowed, drink a large
amount of water or milk. Seek medical attention immediately. When handling acid, always wear
eye goggles or a face shield and rubber gloves.
(2) Strict prohibition of fire and ventilation
Since batteries generate explosive hydrogen gas, no fire should be drawn near. Before the battery
charging, keep the battery cover open and check the ventilation status. Charging in an enclosed
space can cause an explosion.
(3) Never place metallic articles on the batteries
If done so, it may cause "short circuit" accidents (dangerous especially while charging)
(Especially dangerous while charging).
Sparks will be generated which is equally dangerous as open fires.
(4) Handling of charger
When connecting or disconnecting a battery from a charger or attempting maintenance, make
sure switches are all off. Ensure that the charger and the battery are matched. If a 300Ah battery
is used with a charger designed to charge a 500Ah battery, it will severely overcharge the battery.
5) OPERATION PRECAUTIONS
(1) Avoid over-discharge
If over-discharged, it will be difficult to restore the batteries to the original state by recharge. In
order to maintain the batteries in use for long period of time, it is recommended to use the
batteries with discharge amount not exceeding 80% of the rated capacity. Further care should be
taken for preventing the unit cell voltage from falling below 1.5V.
(2) Avoid over-charge
If overcharged, the rise in battery temperature will become excessive, resulting in deterioration of
plates and other parts and markedly shortening of battery life.
(3) Avoid excessive elevation of temperature
Be sure to open the cover of battery housing tray before charging. If there is a possibility of
temperature to exceed 55°C, discontinue the charge operation temporarily, or reduce the charge
current.
6) CHECKING
(1) Unpacking
Electric traction storage batteries (herein after refer to as "batteries") are delivered to customers in
dry-charged condition. At unpacking, check whether the batteries and accessories have been
damaged. If there are observed defects, you should notify the condition to our branch office or
agent. Never remove the sealing plug until the battery is put into service.
7-6
(2) Performance and maintenance of batteries
① Initial charge
Wet-charged battery gradually decreases its capacity during storage. In order to provide
sufficient discharge capacity in the first discharge, the good initial charge is required. The
conditions of initial charging are seen as below at room temperature.
a. By modified constant voltage charger
Connect the battery to the charger and turn on the equalizing charge "ON." The battery will be
fully charged and terminated automatically.
b. By constant voltage constant current charger (standard)
Connect the battery to the charger and turn on the equalizing charge "ON." The battery will be
fully charged and terminated automatically.
c. By constant current charger
Connect the charger to the battery and charge the battery by 0.1C×5 hour rate nominal
capacity current for 24 hours or more. The charge shall be terminated when one of the following
conditions is identified.
·When a constant value is indicated for more than 1 hour after the battery voltage has
reached the maximum value.
·When more than 1 hour of charge is continued after the electrolyte specific gravity has risen
fully and becomes constant.
② Discharge and capacity
The capacity of batteries is indicated at 5 hour rate capacity which means the battery can be
discharged for 5 hours with the discharge current calculated by dividing the capacity value by 5
until the unit cell mean voltage reaches down to 1.7V at the electrolyte temperature of 30°C.
That is, the capacity is indicated by AH (ampere hour) being calculated as the product of ampere
(A) and time (H). However, even if it is the same type of batteries, the capacity varies with the
discharge conditions (discharge current, battery temperature and specific gravity of electrolyte).
Even if the batteries discharged its full capacity, if immediately charged to full, there will be no
harmful effects remained. Ideal charging amount (AH) is 110-125% of the amount of previous
discharge.
③ Specific gravity of electrolyte
Specific gravity of electrolyte drops at discharge and rises at charge. When the batteries are fully
charged, it becomes almost constant and shows no further rise. The specific gravity value varies
with the change in temperature. Therefore specific gravity measurement should be made with
temperature of electrolyte at the same so the measured specific gravity value could be corrected
to that at the standard temperature of 25°C by the following formula.
S25 = St + 0.0007 (t-25)
Where, S25 : Specific gravity at 25°C
St : Actually measured specific gravity at t°C
t : Electrolyte temperature (°C)
The standard specific gravity for this type of battery is 1.280±0.01(25°C) at full charge condition.
If the electrolyte is decreased naturally while using, distilled water shall be replenished up to the
specified level. (Never refill sulfuric acid).
Only when large quantity of electrolyte is lost due to spillage, etc., dilute sulfuric acid specified in
gravity shall be added.
7-7
④ Normal charge
Charge the discharged batteries as quickly as possible. The temperature of electrolyte before
starting the charging operation shall preferably be below 45°C, and the temperature during the
charge should be maintained at no higher than 55°C. (Under any unavoidable situations, it
should never be above 55°C). Methods of charging vary in precise meaning with the types of
chargers used. A standard charging method is described hereunder. (If a special method is
mentioned to be adopted, follow that instruction).
a. Charging by modified constant voltage automatic charger
There is almost automatic charger today which completes the charging just only connecting the
plug between battery and charger without outer operating timer. But if your charger has it, after
setting the timer for 3-4 hours and turn on the charger and the charger is left as it is, then the
charge will be made automatically. In principle, regardless of the amount of previous discharge,
it is not required to alter the setting of timer time. The recommendable current value of this type
of charger is "5 hour rate current ×1.0~1.5" at the start of charging, and at the final stage it is "5
hour rate current ×0.15~0.25". Normally the charge is terminated within 8~12 hours
automatically.
b. Charging by constant current constant voltage automatic charger
After a lapse of specified charging time after the switch is turned on, the charge will be
completed by turning off the switch. The charging time can be calculated by the following
formula.
Amount of previous discharge(AH)
Charging time = + 2~3(H)
Capacity of charger(A)
When the amount of previous discharge is not known, use the 5 hour rate rated capacity of the
batteries. At immediately after charging, the charge current is allowed up to 3 times 5 hour rate
current. For charger provided with a timer, the charge will terminate automatically if the timer is
set at the specified time according to the operation manual.
c. Charging by constant current charger
Connect the charger to the battery and charge the battery by 0.1C×5 hour rate nominal
capacity current for 24 hours or more. The charge shall be terminated when one of the following
condition is identified.
⑤ Equalizing charge
When large number of cells are used in a set of battery, the voltage and specific gravity of
respective cells tend to become unequal, resulting in necessity of charging all the cells at an
appropriate time in order to equalize them. This is called equalizing charge. Normally the
equalizing charge should be carried out once every month. The methods are in normal type
charger, extend the charge for 5 more hours after full charge at the final stage current, and in
automatic charger which is in most cases provided with timer, extend the time setting for 3-6
more hours.
7-8
⑥ Replenishment of distilled water
Only the water content of electrolyte is decreased due to electrolysis of distilled water during
charge and natural evaporation. If a battery used with the electrolyte decreased excessively,
plates will deteriorate resulting in markedly shortening of battery life. Be sure to check the
electrolyte level once every week. If the electrolyte level is lowered, replenish distilled water up to
the specified level. In this case, never attempt to replenish sulfuric acid or tap water. Use only
distilled water for battery replenishment. If the amount of water required for weekly addition to a
unit cell for 100AH of battery capacity is in excess of 45 cc, it is assumed that the cell is receiving
overcharge. Accordingly, be sure to reduce slightly the daily charge amount. Under the normal
conditions, the addition of water per week is 45 cc or less. Incidentally, distilled water
replenishment should be made before charging to the content of minimum level. (For the
purpose of uniform stirring of electrolyte by charging).
If the electrolyte level is improper after completion of charging, you may topping up the
electrolyte level to the maximum level.
a. Determination of replenishment time and methods (cell with ONE TOUCH CAP)
Confirm the electrolyte level by looking at the float in the ONE TOUCH CAP. If too low as shown
in figure, replenish distilled water. Replenishment shall be performed after opening the cover of
the plug using syringe and jug. When refilling is completed, close each cover completely until
"click" sound is heard.
Minimum Level Maximum Level
Cell cover
Cell cover
Float Float
B153EL041 B153EL042
7-9
⑦ Cleaning
If electrolyte spills or the cells are polluted with dust or stains, it will cause generation of leak
current. Wipe off dust and stains with moist cloth and clean in such a manner that the cells are
kept in dry condition. In the case of plastic containers or covers, never use such organic solvents
as paint thinner and gasoline. If used, the plastic containers or covers may suffer cracking. If you
are forced to use them, be sure to use white kerosene.
⑧ Notice on charging
The charging area must be well ventilated to facilitate exhaust of gas generated from the battery
during charging. Charge the battery in an area free from iron working, welding, etc. Further the
battery generates hydrogen, oxygen, acid mist and on rare occasions, hydrogen sulfide during
charging depending on the case. Special care may be required in the case of equipment and
objects near the battery that may contaminated or damaged. Do not pull out the charging plug
during charging, as it will cause sparks. Since hydrogen gas generated during charging may
remain in the area surrounding the battery after charging, never bring fire or flame close to this
area. In case of counter-balance type vehicles, open the battery cover before charging.
⑨ Repair of failure cell
a. To remove a cell from the circuit or battery from steel tray, it is first necessary that the intercell
connector be removed.
b. Before performing any repairs, you must open one-touch caps for gas purging of all cells. After
you have finished that, must remove connector covers and on-touch caps from failure cell
including surrounding cells. All vent holes of cells removed of one-touch caps must cover by
four layers of water dampened cloth and then proceed with repairs. Using an acid syringe
withdraw sufficient electrolyte from failure cell to reduce the liquid levels until minimum level
indicating of one touch caps.
c. The safe and most efficient method of removing a connector from failure cell as well as all
surrounding cells is with hand or electric drill (25 mm).
You must make sure to clear of explosive hydrogen gas in the cells before repairs. Be
careful not to drill to far into the cell and damage the unit. During drilling operation make
sure lead curls produced do not contact opposite cell poles and cause a spark.
d. Upon completion of drilling the intercell connectors, can be lifted off.
e. Lifted off the failure cell from circuit after removing of intercell connector.
f. Installing new cell and connector.
g. With surfaces properly cleaned and neutralized, position the connectors.
h. Place damp rags around each lead head. Hold tip of the welder in center of post move welder
completely around top of post and out to the area where the post meets the connector. Move
welder back to center of post and add molten lead until area is filled to top of connector. Again,
move welder completely around area, with tip on molten lead. If you have jig for welding
connector, have easier and better welding work.
i. When replacing electrolyte in a repaired cell, use sulphuric acid of the same specific gravity that
is found in the balance of the battery.
j. Finally, rejoin connector covers and one-touch caps to the cells.
7-10
⑩ Summary of daily maintenance
a. Avoid overcharge. After discharge, charge the batteries immediately. The standard frequency of
equalizing charge is more than once every month.
b. Be sure to check the electrolyte level once every week. If found decreased, replenish distilled
water up to the specified level.
c. The top surface of battery cells should be kept clean and dry.
d. Be sure to keep open the cover of battery housing tray during charge.
e. Never draw near open fires such as lighted cigarettes or burning matches during charge.
(3) Others
① Storage of batteries
When batteries are stored, keep them away from room heaters or other heat generating sources.
Clean, cool and dry place where no direct sunlight is suited for battery storage. Before putting
into storage, it is important to charge the batteries and keep the electrolyte level at the specified
level.
When the temperature in storage location is higher than 20°C, check the specific gravity once a
month, and when lower than 0°C, check it once every two months. If the measurements show
values lower than 1.230 (20°C), it is required to charge the battery in accordance with the
method described in NORMAL CHARGE.
② Maintenance record
It is recommended to keep maintenance record in order to know the operational conditions of
batteries. Daily charge and discharge, equalizing charge requirements, and distilled water
replenishment requirements can be clarified at a glance. Measurements of specific gravity and
temperatures once every two to four months after equalizing charge and maintenance thereof
will serve for battery health diagnosis.
③ Electrolyte temperature
The operating temperature range of batteries is -10~45°C (temperature of electrolyte). If the
batteries are exposed to cold atmosphere in discharged condition, the electrolyte may freeze, and
in extreme cases, the capacity will be decreased, but, if not frozen, no adverse effects will be
exerted.
Contrarily if the temperature is high, especially if used at above 55°C, the battery life will be
considerably shortened. Care must be taken so that the temperature during charge will be
maintained at 55°C or lower. Even under unavoidable circumstances it should not exceed 55°C.
7-11
7) TROUBLESHOOTING
Nature of trouble Symptoms Causes Corrective Action
Deformation · Deformation of container. · Excessive temperature · Replace
Lid or one touch cap rising or external impact
Breakage · Electrolyte leakage acco- · External impact, improper · Replace or install a new
rding to breakage of cont- handling, excessive vibrat- one
ainer, lid or one touch cap ion
· Termination of connector · Excessive temperature · Replace
or pole post etc. rising or external impact
Sulfate · Specific gravity drops and · When left in state of disch- · Need equalizing charge
capacity is decreased. arge or left long without
equalizing charge.
· Charge voltage rises rapi- · Insufficient charge. · Need equalizing charge
dly with immature gassing · When electrolyte is so de- · Need equalizing charge
in earlier stage but specific creased that plate is de-
gravity does not rise and posed.
charge can't be carried · When concentration of · Adjust specific gravity
out. electrolyte rises.
· When impurities are mixed · Replace electrolyte
in electrolyte.
Decrease and · May be easily detected by · Rise of temperature due to · Replace
falling of specific measurement of the spec- such trouble.
gravity ific gravity. · When left long period with- · Refill water in regular per-
out refilling of water. iod
· Short circuit. · Replace
Rise of specific · May be easily detected by · Diluted sulfuric acid is · Adjust specific gravity after
gravity measurement of the spec- used in refilling. full charge.
ific gravity. · When the electrolyte level · Refill distilled water.
excessively drops.
Mixing of · Decrease of capacity. · Metals such as iron, copper · Under a fully discharged
impurities nickel and manganese. condition, pour out the
· Drop of charge and disch- · Impurities such as sea electrolyte. Then pour in
arge voltage. water, chloric acid, nitric an acid of the specific
acid etc. gravity higher by 0.03~0.05
· Odor of generated gas and · Filling of impure water. than that of the drained
coloring of the electrolyte. acid. Charge fully and
adjust the specific gravity to
the specified value.
7-12
3. DRIVE MOTOR
1) STRUCTURE
8 4
10
3
12
11
22B9EL07
1 Rotor 5 Block-Terminal A 9 Bearing

2 Stator 6 Speed sensor kit 10 Bearing
3 Endbell De 7 Stud bolt 11 Oil seal
4 Endbell 8 Protector-Terminal 12 O-ring
7-13
2) SPECIFICATION
Item Unit Specification
Type - AQDG4001
Rated voltage Vac 30
Rated output kW 7.0×2
Insulation - Class F
3) MAINTENANCE INSTRUCTION
※ Before starting the maintenance please disconnect the power supply.
(1) Ball bearing
Both ball bearing are maintenance free. Should it be necessary to remove the bearings in case of
repair, they should be replaced. In any case the sealing parts (shaft sealing ring etc.) have to be
replaced.
If a bearing which is to be replaced has only one sealing lip, this should be greased with quality
bearing grease.
After approximately 10,000 operating hours the bearings have to be replaced.
(2) Disassembly and assembly
The motor is assembled and disassembled according to the relevant sectional drawing and part
list. (See page 7-13)
7-14
4. PUMP MOTOR
1) STRUCTURE
2
6
7 9
4
1
3 9
10
22B9EL08
1 Rotor 5 Block-Terminal A 9 Bearing

2 Stator 6 Speed sensor kit 10 Oil seal
3 Endbell De 7 Stud bolt
4 Endbell 8 Protector-Terminal
7-15
2) SPECIFICATION
Type - AMDL4001
Rated voltage Vac 30
Rated output kW 17
Insulation - Class F
3) INTERNAL INVOLUTE SPLINE DATA
Flat root side fit - Class 7

No of teeth EA 11
Spline pitch mm 16/32
Pressure angle Degree 30
Major diameter mm 19.7104
Form diameter mm 19.1516
Minor diameter mm 16.0274
Pin diameter mm 2.7432
4) MAINTENANCE INSTRUCTION
※ Before starting the maintenance please disconnect the power supply.
(1) Ball bearing
Both ball bearing are maintenance free. Should it be necessary to remove the bearings in case of
repair, they should be replaced. In any case the sealing parts (shaft sealing ring etc.) have to be
replaced.
If a bearing which is to be replaced has only one sealing lip, this should be greased with quality
bearing grease.
After approximately 10,000 operating hours the bearings have to be replaced.
(2) Disassembly and assembly
The motor is assembled and disassembled according to the relevant sectional drawing and part
list. (See page 7-15)
7-16
5. CONTROLLER SYSTEM
1) STRUCTURE
Traction controller Pump controller

22B7EL10
(1) Specifications
Model Model Application Type Power Current limit
DUAL AC2 Power Traction MOSFET 36-48V, 450+450A 450A/3min

22/25/30/32/35B-9
AC3 Pump MOSFET 36-48V, 600A 600A/3min
7-17
2) OPERATIONAL FEATURES
(1) Features
① Speed control.
② Optimum behavior an a slope due to the speed feedback:
·The motors speed follows the accelerator, starting a regenerative braking if the speed
overtakes the speed set-point.
·The system can perform an electrical stop on a ramp (the machine is electrically hold on a
slope) for a programmable time.
③ Electronic differential feature with torque balance between external and internal wheel.
④ Regenerative release braking based upon deceleration ramps.
⑤ Regenerative braking when the accelerator pedal is partially released (deceleration).
⑥ Direction inversion with regenerative braking based upon deceleration ramp.
⑦ Regenerative braking and direction inversion without contactors: only the main contactor is
present.
⑧ Optimum sensitivity at low speeds.
⑨ Voltage boost at the start and with overload to obtain more torque (with current control).
⑩ Hydraulic steering function:
·The traction inverter sends a "hydraulic steering function" request to the pump inverter on the
can-bus line.
⑪ Backing forward and reverse options are available, with the tune and the speed of the function
programmable with Zapi console or buttons on a display.
⑫ High efficiency of motor and battery due to high frequency commutations.
⑬ Modification of parameters through the programming console or buttons on a display.
⑭ Internal hour-meter with values that can be displayed on the console.
⑮ Memory of the last five alarms with relative hour-meter and temperature displayed on the
console.
16 Diagnostic function with Zapi console for checking main parameters.
17 Built in BDI feature.
18 Flash memory, software downloadable via serial link and via CANBUS.
(2) Diagnosis
The microcontrollers continually monitor the inverter and carry out a diagnostic procedure on the
main functions. The diagnosis is made in 4 points.
① Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor charging,
phase's voltages, contactor drivers, can-bus interface, if the switch sequence for operation is
correct and if the output of accelerator unit is correct, correct synchronization of the two μCS,
integrity of safety related inputs hardware.
② Standby diagnosis in standby that checks: Watchdog circuit, phase's voltages, contactor driver,
current sensor, can-bus interface.
③ Diagnosis during operation that checks: Watchdog circuits, contactor driver, current sensors, can-
bus interface.
④ Continuous diagnosis that checks: Temperature of the inverter, motor temperature.
Diagnosis is provided in two ways. The digital console can be used, which gives a detailed
information about the failure; the failure code is also sent on the Can-Bus.
7-18
3) DESCRIPTION OF THE CONNECTORS
(1) Traction controller
1 12 1 3
13 23 4 5
24 35 8 1 6 8
CONN C CONN B CONN A
20B7EL13
7-19
No. of Pin Function Description
A1 CAN_H High level CANBUS.

A2 CANT_H -
A3 CAN_POS -
Low level CANBUS: to be used as repetition for CAN_L line or to
A4 CAN_L_OUT
be connected to CANT_H to insert termination resistance.
A5 CANT_L -
A6 CAN_L Low level CANBUS.
High level CANBUS: to be used as repetition for CAN_ H line or
A7 CAN_H_OUT
to be connected to CANT_L to insert termination resistance.
A8 CAN_NEG -
B1 PCLRXD Positive serial reception.
B2 NCLRXD Negative serial reception.
B3 PCLTXD Positive serial transmission.
B4 NCLTXD Negative serial transmission.
B5 GND Negative console power supply.
B6 +12 Positive console power supply.
B7 FLASH -
B8 FLASH -
C1 PENC_R Positive of right motor encoder power supply (+12 V).
C2 NENC_R Negative of right motor encoder power supply.
C3 KEY Connected to + batt trough a key switch and a 10 A fuse in series.
Common of FW / REV / HB / PB / SEAT / ENABLE / SR /
C4 CM
ACCEL.SW/microswitches.
C5 SEAT Seat presence signal; active high.
C6 FORWARD Forward direction request signal; active high.
C7 REVERSE Reverse direction request signal; active high.
C8 ENABLE Traction request signal; active high.
C9 PB Pedal brake request signal; active high.
C10 HB Hand brake
C11 PENC_L Positive of left motor encoder power supply (+12 V).
C12 NENC_L Negative of left motor encoder power supply.
C13 PHA_R Right motor encoder phase A.
C14 PHB_R Right motor encoder phase B.
C15 NPOTST Negative of steering potentiometer
C16 PPOTST Positive of steering potentiometer (+12 V).
C17 CPOTST Steering potentiometer wiper signal.
C18 CPOTB Load sensor potentiometer wiper signal.
7-20
C19 NPOTB -BATT.

C20 NPOT Negative of accel pedal potentiometer.
C21 CPOT Accel pedal potentiometer wiper signal.
C22 PHA_L Left motor encoder phase A.
C23 PHB_L Left motor encoder phase B.
C24 NTHERM_R Negative of right traction motor temperature sensor.
C25 PTHERM_R Right traction motor temperature signal.
C26 NLC Output of main contactor coil driver (drives to -BATT).
C27 PLC Positive of main contactor coil.
C28 NBRAKE (MCV SOL) Output of solenoid coil.
C29 PBRAKE (MCV SOL) Positive of solenoid coil.
C30 PAUX (FAN RELAY) Positive of fan relay.
C31 NAUX (FAN RELAY) Output of fan relay driver
C32 -BATT
Accel/load sensor potentiometer positive, 5/10 V output;
C33 PPOT
use load > 1 kohm.
C34 NTHERM_L Negative of left traction motor temperature sensor.
C35 PTHERM_L Left traction motor temperature signal.
7-21
(1) Encoder installation
① Traction controller card is fit for different types of encoder. To control AC motor with Zapi inverter,
it is necessary to install an incremental encoder with 2 phases shifted of 90˚. The encoder power
supply can be +12V. It can have different electronic output.
C11/C1 : +12V : Positive of encoder power supply.
C12/C2 : GND : Negative of encoder power supply.
C22/C13 : A : Phase A of encoder.
C23/C14 : B : Phase B of encoder.
② Connection of encoder with open collector output; +12V power supply.
20B7EL26
③ The encoder power supply voltage and output electronic has to be communicated to ZAPI in
order to correctly set the selection jumpers in the logic card.
7-22
(2) Pump controller
22B7EL14
No. of pin Function Description

A1 +12V (+5V) Positive of encoder power supply.
A2 ENC GND Negative of encoder power supply.
A3 PPOT Lift potentiometer positive: 12V output; keep load > 1kΩ.
A4 BRAKE OIL Brake oil.
A5 LIFT ENABLE Input for potentiometer lifting enable input; it is active HIGH.
A6 TILT UP/DOWN Input for tilt up and tilt down digital input; it is active HIGH.
A7 TILT LEVELLING Tilt levelling input; it is active HIGH.
A8 AUX IN/OUT Input for aux in and aux out digital input; it is active HIGH.
A9 SHIFT RGT/LFT Input for shift right and shift left digital input; it is active HIGH.
A10 SBR Input for side battery removal digital input; Active low.
A11 LIFT LIMIT SW Speed reduction input. Active low.
A12 SAFETY If not connected to -batt the MC coil power output will be disabled. It can
also be used as a general purpose input.
A13 ENC A Phase A of encoder.
A14 ENC B Phase B of encoder.
A15 NPOT Negative of lift potentiometer.
A16 CPOT Lift potentiometer wiper.
A17 CAN T CAN termination; connect to CAN H (A18) to insert can termination
resistance.
7-23
A18 CAN H High level CAN-BUS voltage I/O.

A19 CAN L Low level CAN-BUS voltage I/O.
A20 NPOT-AUX (TILT ANGLE) Tilt angle potentiometer negative.
A21 CPOT-AUX (TILT ANGLE) Tilt angle potentiometer wiper.
A22 ENC A* Phase A inverted of encoder (encoder with differential output).
A23 ENC B* Phase B inverted of encoder (encoder with differential output).
A24 -BATT -Batt.
A25 MOT TH Input for motor temperature sensor.
A26 NLC Negative of the pump line contactor.
A27 PLC Positive of the pump line contactor.
A28 NAUX Spare output.
A29 PAUX Positive for output A28. Spare.
A30 CM Common of digital microswitches.
This input allows the customer to select the software for traction
A31 MODE
or lifting application. To be connected with A35.
A32 PPOT-AUX Tilt angle positive: 10V output; keep load> 1kΩ.
Connected to the power supply through a key switch (CH) with a
A33 KEY
10A fuse in series.
A34 -BATT -Batt.
A35 -BATT -Batt.
B1 PCLRXD Positive serial reception.
B2 NCLRXD Negative serial reception.
B3 PCLTXD Positive serial transmission.
B4 NCLTXD Negative serial transmission.
B5 GND Negative console supply.
B6 +12V Positive console supply.
B7 FLASH -
B8 FLASH -
7-24
4) FUNCTION CONFIGURATION
■ TRACTION CONTROLLER-MASTER
Using the CONFIG MENU of the programming console, or using a display, the user can configure
the following functions.
(1) Submenu "SET OPTIONS"
① Hour counter
- RUNNING : The counter registers travel time only.
- KEY ON : The counter registers when the "key" switch is closed.
② Battery check
- ON : The battery discharge level check is carried out; when the battery level reaches 10%, an
alarm is signalled and the maximum current is reduced to the half of the programmed
value.
- OFF : The battery discharge level check is carried out but no alarm is signalled.
③ Traction cutout
When the alarm "BATTERY LOW" appears, if this option is programmed to ON the traction
maximum speed is reduced to 60Hz.
④ Lift cutout
When the alarm "BATTERY LOW" appears, if this option is programmed to ON the lift function is
disabled.
⑤ S.R.O.
If this option is set to on the static return to off is requested for starting the truck. The required
sequence is :
·Seat-direction lever-accelerator pedal or :
·Seat-accelerator pedal-direction lever within the seq. delay time
If this option is set to off the required sequence to start the truck is :
·Direction lever-accelerator pedal or :
·Accelerator pedal-direction lever within the seq. delay time
⑥ Hydro key on
- ON / OFF : If this option is programmed ON the traction inverter manages an hydraulic steering
function when the "key" is switched ON.
⑦ Stop on ramp
- ON : The stop on ramp feature (truck electrically hold on a ramp) is managed for a fixed time (6
sec.).
- OFF: The stop on ramp feature is not performed.
⑧ Aux input #1
- EXCLUSIVE HYDRO : Input C10 activates hydraulic steering function, output A31 is activated.
- OPTION #1 : Input C10 is the input for an handbrake device, active low (open switch).
- OPTION #2 : Input C10 is the input for a speed reduction device, active low (open switch).
⑨ Set temperature
- DIGITAL : A digital (ON/OFF) motor thermal sensor is connected to C25 (C35) input.
- ANALOG : An analog motor thermal sensor is connected to C25 (C35) (the curve can be
customized on a customer request).
- NONE : No motor thermal sensor switch is connected.
7-25
⑩ Steer table
This parameter is used to set the correct steering table.
- OPTION #4 : The steering table is the one for 4 wheels truck.
⑪ Display
If this option is set to on the communication with the Zapi graphic display is enabled.
⑫ Pedal brake stop
This parameter defines how truck drive if accel pedal & brake pedal is pressed simultaneously.
If set to on, truck is stopped when pedal brake is pressed.
If set to off, the traction current is reduced to half of the maximum current.
(2) Submenu "ADJUSTMENTS"

① Set battery type
It selects the nominal battery voltage.
② Adjust battery
Fine adjustment of the battery voltage measured by the controller. Please increase or decrease
the value 1 by 1 and check the voltage.
③ Max steer right (only available on console)
This is the function to record in the controller EEPROM the steering poti output voltage when the
wheels are fully turned right (maximum of the steering poti range).
④ Max steer left (only available on console)
wheels are fully turned left (minimum of the steering poti range).
⑤ Set steer 0-pos. (only available on console)
wheels are straight.
⑥ Set steer right
This parameter sets the max steering angle in right direction.
⑦ Set steer left
This parameter sets the max steering angle in left direction.
7-26
⑧ Throttle 0 zone
It establishes a deadband in the accelerator input curve (see also curve below).
⑨ Throttle X point
This parameter changes the characteristic of the accelerator input curve.
⑩ Throttle Y point
This parameter changes the characteristic of the accelerator input curve.
SPEED f(Hz)
MAX SPEED
TROTTLE Y
POINT
FREQ. CREEP
V
VACC THROTTLE 0 THROTTLE X VACC

MIN ZONE POINT MAX
20B7EL17
VACC MIN and VACC MAX are values programmable by the "Program Vacc" function.
⑪ Cooling fan work
Cooling fans installed on nearby motors and controllers will work as follows;
Option #1 : fans work always
Option #2 : fans work in case a temperature of controller or motor exceeds a temperature set in
START TEMP. FAN menu
Options #2 : fans work when motors work.
⑫ Start TEMP. FAN
if COOLING FAN WORK menu is set as option #2, This menu is used to set a temperature
limitation which allows fans to work when a temperature of controller or motor exceeds the
limitation.
⑬ Adjustment #2 bdi
It adjusts the lower level of the battery discharge table. Higher level means higher voltage.
⑭ Adjustment #1 bdi
It adjusts the upper level of the battery discharge table. Higher level means higher voltage.
⑮ Adjustment #03 :
Set an increment of battery charge above actual value. If battery voltage exceed this total value
the software recognize charging, and battery charge percentage increase to correct value also if
battery isn't fully charged.
16 Main cont. voltage
This parameters adjusts the line contactor coil voltage (PWM output C26).
17 Aux output voltage
This parameters adjusts the solenoid coil voltage (PWM output C28).
18 Adjustment #04 :
This parameter determines the motor temperature level at which the "Motor temperature" alarm
is signalled. This parameter must be adjusted only if the "Set temperature" (menu "Set option")
parameter is programmed "Analog".
7-27
19 Speed factor
It adjusts the speed coefficient to have the correct speed indication on the display. This coefficient
has to be regulated depending on truck mechanic characteristics. It results from the following
formula :
Speed factor = 88 * rr * p /Ø
where :
rr = total gearbox ratio
Ø= traction wheel diameter (cm)
P = number of pair poles of the motor
20 Load sensor (option)
ON : Load Sensing Function is activated
OFF : Load Sensing Function is disactivated
21 REF. load weight (option)
This parameter is used to show and configurate the reference load weight.
22 Overload weight (option)
This parameter is used to show and configurate the trigger condition for OVER LOAD alarm.
If the loaded weight exceeds the weight indicated in this paramter, OVER LOAD alarm and
function limitation will occur accroding to OVERLOAD TYPE paramter.
23 Overload type (option)
This option specifies how overload alarm works in overloaded situation.
NONE : There would'n be any kind of alarms or limitations.
If re-configuration of V.A.S.S LOAD is required, please set this parameter as NONE, then
proceed re-configuration.
Option #1 : If the weight of load filed on forks exceeds the overload weight set in overload
parameter, OVER LOAD alarm will be displayed and followed by traction & pump limitation
except lift down & steering function.
Option #2 : If the weight of load filed on forks exceeds the overload weight set in overload
parameter, OVER LOAD alarm will be displayed.
24 Load speed UPD (option)
For accuracy, Load Sensor only works when the traction motor speed is lower than as set in this
parameter.
7-28
(3) Parameter change
① Acceler. delay
It determines the acceleration ramp.
Less value means better acceleration performance.
② Release
elease braking
It controls the deceleration ramp when the travel request is released.
Less value means better braking performance.
③ Invers. braking
It controls the deceleration ramp when the direction switch is inverted during travel.
④ Pedal braking
It determines the deceleration ramp when the travel request is released and the brake pedal
switch is closed.
⑤ Speed limit brk.
Deceleration ramp when the pedal position is changed but not completely released.
⑥ Brake cutback
It determines the deceleration ramp when the speed reduction input becomes active and the
motor slow down.
⑦ Max speed forw
It determines the maximum speed in forward direction.
⑧ Max speed back
It determines the maximum speed in backward direction.
⑨ Cutback speed 1
Speed reduction when the cutback switch is active.
⑩ Turtle speed
Hz. It determines the truck maximum speed when the turtle mode is activated.
⑪ Curve cutback
Speed reduction when the truck is doing a curve. The parameter sets the speed setpoint when
the maximum steering angle is reached (4 wheels truck, the internal wheel is stopped). In
intermediate steering angles, the speed setpoint will be within a range between the straight wheel
speed and the CURVE CUTBACK SPEED.
7-29
⑫ Frequency creep
Minimum speed when the forward or reverse switch is closed, but the accelerator is on a
minimum position.
⑬ Maximum current
This changes the maximum current of the inverter.
⑭ Acc. smooth
It gives a parabolic shape to the acceleration ramp.
⑮ Inv. smooth
It gives a parabolic shape to the acceleration ramp after a direction inversion.
16 Stop smooth
Hz. It sets the frequency where the smooth effect of the parabolic acceleration ends.
17 Seat delay time
It determines the delay time between the opening of the seat switch on CNC#5 digital input and
the start of the truck electrical braking.
18 Sequence de. time
It sets the maximum delay time between the accelerator is pressed and the direction lever is
moved out of the neutral position.
If this time is expired the truck stops with warning : “SEQUENCE FAULT”.
19 CHAT TIME
After no travel or pump request is active for the chat time the line contactor is automatically
opened. To restart, the the operator needs to press the accelerator pedal or activate the hydraulic
levers.
7-30
■ TRACTION CONTROLLER-SLAVE
Using the config menu of the programming console, or using a display, the user can configure the
following functions.
Not available.
① Set battery type
It selects the nominal battery voltage.
② Adjust battery
Fine adjustment of the battery voltage measured by the controller. Please increase or decrease
the value 1 by 1 and check the voltage.
③ Aux output voltage
This parameter adjusts the voltage of the auxiliary output coil, PWM output A31.
① Release braking
It controls the deceleration ramp when the travel request is released.
② Seat delay time
It determines the delay time between the opening of the seat switch on CNC#5 digital input and
the start of the truck electrical braking.
■ PUMP CONTROLLER
Using the config menu of the programming console, the user can configure the following functions.
① Hour counter
- RUNNING : The counter registers travel time only.
- KEY ON : The counter registers when the "key" switch is closed.
② Set temperature
- DIGITAL : A digital (ON/OFF) motor thermal sensor is connected to A25 input.
- ANALOG : An analog motor thermal sensor is connected A25 (the curve can be customized on
a customer request).
- NONE : No motor thermal sensor switch is connected.
③ Joystick (Option)
- OFF : The truck model includes mechanical lever distributor (default)
- ON : The truck model includes electro-hydraulic distributor and finger tips. Can communication
with Can tiller and Hydro CB zapi modules is enabled.
④ Shift function
- ON : Fingertip Side Shift function is activated.
- OFF : Fingertip Side Shift function is disactivated.
⑤ Aux function
- ON : Fingertip Aux function is activated.
- OFF : Fingertip Aux function is disactivated.
⑥ Digital lift
- OFF : The lift sensor includes a lift switch and an analogue lift sensor. Lift speed can be
controlled proportionally with lever position.
- ON : The lift sensor includes a lift switch only. Lift speed cannot be controlled proportionally.
7-31
① Set battery type : Selects the nominal battery voltage.
② Adjust battery : Fine adjustment of the battery voltage measured by the controller. Please
increase or decrease the value 1 by 1 and check the voltage.
③ Throttle 0 zone : Establishes a deadband in the accelerator input curve (see also curve below).
④ Throttle X zone : This parameter changes the characteristic of the accelerator input curve.
⑤ Throttle Y zone : This parameter changes the characteristic of the accelerator input curve.
SPEED f(Hz)
MAX SPEED
TROTTLE Y
POINT
FREQ. CREEP
V
VACC THROTTLE 0 THROTTLE X VACC

MIN ZONE POINT MAX
20B7EL17
VACC MIN and VACC MAX are values programmable by the "PROGRAM VACC" function.
⑥ Adjustment #04 : This parameter determines the motor temperature level at which the "MOTOR
TEMPERATURE" alarm is signalled. This parameter must be adjusted only if the "SET
TEMPERATURE" (menu "SET OPTION") parameter is programmed "ANALOG"
⑦ PWM on main contactor
- OFF: The inverter applies the battery voltage to the coil on A27 output.
- ON: The PWM reduces the voltage to the set value.
⑧ PWM on aux output
- OFF: The inverter applies the battery voltage to the coil on A29 output.
- ON: The PWM reduces the voltage to the set value.
⑨ MC/AUX PWM:
PWM It sets the PWM level in % on the outputs A27 and A29. Here is used to drive a
main contact for pump.
⑩ Fork leveling
- ON : AUTO TILT LEVELING function is activated.
- OFF : AUTO TILT LEVELING function is disactivated.
7-32
① Acceler delay
More value means better deceleration performance.
② Deceler delay
More value means better deceleration performance.
③ Max speed up
Determines the maximum lifting speed with a potentiometer control.
④ Min speed up
Determines the minimum lifting speed with a potentiometer control when the lifting enable switch
is closed.
⑤ Cutback speed
Determines the lift speed reduction in percentage when the speed reduction switch is activated.
⑥ Tilt speed
Tilt speed, fine regulation.
⑦ Shift speed
Shift speed, fine regulation.
⑧ Aux speed
Auxiliary function speed, fine regulation.
⑨ Hyd speed fine
Hydro speed, fine regulation.
⑩ Maximum
aximum current
The maximum current of the inverter.
⑪ Idle
dle time
Time delay when an hydraulic steering function request is switched off.
■ DISPLAY
Operators can have below functions through display.
(1) Password
If determines to set the function of user password when key on.
- OFF : No use
- ON : Activate the user password (Default password is "00000" and it can be re-set at user-menu)
(2) Maintenance
If determines to set the function of maintenance alarm when if come to service interval.
- OFF : No use
- ON : Activate the maintenance alarm function.
(3) Hour counter
It indicates the machine operating hours.
- Key ON : Key on time
- Pump : Pump motor operating time.
- Traction : Traction motor operating time.
7-33
5) PROGRAMMING & ADJUSTMENTS
There are two ways to adjust parameter via a console or buttons on a display.
※ Adjustments via buttons on a display, please refer to the display section. (page 7-47)
ADJUSTMENTS VIA CONSOLE (Option)
Adjustment of parameters and changes to the inverter's configuration are made using the digital
console. The console is connected to the "B" connector of the inverter.
(1) Descriptions of console
Inverter B
connector
Console connector
Display
Buttons
20B7EL15
※ Please connect and disconnect it from the inverter after a key switch off.
7-34
(2) Description of standard console menu
① Traction controller-Master
wlkhsGiyhrlGz{vw vuVvmm
Y[VZ]V[_V^YV_WV`]
svhkGwv{ }
22B9EL18
7-35
② Traction controller-Slave
22B9EL19
7-36
③ Pump controller
jvuulj{G{vG\
zopm{Gm|uj{pvu
h|Gm|uj{pvu
tv{vyG{wl z{hukhykGw|twVvw{pvuJX
Y[VZ]V[_V^YV_WV`]
tjVh|Vw~t
22B9EL20
7-37
(3) Description of the console SAVE function
The SAVE function allows the operator to transmit the parameter values and configuration data of
the chopper into the console memory. It is possible to load 64 different programmers.
The information saved in the console memory can then be reloaded into another chopper using
the RESTORE function.
The data that is available via the SAVE function is as follows:
- All parameter values (Parameter change).
- Options (Set. options).
Flow chart showing how to use the SAVE function of the digital console.
① Opening Zapi display.

DUALAC2 POWER ZAPI V0.0
48V 450A 00000
② Press ENTER to go into the general menu.
③ The display will show:
④ Press ROLL UP or ROLL DOWN button until

SAVE PARAM. appear on the display.
⑤ The display shows:
⑥ Press ENTER to go into the SAVE function.
⑦ If this facility has been used before the type of

chopper data stored appears on the top main
with a 2 digit reference.
⑧ Keep pressing either ROLL UP or ROLL DOWN
keys until the second Main indicates a FREE
storage facility.
⑨ Press ENTER to commence SAVE routine.
⑩ You can see the items that are being stored

whilst the SAVE routine is happening.
⑪ When finished, the console shows :
⑫ Press OUT to return to the opening Zapi display.
22B7EL21
7-38
(4) Description of the console RESTORE function
The RESTORE PARAM function allows transfer of the console's stored data into the memory of
the chopper. This is achieved in a fast and easy way using the method previously used with the
SAVE PARAM. function.
The data that is available via the RESTORE PARAM. function is as follows :
- All Parameter Values (Parameter change).
- Options (Set options)
When the RESTORE operation is made, all data in the chopper memory will be written over
and replace with data being restored.
Flow chart showing how to use the RESTORE function of the digital console.
① Opening Zapi display. DUALAC2 POWER ZAPI V0.0

48V 450A 00000

SAVE PARAM. appear on the display.
⑥ Press ENTER to go into the RESTORE PARAM

function.
⑦ The display shows the type of model stored,
with a code number.
⑧ Keep pressing either ROLL UP or ROLL DOWN
keys until the desired model appears on the
display.
⑨ Press ENTER to commence restore operation.
⑩ The display asks "ARE YOU SURE?".
⑪ You can see the items that are being stored in

the chopper memory whilst the RESTORE
routine is happening
⑫ When finished, the console shows :
⑬ Press OUT to return to the opening Zapi display.
22B7EL22
7-39
(5) Description of alarms menu
The microprocessor in the controller records the last five alarms that have occurred. Items
remembered relative to each alarm are: the code of the alarm, the number of times the particular
Alarm occurred, the hour meter count, and the inverter temperature.
This function permits a deeper diagnosis of problems as the recent history can now be accessed.
Flow chart showing how to use the ALARMS function via the digital console.
① Opening Zapi display. DUALAC2 POWER ZAPI V0.0

48V 450A 00000

PARAMETER CHANGE. appear on the display.
⑥ Press ENTER to go into the ALARMS function.
⑦ The display will show the most recent alarm.
⑧ Each press of the ROLL UP button brings up

following alarms. Pressing ROLL DOWN returns
to the most recent.
⑨ If an alarm has not occurred, the display will
show: ALARM NULL.
⑩ When you have finished looking at the alarms,

press OUT to exit the ALARMS menu.
⑪ The display will ask "CLEAR LOGBOOK?".
⑫ Press ENTER for yes, or OUT for NO.
⑬ Press OUT to return to the opening Zapi display.
22B7EL23
7-40
(6) Description of console program vacc function
This function looks for and remembers the minimum and maximum potentiometer wiper voltage
over the full mechanical range of the pedal. It enables compensation for non symmetry of the
mechanical system between directions.
The operation is performed by operating the pedal after entering the PROGRAM VACC function.
Flow chart showing how to use the PROGRAM VACC function of the digital console:
DUALAC2 POWER ZAPI V0.0

① Opening Zapi display. 48V 450A 00000

PROGRAM VACC. appear on the display.
⑥ Press ENTER to go into the PROGRAM VACC

routine.
⑦ The display will show the minimum and
maximum values of potentiometer wiper output.
Both directions can be shown.
⑧ Press ENTER to clear these values.
Display will show 0.0.
⑨ Select forward direction, close any interlock
switches that may be in the system.
⑩ Slowly depress the accelerator pedal (or tiller
butterfly) to its maximum value. The new
minimum and maximum voltages will be
displayed on the console plus an arrow
indicating the direction.
⑪ Select the reverse direction and repeat Item10.
⑫ When finished, press OUT.
⑬ The display will ask : "ARE YOU SURE?".
⑭ Press ENTER for yes, or OUT for NO.
⑮ When finished, the console shows:
16 Press OUT again to return to the opening Zapi

22B7EL24
menu.
7-41
(7) DESCRIPTION OF CONSOLE USING
① Access to SET MODEL menu.
The only parameter present in SET MODEL function is CONNECTED TO.
By setting this parameter, operator can connect ZAPI console to every ZAPI product connected
to CAN-BUS line. This functionality allows completely control of every ZAPI product without
changing the position of the console connector.
a. Opening Zapi menu.

DA2H 2B9
b. Press ROLL UP & SET UP buttons to enter

CONFIG MENU.
c. The display will show: SET MODEL. If another
menu is displayed, press ROLL UP or ROLL
DOWN until SET MODEL appears.
d. Press ENTER to go into the SET MODEL.
e. The display will shows the first option, only

CONNECTED TO option is present in this menu.
f. Press SET UP or SET DOWN buttons in order

to select the desired value for selected option.
g. New desired value appears.
h. Press OUT to exit the menu.
i. The display will ask "ARE YOU SURE?"
j. Press ENTER for YES, or OUT if you do not

accept the changes.
k. SET MODEL menu appears.
l. Press OUT again. Console now disconnects

and reconnects.
m. Display now shows the opening Zapi Menu of

the ZAPI product corresponding to option
selected at point g.
20B7EL28
7-42
② Flow chart showing how to make changes to option menu :
a. Opening Zapi menu. DA2H 2B9
b. Press ROLL UP & SET UP Buttons to enter

CONFIG MENU.
c. The display will show: SET MODEL.
d. Press ROLL UP or ROLL DOWN until SET

OPTIONS appears.
e. SET OPTIONS menu appears.
f. Press ENTER to go into the SET OPTIONS

menu.
g. The display will show the first option.
h. Press ROLL UP or ROLL DOWN buttons until

desired option appears.
i. Desired option appears.
j. Press SET UP or SET DOWN buttons in order

to modify the value for selected option.
k. New value for selected option appears.
l. Press OUT to exit the menu.
m. Confirmation request appears.
n. Press ENTER to accept the changes, or press

OUT if you do not accept the changes.
o. SET OPTIONS menu appears.
p. Press OUT again. Display now shows the

opening Zapi menu.
20B7EL29
7-43
③ Flow chart showing how to use the tester function of the digital console:
DA2H 2B9
a. Opening Zapi menu.
b. Press ENTER to go into the MAIN MENU.
c. The display will show: PARAMETER CHANGE.
d. Press ROLL UP or ROLL DOWN until TESTER

menu appears on the display.
e. The display will show: TESTER.
f. Press ENTER to go into the TESTER function.
g. The first variable to be tested is shown on the

display.
h. Press either ROLL UP or ROLL DOWN buttons.
i. Next variable for measurement appears.
j. When you have finished press OUT.
k. The Display will show: TESTER.
l. Press OUT again and return to opening Zapi

menu.
20B7EL30
Remember it is not possible to make any changes using TESTER.

All you can do is measure as if you were using a pre-connected multimeter.
7-44
6) MORNITORING MENU
In Console, This menu appears as “TESTER” MENU
(1) Traction controller-Master
① Motor voltage
This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full
voltage (which depends of the battery voltage).
② Frequency
This is the frequency of the voltage and current supplied to the motor.
③ Encoder
This is the speed of the motor, expressed in the same unit of the frequency; this information
comes from the speed sensor.
④ Slip value
This is the difference of speed between the rotating field and the shaft of the motor, expressed in
the same unit of the frequency.
⑤ Current rms
Root Mean Square value of the motor current.
⑥ Temperature
The temperature measured on the aluminum heat sink holding the MOSFET devices.
⑦ Temperature #1
This is the temperature of the right motor; if the option is programmed "None" (see page 7-26) it
shows 0°.
⑧ Temperature #2
This is the temperature of the left motor; if the option is programmed "None" (see page 7-26) it
shows 0°.
⑨ Accelerator
The voltage of the accelerator potentiometer's wiper (CPOT).
⑩ Steer angle
This is the indication of the angular position of the steered wheel.
⑪ Internal wheel cutback
This is the indication of the speed reduction applied to the internal wheel; in other words, it shows
the ratio of the two speeds.
⑫ Forward switch
The level of the forward direction digital input FW.
- ON / +VB = Input active, switch closed.
- OFF / GND = Input non active, switch open.
⑬ Backward switch
The level of the reverse direction digital input BW.
⑭ Enable switch
The level of the enable digital input:
7-45
⑮ Seat switch
The level of the seat microswitch digital input.
16 Cutback switch
The level of the speed reduction microswitch.
- ON / GND = Input active, switch opened.
- OFF / +VB = Input non active, switch closed.
17 Brake switch
The level of the pedal brake microswitch.
18 Exclusive hydro
Status of the exclusive hydro switch.
19 Brake pedal pot.
Voltage of the brake potentiometer's wiper (CPOTB). The parameter is active only if the PEDAL
BRAKING parameter is set ANALOG.
20 Hand brake
The level of the handbrake microswitch.
- ON / GND = Input active, switch opened.
- OFF / +VB = Input non active, switch closed.
21 Voltage booster
This is the booster of the voltage supplied to the motor in load condition; it is expressed in a
percentage of the full voltage.
22 Battery voltage
Level of battery voltage measured at the input of the key switch.
23 Battery charge
The percentage Charge level of the battery.
24 Load pot
Voltage value of load sensor.
(2) Traction controller-Slave

① Motor voltage
② Frequency
③ Encoder
④ Slip value
⑤ Current rms
Root mean square value of the motor current.
7-46
⑥ Temperature
The temperature measured on the aluminum heat sink holding the MOSFETdevices.
⑦ Voltage booster
⑧ Battery voltage
Level of battery voltage measured at the input of the key switch.
⑨ Seat switch
The level of the seat microswitch digital input.
- OFF / GND = Input non active, switch opened.
⑩ Forward switch
The level of the forward direction digital input FW.
⑪ Backward switch
The level of the reverse direction digital input BW.
7-47
(3) Pump controller
① Motor voltage
② Frequency
③ Encoder
④ Slip value
⑤ Current rms
Root Mean Square value of the motor current.
⑥ Temperature
The temperature measured on the aluminum heat sink holding the MOSFET devices.
⑦ Motor temperature
This is the temperature of the motor; if the option is programmed "None" it shows 0。.(refer to
7-31 page)
⑧ Lifting switch:
Status of the lifting switch.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch.
⑨ Security switch:
Status of the SBR switch.
⑩ Hydro speed req.:
Status of the hydro speed request of the pump.
⑪ Lift/lower req.:
Level of the lift and lower analogue signal.
⑫ Tilt request:
Voltage of the tilt analogue signal.
⑬ Shift request:
Voltage of the shift analogue signal.
⑭ Aux request:
Voltage of the auxiliary analogue signal.
⑮ Cutback switch:
Status of the speed reduction switch.
- ON / GND = Active entry of open switch.
- OFF / +VB = Non active entry of closed switch.
7-48
16 Voltage booster:
17 Battery voltage:
Level of battery voltage measured at the input to the key switch.
7-49
7) GENERAL SUGGESTION FOR SAFETY
For a proper installation take care of the following recommendations:
After operation, even with the key switch open, the internal capacitors may remain charged for
some time. For safe operation, we recommend that the battery is disconnected, and a short circuit
is made between battery positive and battery negative power terminals of the inverter using a
resister between 10 ohm and 100 ohm.
During battery charge, disconnect the controller from the battery.
Do not connect the controller to a battery with a nominal voltage different than the value indicated
on the controller label. A higher battery voltage may cause power section failure. A lower voltage
may prevent the logic operating.
Before doing any operation, ensure that the battery is disconnected and when all the installation is
completed start the machine with the drive wheels raised from the floor to ensure that any
installation error do not compromise safety.
Take care all the inductive devices in the truck (horn, solenoid valves, coils, contactors) have a
proper transient suppression device.
※ The method of discharging internal capacitor

Bofore checking controllers, motors, cables and etc., discharge the internal capacitor in controllers
by following below steps ;
① Disconnect the battery cable.
② Emergency contactor on and key on.
③ Wait untill all warning lamps (red LED) on display become off.
④ Discharging process is finished.
7-50
6. INSTRUMENT PANEL : DISPLAY
1) STRUCTURE
The DISPLAY has 6 red LEDs indicating the status information of the lift truck to the driver.
Spare #1 Spare #2
Oil level Park brake

Wrench Seat belt
Thermometer Seat
22BH9OM65
7-51
2) WARNING LAMP
(1) Brake oil level warning lamp
Blinks when the brake oil level in the reservoir is below the lower
limit.
22BH9EFD01
(2) Wrench warning lamp

This LED lights when an electric device (controller, motor, cable,
etc.) is in alarm condition.
22BH9EFD02
(3) Thermometer warning lamp

This LED lights when the controller or motor temperature is high.
22BH9EFD03
(4) Seat warning lamp

This LED lights when the operator is not on the seat.
22BH9EFD04
(5) Seat belt warning lamp

(1) This LED blinks in following 2 cases.
① When operator starts the truck, LED blinks for 5 seconds,
which means initial diagnosis is on going, and buttons on
display will work properely just after the diagnosis is
completed.
22BH9EFD05 ② LED blinks when the seat belt is not correctly fastened.
(6) Handbrake warning lamp
(1) This LED lights when the handbrake is activated.
22BH9EFD06
7-52
3) BUTTONS
(1) UP button
Press to select upward move
22BH9EFD07
(2) DOWN button (DOWN/TURTLE button)

Press to select downward move
TURTLE MODE ON/OFF
22BH9EFD08
(3) LEFT/MENU button

Press to select leftward move
Go into the menu
22BH9EFD09
(4) RIGHT/PERFORMANCE button

Press to select rightward move
POWER MODE H/N/E
22BH9EFD10
(5) Cancel (ESC) button

Press to select cancel
Keep pressing this button shows PASSWORD entry field.
22BH9EFD11
(6) ENTER button

Press to select Enter
22BH9EFD12
7-53
4) LCD FUNCTION (MAIN SCREEN)
1 6
2 10
3
7
5
8
MAIN SCREEN
22BH9EFD13
1 Current time 6 Hour meter

2 Turtle mode 7 Wheel position and running direction
3 Truck speed pointer 8 Power mode
4 Speed level 9 BDI (Battery Discharge Indicator)
5 Truck speed 10 Load weight (option)
(1) Current time

The number shows the current time according to the setting, which can be changed by DISPLAY
Setting [6. 5), Page 7-56].
(2) Turtle mode
The turtle symbol is normally off. When this symbol appears, the Turtle Mode is activated
regardless of the Power Mode of the truck to reduce the maximum speed to the setpoint. This
mode can be activated by pressing the button.
7-54
(3) Truck speed pointer
The speed of the truck is indicated with a pointer.
(4) Speed level
It indicates the speed level by 2 km.
(5) Truck speed
The truck speed is shown in number. According to the DISPLAY setting km/h or mph unit is
available.
(6) Hour meter

The number shows the hours worked. The letter present near the hour meter shows which hour
meter is displayed.
- hK: the Key Hour shows the truck Key ON time;
- hT: the Traction Hour shows the Gate ON (driven) time of the traction motor.
- hP: the Pump Hour shows the Gate ON (driven) time of the pump motor.
(7) Wheel position and running direction
The arrow point is up when the truck is forward running and points down when the truck is
reverse running. The arrow point is moved to the leftward or the rightward according as the
direction of the steering angle.
(8) Power mode
The letter; H, N, or E, shows the Power Mode which is being used in the controller. The mode can
be scrolled by pressing the button sequentially. When a mode is selected, the related
information will be sent via CAN-BUS to traction and pump controllers that will manage this data.
H (High) - corresponds to the highest performance
N (Normal) - corresponds to normal performance
E (Economic) - corresponds to economic performance
(9) BDI (Battery
( attery Discharge Indicator)
The battery state of charge is shown by ten bars. Each bar represents the 10% of the battery
charge. As the battery becomes discharged, the bars turn off progressively, one after another, in
proportion to the value of the residual battery charge. When the residual battery charge is 20% or
under, the bars displayed become red.
※ How to adjust BDI
If necessary, service man can a adjust BDI with adjustment #1, #2 BDI menu.
① Adjustment #1 BDI
It adjusts the upper level of the battery discharge table. Higher level means higher voltage.
② Adjustment #2 BDI
It adjusts the lower level of the battery discharge table. Higher level means higher voltage. (for
detail menu, please refer to page 7-27)
7-55
5) HOW TO USE DISPLAY MENU
22BH9EFD14
7-56
22BH9EFD15
7-57
6) DESCRIPTION OF THE TRUCK MENU
(1) Access to truck menu
If this button is pressed long, the PASSWORD dialog appears.
Enter correct PASSWORD, then on MAIN SCREEN, Press button to access the controller
“TRUCK MENU”
(2) How to change detail menus
The detail items of menu can be changed as follows ;

758&.0(18
6(77,1* 0$67(5
6(77,1* 0$67(5 6(7237,216

021,725,1* 6/$9( $'-8670(176
$/$50+,6725< 3803 3$5$0(7(5&+$1*(
9$66
0$67(5 0$67(5
0$67(5
3$5$0(7(5&+$1*( $&&(/'(/$< $&&(/'(/$<

$&&(/'(/$< $5(<28685("

6(& 6HF
<(6(17(512(6&

22B9EL24
Selection can be made in 4 methods as follows ;
- ON/OFF Selection
0$67(5
%$77(5<&+(&.
21
2))
22B9EL25
Select a desired value with , button, then save with button or press button to escape
without saving.
- Type Selection
0$67(5
&22/,1*)$1:25.
237,21
237,21
237,21
22B9EL30
without saving.
7-58
- Figure input
22B9EL31
Select a desired value with , , , button, then save with button or press button
to escape without saving.
- Level Selection
0$67(5

3$5$0(7(5&+$1*(

6HF
22B9EL30
without saving.
7-59
7) ALARM & ALARM HISTORY
(1) How to check alarms
Normally, ALARM SCREEN pops up if any kind of a alarm happens, but service man can switch
between a MAIN SCREEN and ALARM SCREEN with , buttons as follows :
(Press more than 1 sec)
{ypw
jvkl uht l
t Y] jGv
zmi ~GGu
22B9EL35
7-60
(2) Detail description of ALARM SCREEN

75,3
&2'(
6)% &RQWDFWRU2SHQ
0
①
ɂ

J ③
ɂ

②
ɂ

6)% :DLWLQJIRU1RGH
22B9EL36
① First yellow capital letter shows in which controller the alarm happens as below;
M : Traction-Master
S : Traction-Slave
P : Pump
V : Mhyrio CB
② Following two letters or digits show alarm code. Please refer to 7. ALARM CODE (Page 7-68).
③ This shows a name of ALARM. Please refer to 7. ALARM CODE (page 7-68).
(3) Alatm history

Alarm History can be looked up as follows ;
758&.0(18 $/$50+,6725<
6(77,1*
021,725,1* :DLWđ
$/$50+,6725<
Step 1 Step 2
0$67(5$/$50
0$67(5$/$50
$/$50+,6725<
&2'(
&2'( 1$0(
0$67(5 &RQWDFWRU2SHQ 1$0(
6WHHULQJ6HQVRU.2 &RQWDFWRU2SHQ
6/$9( RFFXUHQFHV
3803 7HPSȔ
.H\7LPHKU
Step 3 Step 4 Step 5-1
0$67(5$/$50
0$67(5$/$50
$5(<28685("
<(6(17(512(6&
Step 5-2
22B9EL37
7-61
① Step 1 : Service man can check the alarm history on ALARM HISTORY menu
② Step 2 : When service man enter the ALARM HISTORY menu, display read entire alarm records
of all controller. So it takes 9~15 seconds to read.
③ Step 3 : When display finish to read alarm records, service man can choose each controller to
read the alarm history.
④ Step 4 : When service man enters each controller’s alarm history, service man can check simply
up to 5 alarms and choose a specific alarm to read detail alarm information.
⑤ Step 5-1 : When service man press button at Step 4, operator can see a detail alarm
information of chosen alarm. Please refer to 6-7)-(4) DETAIL ALARM INFORMATION (page
7-62)
⑥ Step 5-2 : When service man press button at Step 4, service man can see a alarm clear
menu. If service man press button, Recorded alarms of selected controller will be erased.
(to verify cleaned alarm records, service man should be back to Step 1 & 2 to refresh.)
If operator press button, just escape to step 3 without clearing
(4) Detail
etail alarm information
①
0$67(5$/$50
&2'(
1$0( ③
② &RQWDFWRU2SHQ
RFFXUHQFHV ④
7HPSȔ
⑤
.H\7LPHKU
22B9EL38
① Code of alarm
② Name of alarm
③ Count of alarm
④ Temperature of controller as alarm occurs.
⑤ Hourmeter of controller as alarm occurs.
7-62
8) VASS SETUP USING DISPLAY MENU
This function searches and memorizes the minimum and maximum potentiometer wiper voltage of
the accelerator pedal, lift lever, and steering sensor which use potentiometer sensors. The belows
show how to use the VASS function of DISPLAY.
(All figures in belows are just example.)
※ While even a motor is running, VASS can not be configurated properly, so please be sure that all
motors are not running before entering configuration process & saving.
(1) ACCEL VASS setting method
9$66
$&&(/
Please make sure that all motors
0,1)25:$5'9
are not running & direction lever
0$;)25:$5'9
is in NEUTRAL position.
0,15(9(56(9
0$;5(9(56(9
9$66
$&&(/5($'< If “READY” appears beside
0,1)25:$5'9 ACCEL, you are in configuration
process.
0$;)25:$5'9
Set direction lever in FORWARD
0,15(9(56(9
position.
0$;5(9(56(9
9$66
$&&(/5($'< Now, you can see that voltage
0,1)25:$5'9 value of MIN FORWARD and
0$;)25:$5'9 MAX FORWARD are changed.
Step on accel pedal fully, then
0,15(9(56(9
Take foot off accel pedal.
0$;5(9(56(9
Now, you can see that voltage

9$66 value of MAX FORWARD are
$&&(/5($'< changed.
0,1)25:$5'9 Set direction lever in REVERSE
0$;)25:$5'9 position. (Sometimes, depending
on controller model, MIN
0,15(9(56(9
FORWARD value looks like that
0$;5(9(56(9
it is fixed as 0.0V, which is
normal.)
9$66
Now, you can see that voltage
$&&(/5($'<
value of MIN REVERSE and
0,1)25:$5'9
MAX REVERSE are changed.
0$;)25:$5'9
Step on accel pedal fully, then
0,15(9(56(9
Take foot off accel pedal
0$;5(9(56(9
22B9EL39-1
7-63
9$66
$&&(/5($'< Now, you can see that voltage value of
MAX REVERSE are changed.
0,1)25:$5'9
Please make sure that all motors are not
0$;)25:$5'9
running & direction lever is in NEUTRAL
0,15(9(56(9
position.
0$;5(9(56(9
9$66
$&&(/),1,6+
$5(<28685("
<(6(17(512(6&
22B9EL39-2
(2) LIFT VASS setting method
9$66
/,)7 Please make sure that all
motors are not running &
0,1/,)79
direction lever is in NEUTRAL
0$;/,)79 position.
9$66 If “READY” appears beside LIFT, you are

/,)75($'< in configuration process.
Now, operator can see that voltage value
0,1/,)79
of MIN LIFT and MAX LIFT are
0$;/,)79 changed.
Full the lift lever toward operator fully
9$66
Now, you can see that voltage value of
/,)75($'<
MAX LIFT are changed.
Please make sure that all motors are not
0,1/,)79
running & direction lever is in NEUTRAL
0$;/,)79 position.
9$66
/,)75($'<

$5(<28685("
<(6(17(512(6&
22B9EL40
7-64
(3) STEER ANGLE VASS setting method
9$66
67((5$1*/(
Please make sure that all
67((55,*+79 motors are not running &
67((5/()79 direction lever is in NEUTRAL
position.
67((53269
9$66 If “READY” appears beside STEER

67((5$1*/(5($'< ANGLE, you are in configuration process.
67((55,*+79 Now, operator can see that voltage value

67((5/()79 of STEER RIGHT is changed.
Turn steer handle to right-end fully,
67((53269
the value will be changed.
9$66
67((5$1*/(5($'< Now, you can see that voltage value of
67((55,*+79 STEER RIGHT is saved.

67((5/()79
Turn steer handle to left-end fully, the
voltage value will be changed.
67((53269
9$66 Now, you can see that voltage value of

67((5$1*/(5($'< STEER LEFT is saved.
67((55,*+79 Turn steer handle to center position, the

voltage value will be changed.
67((5/()79
Please make sure that all traction motors
67((53269
are not running
9$66
67((5$1*/(5($'<
$5(<28685("
<(6(17(512(6&
22B9EL41
7-65
9) STRUCTURE OF TRUCK MENU
TRUCK MENU is in order to make configuration of truck easily, and consists of 3 major categorys :
SETTING, MONITORING, ALARM HISTORY.
[To know how to get in to TRUCK MENU, refer to 6-6)-(1) “ACCESS TO TRUCK MENU” page 7-58]
(1) Settings
758&.0(18 6(77,1*
6(77,1* 0$67(5
6/$9(

021,725,1*
$/$50+,6725< 3803
9$66
0$67(5
6(7237,216
$'-8670(176
3$5$0(7(5&+$1*(
22B9EL42
In SETTINGS, service man can choose a specific controller’s submenu or VASS menu.
① MASTER->SET OPTIONS
Refer to 5-4)-■“TRACTION-MASTER CONTROLLER”-(1) “SET OPTIONS” (page 7-25)
② MASTER->ADJUSTMENTS
Refer to 5-4)-■”TRACTION-MASTER CONTROLLER”-(2) “ADJUSTMENTS” (page 7-26)
③ MASTER->PARAMETER CHANGE
Refer to 5-4)-■”TRACTION-MASTER CONTROLLER”-(3) “PARAMETER CHANGE” (page 7-29)
④ SLAVE->SET OPTIONS
Not available
⑤ SLAVE->ADJUSTMENTS
Refer to 5-4)-■”TRACTION-SLAVE CONTROLLER”-(2) “ADJUSTMENTS” (page 7-31)
⑥ SLAVE->PARAMETER CHANGE
Refer to 5-4)-■”TRACTION-SLAVE CONTROLLER”-(3) “PARAMETER CHANGE” (page 7-31)
⑦ PUMP->SET OPTIONS
Refer to 5-4)-■“PUMP CONTROLLER”-(1) “SET OPTIONS” (page 7-31)
⑧ PUMP->ADJUSTMENTS
Refer to 5-4)-■”PUMP CONTROLLER”-(2) “ADJUSTMENTS” (page 7-32)
⑨ PUMP->PARAMETER CHANGE
Refer to 5-4)-■”PUMP CONTROLLER”-(3) “PARAMETER CHANGE” (page 7-33)
⑩ V.A.S.S
Refer to 6-8) “VASS SETUP USING DISPLAY MENU” (page 7-63)
7-66
(2) Monitoring
758&.0(18 021,725,1*
6(77,1* 0$67(5

021,725,1* 6/$9(
$/$50+,6725< 3803
021,725,1*
0$67(5
9ROWDJHERRVWHU
%DWWHU\YROWDJH9
%DWWHU\FKDUJH9
'HYLFH1DPH+<
+:9(5'$0
22B9EL43
In MONITORING MENU, service man can check various stats of trucks.

① MASTER
Refer to 5-6)-(1) “Traction controller-master” (page 7-45)
② SLAVE
Refer to 5-6)-(2) “Traction controller-Slave” (page 7-46)
③ PUMP
Refer to 5-6)-(3) “Pump controller” (page 7-48)
(3) Alarm history

Refer to 6-7) “ALARM & ALARM HISTORY” (page 7-60)
7-67
7. ALARM CODE
1) TRACTION-MASTER & SLAVE CONTROLLER
Condition that has to occur to come out from
Code Alarm name Description
alarm status
08 WATCHDOG Alarm: the Watchdog circuit has - If the alarm is present in Init status, remove
been triggered the alarm condition
- If the alarm has occurred in stby or running
mode, it is necessary to remove alarm
condition and to activate a traction request
0D EEPROM KO Warning: Eeprom fault, controller To remove Warning cause
will use default parameters
11 LOGIC FAILURE #3 Alar m: failure in over-load - To remove alarm condition + activation of
protection hw circuit traction request
- Check the Controller
12 LOGIC FAILURE #2 Alarm: failure in U, V, W voltage To remove alarm condition + activation of
feedback circuit traction request
13 LOGIC FAILURE #1 A l a r m : a n ove r vo l t a g e o r - To recycle the key switch
undervolt. condition has been - Sometimes if battery voltage is too low, it can
detected be happens
1E VMN LOW Alarm: wrong voltage on motor - If the alarm is present in Init status, remove
power outputs; failure in the the alarm condition
power section or in the mosfet - If the alarm has occurred in stby or running
driver circuit or in the motor mode, it is necessary to remove alarm
- Check the U,V,W cable and motor and if there
is any shorted circuit with frame or any other
parts of truck
1F VMN HIGH Alarm: wrong voltage on motor - If the alarm is present in Init status, remove
- Check the U,V,W cable and motor and if there
is any shorted circuit with frame or any other
parts of truck
25 CONTACTOR Alarm: line contactor power - To remove alarm cause within a timeout; if the
CLOSED contact is stuck timeout is elapsed, it is necessary to re-cycle
the key
- Check the contactor & cables attached to the
contactor
26 CONTACTOR OPEN Alarm: line contactor power - To remove alarm cause within a timeout; if the
contact does not pull-in timeout is elapsed, it is necessary to re-cycle
the key
- Check the contactor & cables attached to the
contactor
31 I = 0 EVER Alarm: While truck is running, - Check the Main contactor
current value is 0 for more than - Check the controller
1 Sec
7-68
alarm status
35 STBY I HIGH Alarm: wrong voltage in the - If the alarm is present in Init status, remove
current sensor feedback circuit the alarm condition
3C CAPACITOR Alarm: power capacitor voltage - To remove alarm condition
CHARGE does not increase when the key - Check the contactor resistance (300Ω, 10W)
is turned ON; failure in the power - Check the controller
section, or in the Logic PCB, or in
the driver PCB, or in the motor
3D HIGH Warning: Master or Slave or both - To remove Warning cause
TEMPERATURE temperature higher than 75°C
41 MOTOR Warning: Master or Slave or both - To remove Warning cause
TEMPERA-TURE motors temperature high - Check the motor temp-sensor
42 BATTERY LOW Warning: battery charge level - To remove Warning cause
below 10%
4A DRIVER SHORTED Alarm: line contactor coil driver is - If the alarm is present in Init status, remove
shorted the alarm cause
mode, it is necessary to remove alarm cause
and to activate traction request
4B CONTACTOR Alarm: line contactor coil driver is - To remove alarm cause and to activate
DRIVER open (not able to drive the coil to traction request
the correct voltage)
4C COIL SHORTED Alarm: - If the alarm is present in Init status, remove
-Init: the LC and EB coil driver the alarm cause
protection circuit is damaged - If the alarm has occurred in stby or running
-Stby or running: short on LC coil mode, it is necessary to remove alarm cause
or EB coil" and to activate traction request
4E VACC NOT OK Warning: acc. signal (CPOT) - To remove Warning cause
voltage higher than VACC MIN - Re-configurate VASS ACCEL
+1V while the traction enable
switch is open
4F INCORRECT START Warning: wrong traction request - To remove Warning cause
sequence
50 FORWARD + Warning: forward and reverse - To remove Warning cause
BACKWARD inputs are both active
52 ENCODER ERROR Alar m: motor speed sensor - To recycle the key
(encoder) does not work properly - Check the motor encoder
54 STEER SENSOR Alarm: steering sensor signal out - To remove alarm cause
KO of range
56 PEDAL WIRE KO Alarm: fault in accelerator negative - To remove alarm cause and activate a
(NPOT) input circuit traction request
EE LOADSENS ERROR Alarm: Load weight sensor detects - To remove alarm cause
that loaded weight exceeds the - Check the load weight sensor
weight limitation, or load weight
sensor is not working properly
7-69
alarm status
EF OVERLOAD Warning: Load weight sensor - To remove warning cause
detects that loaded weight
exceeds the weight limited
i n OV E R L OA D W E I G H T
programming.
F0 MOTOR STALL Warning: the encoder signal - To recycle the key
is constantly zero when the - Check the motor and encoder
maximum torque is applied to the
motor
F2 PUMP Warning: a warning is active on - To remove warning cause
WARNING the pump module
F3 SEQUENCE Warning: an incorrect star t - To remove Warning cause
FAULT sequence has been detected
on the seat, pedal and levers
commands
F4 SLAVE Warning: a warning is active on - To remove warning cause
WARNING the SLAVE module
F5 WRONG SET Alarm: the battery voltage does - To remove alarm cause
BATTERY not correspond to SET BATTERY
programming
F6 SLAVE KO Alarm: Master µC detects a Slave - To recycle the key
(master µC malfunctioning - Check if any other alarm happens
only) (Some alarms such as CHAT TIME or
PEDAL WIRE KO, alar ms related to
CONTACTOR, DISPLAY ENABLE, alarms
related to CANBUS can make this alarm
sometimes.)
- Check the communication with all controllers
(display TRUCK MENU->MONITORING->
choose controller->H/W VER, S/W VER.
If CAN communication is not availabel, H/W
VER, S/W VER will be blank.)
F6 MASTER KO Alarm: Slave µC detects a Master - To recycle the key
(slave µC malfunctioning or a mismatch - Check If any other alarm happens
only) between inputs status and Master (Some alarms such as CHAT TIME or PEDAL
commands (via Canbus) WIRE KO, alarms related to CONTACTOR,
DISPLAY ENABLE, alarms related to
CANBUS can make this alarm sometimes.)
VER, S/W VER will be blank.)"
7-70
alarm status
F7 NO CAN MSG.N Alarm: Master/Slave has lost - To remove alarm cause
Can communication with #X - Check if any other alarm happens
(Some alarms such as CHAT TIME or PEDAL
WIRE KO, alarms related to CONTACTOR,
F8 DISPLAY ENABLE Warning: the display enable - To remove warning cause
signal has not been received to
operate the truck
F9 THERMIC SENSOR Warning: Master or slave temp. - To remove Warning cause
KO sensor is out of range
FA INPUT MISMATCH Alarm: Slave µC has detected a - To recycle the key
mismatch between inputs status
and the input status transmitted
via Canbus by Master µC
FA HANDBRAKE W a r n i n g : h a n d b r a k e - To remove Warning cause
microswitch is open and a travel
request is active
FB WAITING FOR Warning: Master Controller - To remove Warning cause
NODE signals that other controllers are - C h e ck i f a n y o t h e r a l a r m h a p p e n s
in alarm status (Some alarms such as CHAT TIME or PEDAL
(display TRUCK MENU-> MONITORING->
- Check other controllers
FC CHAT MODE Warning: the chat time has - To activate traction or pump request
expired
FD AUX OUTPUT KO Alarm: MCV SOL driver shorted - If the alarm is present in Init status, remove
or open the alarm cause
FE CANBUS KO Alarm: master has lost can To remove warning cause
DISPL. communication with the display
7-71
2) PUMP CONTROLLER

alarm status
08 WATCHDOG Alarm: the Watchdog circuit has - If the alarm is present in Init status, remove
been triggered the alarm condition
0D EEPROM KO Warning: Eeprom fault, controller To remove Warning cause
will use default parameters
12 LOGIC FAILURE #2 Alarm: failure in U, V, W voltage - To remove alarm condition + activation of
feedback circuit traction request
13 LOGIC FAILURE #1 A l a r m : a n o ve r vo l t a g e o r - To recycle the key switch

undervolt. condition has been - Sometimes if battery voltage is too low, it can
detected be happens
1E VMN LOW Alarm: wrong voltage on motor - If the alarm is present in Init status, remove
- Check the U, V, W cable and motor and if
there is any shorted circuit with frame or any
other parts of truck
1F VMN HIGH Alarm: wrong voltage on motor - If the alarm is present in Init status, remove
- Check the U, V, W cable and motor and if
there is any shorted circuit with frame or any
other parts of truck
31 I = 0 EVER Alarm: While truck is running, - Check the Main contactor
current value is 0 for more than 1 - Check the controller
Sec
35 STBY I HIGH Alarm: wrong voltage in the - If the alarm is present in Init status, remove
current sensor feedback circuit the alarm condition
3C CAPACITOR Alarm: power capacitor voltage - To remove alarm condition
CHARGE does not increase when the key - Check the contactor resistance (300Ω, 10W)
is turned ON; failure in the power
section, or in the Logic PCB, or in
the driver PCB, or in the motor
3D HIGH Warning: Controller temperature - To remove Warning cause
TEMPERATURE higher than 75°C
7-72
alarm status
41 MOTOR W a r n i n g : P u m p m o t o r ’ s - To remove Warning cause
TEMPERA-TURE temperature high - Check the motor temp-sensor
42 BATTERY LOW Warning: battery charge level To remove Warning cause
below 10%
4A DRIVER Alarm: line contactor coil driver is - If the alarm is present in Init status, remove
SHORTED shorted the alarm cause
4B CONTACTOR Alarm: line contactor coil driver is To remove alarm cause and to activate traction
DRIVER open (not able to drive the coil to request
the correct voltage)
4C COIL SHORTED Alarm : - If the alarm is present in Init status, remove
- Init: the LC and EB coil driver the alarm cause
protection circuit is damaged - If the alarm has occurred in stby or running
- Stby or running: short on LC mode, it is necessary to remove alarm cause
coil or EB coil and to activate traction request
4E VACC NOT OK Warning: acc/lift signal (CPOT) - To remove Warning cause
voltage higher than VACC MIN - Re-configurate VASS LIFT
+1V while the traction/lift enable
switch is open
4F INCORRECT Warning: wrong traction/pump To remove Warning cause
START request sequence
50 FORWARD + Warning: forward and reverse To remove Warning cause
BACKWARD inputs are both active
52 ENCODER Alarm: motor speed sensor - To recycle the key
ERROR ( e n c o d e r ) d o e s n o t w o r k - Check the motor encoder
properly
56 PEDAL WIRE KO Alarm: fault in accelerator/Lift To remove alarm cause and activate a traction/
negative (NPOT) input circuit pump request
DF S B R S W I T C H SIDE BATTERY REMOVAL - To remove Warning cause
OPEN sensor is open - Check the sensor
E3 TILT SENS OUT Value of tilt sensor (AUTO TILT - Check the Tilt Sensor of AUTO TILT
RNG LEVELING) is out of range LEVELING Option
- Re-configurate Tilt Sensor of AUTO TILT
LEVELING Option
E4 T I L T S E N S Value of tilt sensor (AUTO TILT - Check the Tilt Sensor of AUTO TILT
LOCKED LEVELING) is fixed even tilt LEVELING Option
request is activated - Re-configurate Tilt Sensor of AUTO TILT
LEVELING Option
E5 AUX FUNCT KO Fingertip aux function is not - Check the MCV valve
working properly - Re-configurate lever
- Check the fingertip controller
E6 SHIFT FUNCT KO Fingertip shift function is not - Check the MCV valve
working properly - Re-configurate lever
7-73
alarm status
E7 TILT FUNCT KO Fingertip tilt function is not working - Check the MCV valve
properly - Re-configurate lever
E8 LIFT FUNCT KO Fingertip lift function is not working - Check the MCV valve
properly - Re-configurate lever
E9 AUX OUT OF RNG Voltage value of AUX sensor is - Re-configurate the AUX lever
out of range - Check the AUX lever
EA SHIFT OUT OF Voltage value of SHIFT sensor is - Re-configurate the SHIFT lever
RNG out of range - Check the SHIFT lever
EB TILT OUT OF RNG Voltage value of TILT sensor is out - Re-configurate the TILT lever
of range - Check the TILT lever
EC LIFT OUT OF RNG Voltage value of LIFT sensor is - Re-configurate the LIFT lever
out of range - Check the Lift lever
ED ACQUIRE AUX Controller is configurating “AUX” - Finish the configuration process
lever function
EE ACQUIRE SHIFT Controller is configurating “SHIFT” - Finish the configuration process
lever function
EF ACQUIRE TILT Controller is configurating “TILT” - Finish the configuration process
lever function
F0 ACQUIRE LIFT Controller is configurating “LIFT” - Finish the configuration process
lever function
F2 MOTOR STALL Warning: the encoder signal - To recycle the key
is constantly zero when the - Check the motor and encoder
maximum torque is applied to the
motor
F4 FORK WRONG DIR D i r e c t i o n o f “ A U T O T I LT - Check if operator operates truck correctly
LEVELING” movement is not - Check the Tilt Sensor of Fork leveling Option
correct - Re-configurate Tilt Sensor of Fork leveling
Option
F5 WRONG SET Alarm: the battery voltage does - To remove alarm cause
BATTERY not correspond to SET BATTERY
TYPE programming
F6 SAFETY KO Alarm: the controller detects - To recycle the key
malfunction on safety circuit - Check if any other alarms happen on
(PUMP CONTROLLER A12-A34) controllers
- Check the safety circuit
F7 NO CAN MS Alarm: Pump controller has lost - To remove alarm cause
Can communication with #X - C h e ck i f a ny o t h e r a l a r m h a p p e n s
(Some alarms such as CHAT TIME or PEDAL
VER, S/W VER will be blank.)"
7-74
alarm status
F8 BRAKE OIL Lack of Brake oil - Check the brake oil tank & sensor
F9 THERMIC SENSOR Warning: Controller temp. sensor - To remove Warning cause
KO is out of range
FB W A I T I N G F O R Warning: Controller signals that - To remove Warning cause
NODE other controllers are in alarm - C h e ck i f a ny o t h e r a l a r m h a p p e n s
status (Some alarms such as CHAT TIME or PEDAL
choose controller->H/W VER, S/W VER. If
CAN communication is not availabel, H/W
- Check other controllers."
FD AUX OUTPUT KO Alarm: EB coil driver shorted or - If the alarm is present in Init status, remove
open the alarm cause
and to activate traction request"
7-75
8. BATTERY CHARGER
This explains basic information related to charger to help you easily understand and use it. This
includes the contents from the way to install a charger to tips for emergency situations. This is
focused on practices aiming to be usefully utilized in the field.
1) BASIC INFORMATION
(1) What is charger
Charger is a device which makes a battery accept D.C electricity under optimal condition as it
transforms A.C provided from external source of electricity.
The charger is a constant-current and constant-voltage way, SCR type charger that it has
advantages as follows
① Even though A.C input voltage fluctuates within 10% of rated voltage (220/380/410/440V), the
current and voltage provided to the battery are stable.
② As minimizing the increase of temperature while charging a battery, it minimizes the stress on
the battery.
③ The noisy of charger is minimal but the charging efficiency is very high.
④ It prevents from under charging and overcharging.
Therefore, it helps the battery to maintain its performance for longer time and to prolong the life
of the battery.
(2) Notice on caring chargers

① If any abnormal status is found while using a charger, immediately stop using and check the
charger. If it is impossible to take an appropriate measure for yourself, please apply for A/S.
② While charging, hydrogen and oxygen gas is produced. Use or approach of fire should be strictly
prohibited.
③ Keep clean to prevent from sneak current and attack on the interface and surroundings of the
battery.
④ Check the electrolyte of the battery every week and provide distilled water immediately if it is
required. (Electrolyte has to be provided between 10~12 mm level on the positive plate inside
storage battery)
⑤ If battery liquid temperature becomes over 55°C, charging should be stopped.
If it is continued,
- the appearance is transformed
- and metal area can be attacked as electrolyte overflows
⑥ Electric forklift truck using battery should be charged as soon as the charging lamp is on while
driving. As batteries are internally discharged naturally if they are deposed for a long time,
charge them once or twice a month to prevent from reducing the lives of batteries.
⑦ When a green sign is on among charging status indication lamps, please notify that it is not
converted as equalized charge for stabilization of charging status.
7-76
(3) Names of each part (independent items)
1 2 3
4 5
6 7 8 9 10
22B9BAT30
1 Main PCB board 5 Monitor PCB 9 Resistance (RD)

2 Main trans (Class H) 6 Overload 10 Resistance (DR)
3 Cooling fan 7 MG S/W
4 SCR module 8 Assistant trans
7-77
2) CHARGER INSTALLATION METHOD
(1) Location for charger installation
① Dry and well ventilated place.
② No inflammable and B7 fire are near by.
③ Safe place where no collision possibility
with people or equipment is.
(2) Check points before installing charger
① Enough capacity of AC input power
source to operate charger.
② Standard electric wire for power source
by capacity.
(3) Table for capacity of charger input cable
Capacity of Input
48 V battery Remarks
cable voltage
200-365 AH 4P - 2.5 mm2
400-80 AH 4P - 4 mm2
For 3Ø220V,
600-800 AH 4P - 6 mm2
one step
850-1000 AH 4P - 10 mm2 Based on higher
24 V battery - 3Ø380 V capacity
200-600 AH 4P - 2.5 mm 3Ø440 V cable should
2
700-1000 AH 4P - 4 mm2 be used.

(2.5 mm2 →
80V battery -
4mm2)
500-600 AH 4P - 6 mm2
700-800 AH 4P - 10 mm2
7-78
3) HOW TO USE A CHARGER
(1) General charging method (Floating
charging)
① Charging by this method supplies electric
power to the charger as operating
external AC power switch of the charger.
② Connect battery connecter and charger
connecter.
·According
According to charging condition
① If there is no abnormality found when the
22B9BAT01
charger checks itself for 3-4 seconds
after inputting AC input power source, the
charger slowly increases the electric flow
for charging and the charging condition
lamp in the lower part of the front panel Display
for floating charging of "input" is on. 85%
② A charging voltage, current, amount and 2
1
time are displayed in order on a monitor
80%
display window. 3 2
③ When charging is processed about 80%,
yellow lamp in the middle of the front 1
panel, which shows that the charging
condition is in the middle, is on and then BOP7BAT02
green lamp is on when charging is

processed over 85% until charging is
completed.
④ When charging is completed, "charging
is completed" lamp is on in the monitor
and other lamps of all monitors become
off.
(2) Equalized charging
① Equalized charging is
Equalized charging is to correct the
battery when it does not normally
perform its functions as the voltage
differences are too big between cells of a
battery.
When equalized charging is required?
- When re-operates the battery after
having left the battery for a long time.
- When a battery is over-discharged.
- When there is large deviation of voltage
and specific gravity between battery
cells.
- When change or supply electrolyte of
battery.
7-79
② Tips for equalized charging
If once push the equalized charging
button on the monitor in the beginning of
charging, the equalized charging lamp
becomes on and starts charging.
※ When the green charging condition
lamp is on (over 85% charged), the
equalized charging switch is locked
that it does not operate even pushing
the button. Equalized charge Equalized charge S/W
indicating lamp
22B9BAT03
(3) Automatic/Manual switching method J2

Automatic connector. Manual switching
connector (J2) is located on a left top
corner of PCB.
※ In case of manual switching for charger Manual connector Automatic connector
checking, make sure that the battery connection connection
connector is separated beforehand.
⊙ MG/SW operation
(Refer to the charger trouble SHEET
components manual) J2 J2
MG/SW
22B9BAT04
(4) Checking charging voltage soft start

function (Refer to the monitor)
① Plug it into a manual connector and input
①
after 5 sec., a floating charge, charging ③
status red LED lights up. ②
② After 15 sec., charging status yellow LED
lights up.
③ After a green LED lights up, if measured
voltage comes out as IuIua63V ~ IuIa64V BOP7BAT10
by measuring output voltage of battery
connector side with multi-meter, then it is
normal.
④ After 30 sec. of switching to a manual
connector, if a buzzer sound rings
continuously for 10 sec. and completion
LED lights up, then it is normal.
⑤ If you confirm that the charger operates in
normal after checking manual switching of
the charger, make sure that the charger is
switched to automatic.
7-80
⑥ If charger's out voltage is under 60 V, it is
abnormal.
Please refer to the error sheet.
⑦ When the charging voltage is indicated as
n o r m a l c o n d i t i o n ( 6 4 V ) , c o nve r t
automatic / manual switch to automatic
and start charging.
※ Display error code on the front cover as
22B9BAT11
following table.
No Code Description of error
1 E.F EPROM fail

2 O.V Over voltage - Refer to page 7-86
3 O.C Over current - Refer to page 7-85, 7-87.
4 F.B Battery error (After starting charging, the voltage doesn't go over 52V for 2 hours.)
Check the battery.
5 O.T Transformer over heat (Stop charging when it is over 160°C).
- If input voltage is high, output current is over normal value and there is heat in the
trans because of SCR control part fault.
- Check the output current and PCB control board
6 O.H Heatsink over heat (Stop charging when it is over 100°C).
- Check the cooling fan, SCR connection cable contact point and control part.
7 A.O Power supply error (input power 220/380V wrong wiring). - Refer to page 7-84.
8 A.F Power supply error (absent phase) - Check if input cable is open.
9 A.C AC fail (black out) - Check if input voltage is right.
10 L.C Low current (If this sign is on for setting value (60 sec), charging is over).
11 F Manual stop.
7-81
4) CHECK POINTS BEFORE APPLYING A/S
(1) AC input power source switch is input.
(2) Check if the battery connector of the order
picker truck and charger's connector are
connected.
(3) Check points when "Error" lamp is on in
the front monitor of the charger.
(4) Check the front cover indicator.
① A.F : Input three phase power source
continuity check = Check if input three Error indication BOP7BAT12
phase power source is normal with AC

voltage meter.
② A.O : Error on selection of input power
source of 220V or 380V - Check it
appropriately with full three phases.
③ A.C : Check if the input power source
(220V or 380V) is normal.
④ O.C : Check the electric current, as
charging current of the battery is over-
standards condition.
⑤ O.V : Check the voltage, as charging
voltage of the battery is over-voltage
condition (66V).
Normally it is 64V±1.0V.
(5) Check other abnormalities as well. Then
apply for A/S when on-site
measurements are not applicable.
7-82
5) ERROR DETECTION
(1) Error list
① Only floating charge lamp is on in the
monitor but it is not charged.
② ON and OFF is repeated with a few
minutes intervals even after starting
charging.
③ Charger TRIP is occurred after
abnormality lamp is on.
In case error code is "O.V"
④ Charger TRIP is occurred after
abnormality lamp is on.
In case error code is "O.C"
⑤ Charger TRIP is occurred after it started
charging and charging completion lamp
is on.
⑥ Charger has no response even the
battery connector is connected.
⑦ SCR module checking method
7-83
(2) Troubleshooting
① Only floating charge lamp is on after indicating "A.O", It's not charged.
· 220/380V Model : Measure the TB.4 (380V) TB.8(220V)

voltage between input voltage
change over tabs 2-4 2-6 4-6 70Ω/
· 220,380,410,440V Model : 30W
Measure the voltage in front of M/S

MS electric socket Manual/Auto TAP (J2) B
AC INPUT MS S/W
T.B
short 7 8
Insert automatic/ bar
manual connector AC PCB RY
Check (J2) at the upper INPUT PCB (LP lamp)
YES YES LP lamp YES Voltage
the rated part of PCB to MS tap
voltage manual, after switch lights up
J2
separating battery ON
connector.
NO NO
TH *
Manual /
Put a black lead of multi-tester to Change PCB Auto S/W
input voltage switch No. 6 and
CN4 contact fault M/S
measure voltage between tab COIL FAN
No.8,PCB CN4,TH contact points PCB RY contact fault
NO
with a red lead.
TB.6
M/S electrical circuit
TH contact fault
Voltage NO CN4 contact fault

Input power supply is not 220V
PCB RELAY fault
supplied.
YES TH manual
· Check external lead cable.
restoration release
· Check the connection of MS COIL fault
external input connecter Relay Relay
contact
· Check external NFB TRIP point
7-84
② ON and OFF is repeated with a few minutes intervals after starting charging.
Indicate "O.C" on the monitor.
- TH is operated (AC input over-current TRIP).
OUTPUT
CURRENT
DE- IN-
CREASE CREASE
Trans
noise is Measure output Current Exceed Adjust output current
NO NO
severe at current using DC value : 10~16A Standard AMP, VR within PCB
MS ON current measure /100AH current Re-adjust to VR
status
YES
· TH Setting fault
YES
· Re-adjust TH TH. TRIP Change TH
setting value
NO
* Refer to SCR Rated
Complete Current
YES Module checking
method SETTING
YES NO
Complete Change PCB
NO Change
SCR MODULE
Separate the battery Check
connector and tune SCR
the charger off Module
YES Check
Check the normal
MAIN NO Change
operating condition
TRANS PCB
of the charger
VOLT
YES
7-85
③ Charger TRIP is occurred after abnormality lamp is on.
In case error code is "O.V" → Over-voltage output / Set at 66V (In case of BATT 48V)
34V (In case of BATT 24V)
108V (In case of BATT 80V)
After separating battery connector, Rotate charging voltage volume,

Check
insert automatic/manual selection located in the middle of PCB, to
the voltage of the NO
connector(J2) at the left side of PCB counterclockwise.
output connecter
to manual and then, MS will be turned Adjust a real output voltage
64V? identical to displayed voltage
“ON”
Reset voltage as turning

YES De- In-
volume volt for setting voltage crease crease
on the center of PCB
Measure
YES the voltage of the VOLT
Adjust voltage so as
output connecter
to have same output
64V?
between actual output
Check contact error
voltage and indication
or breaking of wiring NO Change
of display
De- In- OK NO of the detect cable PCB
crease crease
connecter pin
Check Check
whether the charger
the detect
is normal condition after
YES voltage of the J3 NO
connecting the
battery connector
64V?
NO
YES
Change PCB
OK
7-86
④ Charger TRIP is occurred after abnormality lamp is on.
After opening the cover which is located on the front bottom side of the charger.
In case error code is "O.C" → Output over current, established as 110~120% of the rated
current.
Measure
Check poor contact of current
the output current
Restart the charger as pushing NO connector (J1), located right side of
by DC current measure
reset switch in the monitor. PCB; check if there is disconnection
10~16A/
(cleaning and wiring )
100AH
YES
Re-establish charge current Measure

volume (AMP) on the center the output current
side of PCB as turning it anti by DC current
clockwise rotation measure
Monitor display
YES NO
Request A/S if problem Change

OK
persists after adjustment PCB
De- In-
crease crease
7-87
⑤ Charger TRIP is occurred after it started charging and charging completion lamp is on.
(In case input voltage is normal - Refer to the error detection No. 1)
Restore the charger as pushing reset switch.
If charging
current measurement After separating battery
NO Measure the output
is normal when it is measured connector, put the automatic/
voltage 64V
with DC ammeter manual S/W (J2) to manual
YES
YES
Change PCB or NO
J2
Request After-Service Contact fault between
Check
the battery connector
SCR Module
and charger connector
Normal Battery is over-
discharged
NO YES
Change Change
SCR Module PCB
7-88
⑥ Charger has no response even if the battery connector is connected.
- In case only floating LED is on, charger input power is cut off or doesn't connect. (In case
the input voltage is normal - Refer to the error detection No. ① )
NO Charger BATTERY
Connector contact fault
Battery
Measure Measure the
NO voltage
the battery voltage voltage within the is normal
Is it under RD of the charger (Over
48V? BATT(+) SHUNT 35V)
J.3
YES RD PCB(+)
YES
PCB(-)
BATT(-)
PCB
(+)(-) Voltage Check the cable and contact
is over YES point status at PCB connector(J3)
12V
On the
Put the auto/manual S/W to manual, after 30
left side of PCB
min. ~1 hr, put the S/W to auto and let it be
Is LP LED
charged normally. NO NO
ON?
If battery voltage doesn’t increase after 1 hr of
starting auto charge, then battery check in YES Change
needed. PCB
Refer to the error detection No.①

Change Check the input power wire line
RD 340/50W in the charger
RD
BATT(+)
70Ω 12V or higher LP, LED
BATT(-)
( based on 48V)
7-89
7) HOW TO CHECK THE SCR MODULE
Circuit Real diagram
K2 K2
G1
K1 G1
3 2 1 K1
* Before checking SCR MODULE, be sure to disconnect bus bar and wire on the terminal.
Measuring point Measure value
No. SURGE PCB
(Real diagram) (Measurement of digital tester)
1 No.1 ~ No.3 Forward : Under 100 k ohm

Reverse : Infinity ( ∞ )
2 No.2 ~ No.3 Forward : Infinity ( ∞ )

3 G1 ~ K1 Forward : Under 100 ohm

Reverse : Under 100 ohm
But It depends on the module.
If it is not 0 ohm, It is Ok.
4 G1 ~ K2 Forward : Infinity ( ∞ )
7-90
8) PCB MAJOR PARTS (NAME AND LOCATION)
②Lp lamp
Auto ⑬Auto/manual
Manual switch TAP ④SHUNT
detect current J2
J2 ⑫Auxiliary ③Detect
connector power supply voltage J3
⑥Correct ⑤Correct ⑦Correct

output output CPU voltage
voltage current
⑧Monitor
display output
⑩SCR control
①Controlling micro unit #1

⑭SCR control ⑨Temperature
connector sensor
⑪Buzzer
22B9BAT26
1 Controlling MICOM #1 6 Correct output voltage 11 Buzzer

2 Lp lamp 7 Correct CPU voltage 12 Auxiliary power supply
3 Detect voltage 8 Monitor display output 13 Auto/manual switch TAP
4 SHUNT detect current 9 Temperature sensor 14 SCR control connector
5 Correct output current 10 SCR control
7-91
22B9BAT27
7-92
CHARGER INTERIOR PARTS
12 5 9 1 3
6 7
2
13
10
14
8
11
22B9BAT28
No Part name Remarks

1 AC fan
2 Over load
3 Resister RD
4 Trans-aux
5 Magnet switch
6 SCR module
7 Monitor
8 DC out cable
9 Resister DR
10 Main transformer
11 AC input cable
12 Main control board
13 Filter
14 Fuse
7-93

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GROUP 3 ELECTRIC COMPONENTS

1. FUNCTIONS OF BATTERY FORKLIFT TRUCK AND ELECTRIC COMPONENTS

1 Cells 6 Cable connector

3) SPECIFICATION AND SERVICE DATA

Type - Lead Acid

Fully charged specific gravity 1.280 (25°C)

Minimum Level Maximum Level

1 Rotor 5 Block-Terminal A 9 Bearing

1 Rotor 5 Block-Terminal A 9 Bearing

Item Unit Specification

3) INTERNAL INVOLUTE SPLINE DATA

Item Unit Specification

Flat root side fit - Class 7

Traction controller Pump controller

Model Model Application Type Power Current limit

DUAL AC2 Power Traction MOSFET 36-48V, 450+450A 450A/3min

CONN C CONN B CONN A

A1 CAN_H High level CANBUS.

C19 NPOTB -BATT.

② Connection of encoder with open collector output; +12V power supply.

No. of pin Function Description

A18 CAN H High level CAN-BUS voltage I/O.

(2) Submenu "ADJUSTMENTS"

VACC THROTTLE 0 THROTTLE X VACC

VACC THROTTLE 0 THROTTLE X VACC

① Opening Zapi display.

③ The display will show:

④ Press ROLL UP or ROLL DOWN button until

⑤ The display shows:

⑥ Press ENTER to go into the SAVE function.

⑦ If this facility has been used before the type of

⑨ Press ENTER to commence SAVE routine.

⑩ You can see the items that are being stored

⑪ When finished, the console shows :

⑫ Press OUT to return to the opening Zapi display.

① Opening Zapi display. DUALAC2 POWER ZAPI V0.0

② Press ENTER to go into the general menu.

③ The display will show:

④ Press ROLL UP or ROLL DOWN button until

⑤ The display shows:

⑥ Press ENTER to go into the RESTORE PARAM

⑩ The display asks "ARE YOU SURE?".

⑪ You can see the items that are being stored in

① Opening Zapi display. DUALAC2 POWER ZAPI V0.0

② Press ENTER to go into the general menu.

③ The display will show:

④ Press ROLL UP or ROLL DOWN button until

⑤ The display shows:

⑥ Press ENTER to go into the ALARMS function.

⑦ The display will show the most recent alarm.

⑧ Each press of the ROLL UP button brings up

⑩ When you have finished looking at the alarms,

⑪ The display will ask "CLEAR LOGBOOK?".

⑫ Press ENTER for yes, or OUT for NO.

⑬ Press OUT to return to the opening Zapi display.

DUALAC2 POWER ZAPI V0.0

② Press ENTER to go into the general menu.

③ The display will show:

④ Press ROLL UP or ROLL DOWN button until

9$66 If “READY” appears beside LIFT, you are