DEC068-06 Tailift FBT15-18 Service Manual

Service Manual for
Tailift tricycle Forklift.

FBT 15/18/15C/18C
TAILIFT ELECTRIC FORKLFT TRUKS

TAILIFT CO., LTD.
DEC068/06 2012
Special thanks for your purchasing Tailift truck!!
TAILIFT ELECTRIC FORKLIFT TRUCKS
Please have this manual available on the truck for reference

any time.
FACTORY：NO.5, ZIHLI 1ST RD., NANKANG,

NANTOU CITY, TAIWAN (R.O.C.)
TEL：+886-49-2263800
FAX：+886-49-2258979
Edition：06
Publish date：2012-09
Pub. No.：DEC 068
Publisher：TAILIFT CO., LTD.
CONTENTS
Chapter 1 Transmission.
1-1 Disassembly-GE&DANAHER………….……...…………... 01
1-2 Disassembly-SME…………………………………………... 02
1-3 Precautions……………………………………….….……… 03
1-4 The disassembly procedure-GE&DANAHER……………… 04
1-5 The disassembly procedure-SME………………….………... 05
1-6 The critical checking points………………….……………… 07
Chapter 2 Steering system.

2-1 The rear wheel control axle-GE.……………….…………… 08
2-2 The rear wheel control axle-DANAHER& SME…………… 09
2-3 Steering cylinder.……………………...……………..……… 11
2-4 Electrical steering system-GE&DANAHER…………..……. 12
2-5 Steering column assembly-GE&DANAHER……………….. 13
2-6 Steering column assembly-SME.….………………………... 14
2-7 Power steering.…………………………...…….…………… 15
2-8 Check and adjustment….…….……………………………... 16
Chapter 3 The hydraulic system, mast and forks.

3-1 Tilt cylinder…………………….…………………………… 17
3-2 Lift cylinder…………..…….……………………………….. 18
3-3 Adjusting the clearance between the outer and inner masts… 19
3-4 Check forks and adjust…………………….………………... 20
3-5 Adjusting the cross bar of the mast.………………………… 21
Chapter 4 Electric control monitor.

4-1 Disassembly-GE….…………….………….………………... 22
4-2 The procedure to disassembly and notes-GE.………………. 23
4-3 Checks-GE….…………….…………….…………………… 24
4-4 Assembly and notes-GE….…………….……….…………... 26
4-5 USB ifak system Software Installation-DANAHER.……….. 28
4-6 Program system setting up-DANAHER….…………………. 36
4-7 Program checking and downloading-DANAHER………….. 49
4-8 Parameter process setting up-DANAHER………………….. 61
4-9 Primera Models-DANAHER……………………………….. 73
4-10 CAN Display Sunny-DANAHER…………………………. 87
4-11 Sunny Models- DANAHER……………………………….. 93
4-12 Disassembly-SME…………………………………………. 114
Chapter 5 The controller.

5-1 The controller-GE…………………………………………… 115
5-2 The components of the controller-GE………………………. 115
5-3 The procedure to disassemble and notes-GE………………... 116
5-4 Check-GE…………………………………………………… 116
5-5 Assembly and key points-GE……………………………….. 118
5-6 Assembly, adjustment and confirmation-GE………………... 119
5-7 The acceleration assembly-GE……………………………… 120
5-8 The direction switch-GE…………………………………….. 122
5-9 The contactor assembly-GE………………………………… 123
5-10 The dash display-SME……………………………….. …... 125
5-11 Charger-GE&DANAHER…………………………….…… 146
5-12 The handset-GE…………………………............................. 146
5-13 Fuse-GE&SME……………………………………………. 147
5-14 The controller-SME………………………………………... 148
5-15 The accelerator assembly-SME……………………………. 149
5-16 One yard of forms of trouble-SME………………………... 150
5-17 The battery and the plugs………………………………….. 160
Chapter 6 The routine check, maintenance and lubrication.

6-1 The routine check and maintenance………………………… 163
6-2 Advised schedule for checks and maintenance……………... 164
6-3 Instruction of the charger …………………………………… 169
6-4 Operational maintenance …………………………………… 170
6-5 Tire Pressure……….………………………………………... 171
6-6 Lubrication chart……………………………………………. 172
6-7 Lubricant table………………………………………………. 173
6-8 The maintenance standard…………….…………………….. 174
6-9 The hydraulic circuit chart…………………………………... 175
6-10 The electric system diagram-GE&DANAHER……………. 176
6-11 The electric system diagram-SME…………………………. 178
Chapter 7 Troubleshooting.
7-1 The transmission system..…………………………………… 180
7-2 The steering system..………………………………………... 180
7-3 The hydraulic system..………………………………………. 180
7-4 The chain and forks.………………………………………… 181
7-5 The brake system.……………………..…………………….. 181
7-6 The electric system.…………………………………………. 182
7-7 Wearing parts list.…………………………………………… 185
Chapter 8 ZAPI SYSTEM 186

Chapter 1 Transmission.
1-1 Disassembly-GE&DANAHER
Mast assembly
Frame
Fork
Counterweight
Front wheel
Rear wheel
Battery
The sequence to disassemble the transmission is as follows:

1. Disassemble the forks first, then the mast assembly.
2. Open the battery tank cover, disassemble the side panels, and then get out the
batteries using hooks.
3. Separate the acceleration pedal and the speed-up pulling cables, then
disassemble the acceleration pedals.
4. Disassemble the parking cable and the hydraulic braking system.
5. Take out the braking pipes and then disassemble the motor wiring.
6. Put blocks under the truck frame, and then disassemble the front and rear
wheels and the counter weights.
7. Take out the nuts fastening the front wheels and the truck frame, then move
the frame away from the front wheels.
1-2 Disassembly-SME&ZAPI
Mast assembly
Frame
Counterweight
Front wheel Battery Rear wheel
The sequence to disassemble the transmission is as follows:

1. Disassemble the forks first, then the mast assembly.
2. Open the battery tank cover, disassemble the side panels, and then get out the
batteries using hooks.
3. Separate the acceleration pedal and the speed-up pulling cables, then
disassemble the acceleration pedals.
4. Disassemble the parking cable and the hydraulic braking system.
5. Take out the braking pipes and then disassemble the motor wiring.
6. Put blocks under the truck frame, and then disassemble the front and rear
wheels and the counter weights.
7. Take out the nuts fastening the front wheels and the truck frame, then move
the frame away from the front wheels.
1-3 Precautions:
Before disassembling or assembling the transmission, please remember the
followings points:
Don’t clean any parts using gasoline, solution or any flammable material. Use
only those non-toxic, non-flammable and commercially recommended
solutions.
(1) Please maintain the transmission according to its standard maintenance
schedule. All parts need to be thoroughly cleaned before assembly.
(2) Keep the spot where you proceed maintenance clean and dust free.
(3) Please make sure that all the tools needed for the maintenance are easily
available, particularly those mentioned in this chapter. Poor parts assembly
will cause a serious damage to the transmission. So do the iron filings and
the remains of the foreign matter.
(4) To overhaul the transmission, the following parts need to be replaced: oil
seals, gasket, fixing rings and any parts, which are broken during the
disassembly.
(5) In case that there is any fracture found inside of the transmission, all the
pipes, shell and the heat exchanger need to be thoroughly cleaned, to prevent
any residuals staying in the system, which may lead to a damage.
◎ Warning
※ In heating an axle or a bearing, Please take advantage of an oven or a heating
panel. Don’t heat them physically directly. If necessary, fill a tank with
recycled oil and heat the axle or the bearing sank in the heated oil tank.
※ All axles and bearing parts need to be lubricated before assembly.
※ All parts after being heated need to be measured again when they cool down.
※ Before reassembling a new oil seals, it needs lubrication, to prevent it from
knotting together or over lubricating, which all will affect the oil seals.
※ Sealed parts, when at connecting, if necessary to block the fluids, no matter
whether it is water or oil, there will be no special gasket or oil seals for them.
※ Sealing resin has to be used. Before applying it, you have to make sure that
all the sealing surfaces be absolutely clean. After applying it, you have to get
rid of the lubricant.
The following resins are recommended: RHODORSIL CAF 1-LOCTITE

PLASTIC GASKET SILASTIC 732 RTV.
1-4 The disassembly procedure-GE&DANAHER:
1. Motor, O-ring 6. Bolts 11. A hexagonal bolt

2. Rotary gear, bearing 7. Draining oil port 12. Rotary gears, bearings
3. A shaft, O-ring 8. Transmission axle 13. An axle
4. Bearing, worm wheel 9. Helical gears 14. The front axle
5. Transmission cover, bearing 10. Gear
◎ The disassembly procedure:
1. Drain the gear oil first by opening the plug (7).
2. Take out 3 pieces of the bolt in the rear of the transmission, then take out the
motor (1) and O-ring.
3. Take out the gears (2) and the bearings.
4. Take apart 10 pieces of the bolt (6) on the transmission cover, using a
spanner. You have to rotate the cover bolt (5) to take it out.
5. Take apart the axle (8) and the helical gears (9) and the gears (10) in
sequence.
6. Pull out the shaft (3) and the O-ring using the bolts.
7. Take out the helical gears (4) and the bearings.
8. Take apart the fastening nuts (11) using the bushing of a diameter 55 mm.
9. Take apart the helical gears (12) and the bearings (13) and the front axle. In
sequence.
10. In case of re-assembly, just do it by reversing the above order.
1-5 The disassembly procedure-SME&ZAPI
1. Front tire axle 23. Roller bearing 45. Spring washer
2. Bolt 24. Snap ring 46. Friction disk
3. Needle bearing 25. Snap ring 47. Pusher disk
4. Oil seal 26. Helix gear 48. Flexible disc
5. Shim 27. Key 49. Packing
6. Roller bearing 28. C-Ring 50. Piston
7. Transmission housing 29. Ball bearing 51. Oil seal
8. Oil plug 30. Snap ring 52. Oil seal
9. Screw plug 31. Helix pinion 53. Brake housing
10. Screw plug 32. Key 54. Bolt
11. Pin 33. Transmission cover 55. Bolt
12. Needle bearing 34. Bolt 56. Plug
13. Spacer 35. Ball bearing 57. Pin
14. Spacer 36. Input shaft 58. Spring washer
15. Snap ring 37. O-Ring 59. Connecting shaft
16. Carrier gear disk 38. Gear 60. Valve
17. Bolt 39. Pin 61. Grease nipple
18. Gear 40. Sparing 62. Spring pin
19. Planet carrier 41. Snap ring 63. Pin
20. Locknut 42. Pin 64. Lever
21. Bearing 43. Reaction disk
22. Planet gear 44. Steel disk
1-6 The critical checking points.
(a) Check the transmission to be cracked or injured.
(b) Measure the gap of the splinted shaft.
※ The judging method unit: mm

Item Limit
The rotation gap in the counter direction. 0.5
◎ The way to measure:

Install a gear on the splinted shaft. Then measure the gap in the counter
direction of the rotation.
(c) Gears.
Check its contacting surfaces or its wearing whether they are still in good
condition.
◎ The way to adjust the gap.

If the big end or the small ends of the gears have signs of injury, please use a
grindstone to fix them.
※ In case that the gears and ring ones are damaged, you have to replace them
all.
(d) Cone-shaped roller bearing.

Check its outer ring and its cone roller surface, to see whether they are
damaged.
(e) Seals.
Check its lip for damage and its material for deterioration.
※ Any rubber products must be replaced after being deteriorated.
(f) O-ring
Check for injury or its material for deterioration.
Chapter 2 Steering system.
2-1 The rear wheel control axle-GE
◎ The tips to disassemble.

1. Hoist up the truck frame. Then support it with wooden blocks inserted under
both sides of the truck frame.
2. While the counter weights being hoisted, remove the bolts and the weights.
3. Remove the nuts (4) by using a spanner. Separate the inner gear set and the
steering cylinder.
4. Pull out the supporting pin (1) first, then remove the nuts with a sleeve of
diameter 45 mm. Separate the inner gear set and the rear wheel axle. Before
this, you need to insert wooden blocks underneath the rear wheel axle, to
prevent it from falling, which might damage the shaft.
5. Remove the anti-dust cover (12) with screwdriver. Generally, there is lots of
grease inside of the cover. Please don’t make them dirty.
6. Remove the nuts (10) of the diameter 45 mm. then remove the rear wheel
axle hub (8).
7. Remove the seals (6). Please take care not to hurt the body.
8. Re-assemble them in the reverse order.
2-2 The rear wheel control axle-DANAHER&SME&ZAPI

1. Hoist up the truck frame. Then support it with wooden blocks inserted under
both sides of the truck frame.
2. While the counter weights being hoisted, remove the bolts and the weights.
3. Take apart the steering sensor first and then (33) nuts. Take the fixed plate.
4. Remove the nuts (10) by using a spanner. Separate the inner gear set and the
steering cylinder.
5. Pull out the supporting pin (2) first, then remove the nuts with a sleeve of
diameter 45 mm. Separate the inner gear set and the rear wheel axle.
6. Before this, you need to insert wooden blocks underneath the rear wheel axle,
to prevent it from falling, which might damage the shaft.
7. Remove the anti-dust cover (21) with screwdriver. Generally, there is lots of
grease inside of the cover. Please don’t make them dirty.
8. Remove the nuts (3) of the diameter 45 mm. then remove the rear wheel axle
hub (18).
9. Remove the seals (16). Please take care not to hurt the body.
Special attention to:
1. When installing the chain retainer (4) and the bearing, please observe the
parallel between them is ±0.50.
2. When fastening the cap nuts (3), please be sure to secure them tightly. After
securing, please make sure that the rear wheel axle retainer can also rotate.
OLD
Adjust the chain tension by turning the nut

and checking it with a finger pressing NEW
against it. The tension of the both sides of
the chain has to be equal.
2-3 Steering cylinder

1. Remove the c-clip (15) first. Then loosen the bolts with a M6 spanner and
separate the left side and the right-side chain retainers (13)(14).
2. Remove the bolts, four of them, with a sleeve of the diameter 16 mm, then
remove the cylinder.
3. Have C-clips (12), spring clips (11), anti-dust seals (8), self-lubricating axle
bushing (7) and the axle cover (6), back up ring (5), seals (4), back up ring
(3), O-rings (2), in sequence.
4. Re-assemble them in the reverse order.
2-4 Electrical steering system-GE&DANAHER A

It is composed by four micro switches and one block
valve, which are driven by the cylinder turning axle.
The four micro switches control the turning,
clockwise and counter clockwise, and the stop of the front wheels, which in
return control the traction of the truck.
The micro switches and the block valve work this
way: B
(1) When the rear wheel is parallel with the
forwarding direction, the block valve doesn’t force
any micro switch, so the truck keeps going straight.
(Fig. A)
(2) When the rear wheel turns 45 degree positive, the
block valve moves leftwards and forces the first
left-side micro switch, so that the front left wheel
stops turning while the front right one still keeps C
turning, like fig. B.
(3) When the rear wheel turns 90 degree, the block
valve moves leftwards and forces the left first and
second micro switches, so that the front left wheel
turns counter clockwise, while the front right one
still keeps turning clockwise. This causes a turning
of a big angle. Like fig. C.
(4) When the rear wheels turn 45 degrees counter D
clockwise, the block valve moves rightwards and
forces the right first micro switch, so that it makes
the front right wheel stops turning while the front
left one still keeps turning clockwise, which
makes the truck to turn right, like fig. D.
(5) When the rear wheel turns 90 degree counter
clock wise, the block valve moves rightwards and E
forces the right first and second micro switch to
turn on, so that the front right wheel turns counter
clockwise while the front left one still keeps
turning clockwise, so that it makes a turning of a
big angel. As shown in fig. E.
2-5 Steering column
assembly-GE&DANAHER (Fig.1)
(1) Remove wiring from the operation box and the buzzer.
(2) Remove the high-pressure tubes from the control cylinder and the control
valve, and then block the inlet of the valve.
(3) Remove two nuts (M12X4) and then the control valve.
(4) Remove the fastening bolt (M10X4) using a spanner, and then remove the
steering column from the chases. Please be careful for the column weight is
quite heavy. Don’t have it damaged.
(5) Remove the assembly bolts.
T h e s te e r in
c o lu m n s e t
A u n iv e rsa
jo in t
Fig. 2
◎ The universal joint (Fig. 2)

(1) Remove the assembly bolts and the check ring.
(2) Use a rubber hammer to break the connection between the universal joint
and the column. Please be careful of the thread direction.
(3) Remove the connection between the universal joint and the power control
valve.
2-6 Steering column assembly-SME&ZAPI (Fig.1)
(1) Remove the high-pressure tubes from the control cylinder and the control
valve, and then block the inlet of the valve.
(2) Remove two nuts (1)(M12X2) and then the control valve. Don’t have it
damaged.
◎ The universal joint. (Fig.2)

(1) Remove the assembly bolts (2)(M10X2) and then take apart the direction
block kit from the forklift.
(2) Remove the universal joint bolts.
(3) Use a rubber hammer to break the connection between the universal joint
and the column. Please be careful of the thread direction.
(4) Remove the connection between the universal joint and the power control
valve.
2-7 Power steering
1.Seal, dual ring. 6.Spring, centering. 11.Gerotor.

2.Bearing, needle thrust. 7.Sleeve, centering. 12.Cap end.
3.Screw, set. 8.Guide, control. 13.Screw, cap.
4.Check ball. 9.Spacer.
5.Housing. 10.Drive.
The following tool isn’t necessary for disassembly and reassembly, but is
extremely helpful.
# Screwdriver (4”-6”, 1/8” flat blade) # Plastic hammer
# Torque wrench (275 lb/in capacity) # 1/4” hex key
# Needle nose pliers
2-8 Check and adjustment
1. Power cylinder.
(1) Check the surface of the piston, to see whether it is uneven, has a friction, or
deformed.
(2) If the pressure cylinder leaks, please check the seal, O-ring. Please be careful
not to damage the O-ring.
(3) Please check the high-pressure tubes, to see whether they are worn out,
scratched. If not further useable, replace them.
2. The steering power.

(1) Pull up the hand brakes. Start the engine to warm up to 40-60 Celsius degree.
(2) Hook a spring scale to the steering wheel. Turn it and read the index. The
reading should not be over 2.5kg-m.
Chapter 3 The hydraulic system, masts and forks.
3-1 Tilt cylinder
※ Disassemble tilt cylinder:

1. Bushing, Connector.
2. Piston rod, O-ring, Oil seal, back up ring, Bearing, Cylinder cover, Dust seal,
O-ring.
3. Back up ring, O-ring, Piston, Oil seal, Nut.
4. Tilt cylinder body, Bushing.
※ The tips to disassembly
◎ To remove the bushing
1. Wrap the cylinder with rag and clamp it securely on a vice, remove the
rushing from the tilt cylinder with a spanner.
2. When the bushing is being removed from the piston rod, please be careful to
prevent the piston rod thread from scratching the shock absorber and the
lining.
Tilt cylinder connector, left and right,
is of a dual active type. There is a
retainer on the piston rod, which can
rotate to position correctly. When the
cylinder is connected to the outer
mast, the retainer will do this (rotate
to new position), whereby the two
cylinders will move simultaneously
with the rails and also the tilt angle
will increase or decrease due to the
cylinder retainer and the axle ring.
3-2 Lift cylinder
◎ Lift cylinder:
1. Lift cylinder body.
2. Dust seal, Cylinder cover, Oil seal, Bearing, Bushing.
3. Lift cylinder rod, Bushing, Back up ring, Oil seal.
4. Decompress valve, O-ring.
※ The movement of both right and left cylinders is parallel. There is a pass-by
connecting oil hose, which allows the oil pressure goes through. With this
feature, the cylinder wall can be protected against rust.
※ Draw the piston rod slowly from the housing. Be careful not to damage the
seal parts on the piston.
3-3 Adjusting the clearance between the outer and inner masts
(1) Measure the gap between the
mail rollers of both right and left
inner masts. Then adjust it to the
standard value.
(2) Measure the gap between the The mast.

mail rollers of both right and left (1) Grease the inner grove of the mast.
inner masts. Then adjust it to the (2) Install the mast support bearing and
standard value. the cover, letting its wide faces align
to the truck frame center
respectively. Insert blocks under the
frame to make greasing easier.
Adjusting the clearance between the Note: Don’t install the center plate as a
two carriages. connector plate.
Install the main rollers and side
rollers.
1.Marked connector plate.

2.The center plate.
3.The connector.
4.Cotter pin.
To the left carriage, measure its size
of C, D and E.
3-4 Check forks and adjust
Forks. (2) Check each roller for uneven.
Check for deformation, crack or (3) Check the mast component, pin and
offset between the two forks. support for cracks.
(4) Check the support bearing for
wearing or any other defects. Check
other chains and wheels the same
way.
(1) Measure each chain length, to make
sure that they are equal long. And
check for wearing or cracks, snap or
The carriage. twisting.
(1) Check the main and side rollers (2) Check each anchor bolts for cracks,
for running smoothly, check the thread for injury.
each roller for wear and crack. (3) Check chain wheel support and
Replace them if necessary. chain wheel for cracks or wearing.
(2) Check the welding of the Make sure the chain wheel can run
support for cracks. freely.
(3) Check the cross bar for The cross bars of the mast.
deformation. (1) Check them for damage, stuck or
any deformation.
Adjusting the chain tension.
(2) Place the truck on a flat stage, with
forks resting on the floor, examine to
see whether the lift cylinder retracts
fully.
(3) Make sure the anchoring bolts
fastened securely on the support
frame.
The mast. (4) Adjust the tension of the chains to
(1) Check each roller for wearing, within 20 mm deep when pressed by
snap or any other defects. a thumb.
While examining the chain tension, be

sure to keep the mast upright.
3-5 Adjusting the cross bar of the mast
(1) Tilt mast forwards, Check the gap L.
(2) If the gap value is over the standard one, please use shim to adjust.
(3) After adjustment, operate the mast to make sure that they can move along
the stroke freely.
Chapter 4 Electric control monitor.
4-1 Disassembly-GE
1. The traction motor.
※ Please block the front wheel first before
disassembly.
(1) Remove the acceleration pedal.
(2) Remove the brake pedal.
(3) Remove the motor wiring.
※ Mark down the connection places.
(4) Hang up the motor and remove the
assembly bolts.
(5) Remove the connecting part between the
motor and the front wheel axle.
2. Steering hydraulic motor.

(1) Remove the right body cover.
(2) Remove the motor wiring.
(3) Remove the oil pressure hose from the
hydraulic pump.
(4) Remove the assembly bolts of the motor.
Remove the motor.
(5) Remove the hydraulic pump.
3. The hydraulic motor of the forks.

(1) Lift the seat and remove the weight.
(2) Remove the motor wiring. Mark down the
correspondent position.
(3) Remove the high-pressure oil hose on the
hydraulic pump.
(4) Hang up the motor; remove the fastening
bolts to the motor.
(5) Move the motor to the outside of the truck.
4-2 The procedure to disassembly and notes-GE
1. The procedure.
(1) Remove the protection band.
(2) Remove the wiring terminals on the carbon brush seat.
(3) Remove the carbon brush from the seat.
(4) Remove the cover.
(5) Remove the brush seat.
(6) Remove the front cover.
(7) Remove the armature.
(8) Remove the wiring on the field.
※ Please make sure of the connection relation.
Don’t damage the plug.
(9) Remove the filed wiring.
1 motor body 15 bearing 31 bolts and wirings

2 rear cover 22 filed core 32 bolts and wirings
3 front cover 23 field wiring 35 pump
4 brush seat 24 terminals 36 linking device
5 brush 25 bolts 37 bolts
6 spring 26 bolts and washers
7 clamp 27 bolts and washers
8 rear plate 28 bolts
9 protection band 29 bolts
11armature 30 bolts and wirings
13 wave gasket
14 bearing
4-3 Checks-GE
1. The armature
(1) Check the surface of the commutator for injury.
◎ The way to fix.
a) Grind the commutator surface.
※ Make sure that the core of the commutator has to be at outside of the
commutator.
b) After grinding, proceed cutting grove fur her.
c) After grove cutting, grind to refine with sand paper (#400). Clean it with
compressed air.
(2) Insulation test.

※ Before test, please clean it with compressed air.
The test way to use an Ammeter.
a) Turn the ammeter switch to kΩ scale.
b) If the ammeter (-)(+) probe point to show it has a
short, turn the ammeter switch to 0Ω scale.
c) (+) Probe contacts the commutator.
(-) Probe rests on the armature axle.
※ The insulation resistance value∞ (1×Ω range).
◎ The way to diagnose with a number ammeter.
(+) Side lays on the armature.
(-) Side supports the armature.
(3) The armature axle.

Check the splinted shaft, the serrate teeth axle and the linking axle for wearing
and deformation.
Replace if they are seriously worn out or deformed.
2. The carbon brush, the brush seat and the spring.

(1) The measuring of the brush wearing.
※ The criteria.
The standard for use limit, with mark Line.
(2) Check the contacting surface of the brush for
normal. If bad, fix it.
◎ The way to fix.
a) Insert a sand paper (#400) into the commutator
and the carbon, with the side of sand facing
sideway.
b) Pull the sand paper both sides and rotates the
commutator.
c) After fixing, clean it with the compressed air.
(3) To set the tension of the spring.
◎ The way to measure the tension.
Hook a spring scale to a spring and pull the scale to the arrow direction shown.
※ In case that the spring or the carbon brush get rusty, please replace them.
3. The field.
(1) Insulation test.
◎ the insulation tests on the armature.
4-4 Assembly and notes-GE:
1. The field coil assembly and the insulation test.
(1) The assembly of the field coil and magnetic pole core.
※ After fastening, please confirm that the field coil won’t vibrate in any
direction. If it does, please fix it.
◎ The way to fix.

a) Disassemble the magnetic pole core and the field coil.
b) Prepare an insulation paper.
c) Insert the insulation paper into between the magnetic pole core and the field
coil.
(2) The insulation test.

The value of the insulation resistance reads above 0.5kΩ (DC 500V ammeter).
◎ The way to measure.

a) Have the negative handle of the ammeter contact the frame of the motor and
the probe hand (positive) tests each field coil in sequence.
(3) Have the terminal of the field coil link to the wiring.
Confirm that there is a gap between the fastening bolt and the motor frame.
2. The assembly of the carbon brush.

After replacing the carbon brush, the brush has to be out of seat.
3. The assembly of the terminals.

Please fasten to the required torque when linking the wiring to the terminals.
4. To check the motor.

(1) Check for noise, the contacting surface for being good.
◎ The way to test.

a) The motor has to be secured.
b) Have the motor contact the voltage, about half of the battery one.
※ If the motor is used for the steering and the hydraulic purpose, please make
sure again of the polarity.
c) Confirm that the motor yields no noise and check the carbon brush for
causing no spark.
(2) The insulation test on the motor.

◎ The way to test.
a) Have the negative hand contact the assembly bolt while the positive probe
hand contact the wiring.
※ During measuring. Keep hands off from the wiring terminal.

4-5 USB ifak system Software Installation-DANAHER
4-6 Program system setting up-DANAHER
4-7 Program checking and downloading-DANAHER
4-8 Parameter process setting up-DANAHER
4-9 Primera Models-DANAHER
4-9-1 Primera OBD.
4-9-2 Primera Error handling.
4-9-3 Prim era circuit drawing.
4-10 CAN Display Sunny-DANAHER
4-11 Sunny Models- DANAHER
4-11-1 Sunny OBD.
4-11-2 Sunny Error handing.
4-11-3 Sunny circuit drawing.
Reference
Tabe 1：
Truck type SDO program
3W AC&DC VMC20_Primera-3wacdc
3W AC VMC20_Sunny-3wac
Tabe 2：
Truck type Component code Program Quantity
1. VMC-20 69U03514C12
Primera 3. OPT-10
4
3W AC&DC 6. ACS-LEFT 69Y05171C01
8. ACS-RIGHT 69Y05171C01
1. VMC-20 69U03526C03
3. OPT-10
Sunny
6. ACS-LEFT 69Y05171C03 5
3W AC
7. ACS-PUMP 69Y05171C03
8. ACS-RIGHT 69Y05171C03
4-12 Disassembly-SME&ZAPI
1. Traction motor.
(1) Take apart mounting bolts (8). After
picking up the fixed cover, hang up the
mast.
(2) Lift the pedal mat, take apart
mounting bolts (13) and pick up the
front and rear pedal mat.
(3) Take apart mounting bolts (5) and
then take out the traction motor and
hung up.
2. Lift motor.
(1) Lift the pedal mat, take apart
mounting bolts (13) and pick up the
front and rear pedal mat.
(2) Take apart mounting bolts (4) and
then another mounting bolts (9),
hydraulic pump and inlet outlet oil
pipe connectors (7)(8).
(3) Take apart wire harness and nuts
of motor.
(4) Lift up the motor.
(5) Lift out the motor from car body.
Chapter 5 The Controller.

5-1 The controller-GE
1. Disassembly.
(1) Disassemble the left cover of the truck frame.
(2) Remove the controller wiring.
※ Please mark down the detailed wiring locations.
(3) Remove the assembly bolts of the controller base.
※ Please remember to unplug the battery before removing the assembly bolts.
Then discharge the battery fully.
5-2 The components of the controller-GE
5-3 The procedure to

disassemble and
notes-GE
(1) Disassembly of the SCR, diode and radiator.
a) Undo the wiring of both negative and positive pole of the SCR and the Diode.
b) Unscrew the bolts of the radiator and then the radiator from the base.
c) Remove the SCR and the diode from the radiator.
※1 Please be careful not to harm the insulation gasket and tubes.
※2 No stricken traces on the contacting surface between the radiator and the
base is allowed.
(2) Remove the capacitor.

a) Discharge the capacitor first.
b) Remove the fixing plate of the capacitor, then the capacitor.
5-4 Check-GE
(1) SCR and the diode.
a) Check the SCR.
◎ The way to check.

a1) Turn the ammeter switch to the resistance scale x 1.
a2) If the probe hand shows short circuit, turn the ammeter switch to 0Ω.
a3) Test SCR with the probe hand.
Check SCR
No. + - Resistance (Ω)
※ While SCR is still linked to the truck, 1 A K ∞
please be sure to unplug the wiring from the 2 K A ∞
battery before checking, removing the
negative and positive pole wiring. 3 A G ∞
** 4 G A ∞
5 G K 30~200Ω
6 K G 30~200Ω
b) Check the diode. Check the diode

◎ Please refer the diagnose method to the No. + - Resistance (Ω)
right table. 1 A K 10~100Ω
2 K A ∞
(But * > **)
※ The values depend on the kind
of the ammeters.
(2) The capacitor.

a) Checking the capacitor.
Discharge it first for safety reason.
b) Turn the ammeter switch to the position of the
resistance scale ×1.
c) Have testing probe sticks contact the both
terminals of the capacitor for 1-2 seconds.
The index hand will read at kΩ. After 1-2 seconds,
it will move from 1MΩ to ∞.
d) Switch the terminals; same as above, have the probe sticks stay they’re for
2-3 seconds. The ammeter index hand will read ”0”.
After 1-2 seconds, it moves from 1MΩ to ∞.
5-5 Assembly and key points-GE

SCR, diode and radiator.
(1) Tighten SCR and diode to required torque.
※ Between the radiator and the insulation spacer,
the insulation spacer and the seat base, No dust
like power is allowed. Please apply silicon to the
joint surface between the radiator and base seat
and on the screw side of all the components.
Then tighten them securely.
(2) Tighten the radiator to the required torque.
(3) Proceed the insulation test after assembly.
◎ The way to test (The insulation of the radiator)
Set the test instrument for the test at ×1kΩ.
Place (+) test probe on the radiator and (-) test probe on the base seat.
※ Criteria (Unit: Ω)
Resistance ∞
(4) Confirmation after assembly

a) Check each wiring terminals and each
component’s terminals for not loose and
tightened.
b) The insulation test on the SCR.
※ The way to test.
Set the test instrument for test at ×100Ω.
Place the (+) test probe on the contacting terminal or any electrical component.
And place the (-) test probe on the base seat.
※ If the reading of the resistance is above 10kΩ.
(5) Assemble, adjust and confirm.
a) Assemble the controller onto the chassis.
Please remember to plug in each wiring terminals. Don’t make any mistake.
Plugging should be secured and tightened.
b) Adjusting and confirming the control circuit.
5-6 Assembly, adjustment and confirmation-GE

Adjusting the current limit. (CL)…. This circuit monitors motor current by
utilizing a sensor in series with the armature. The information detected across
the sensor is fed back to the card so current may be limited to the pre-set value.
Adjustment of reversing phase to function as brake (PLUG)…Adjust the

reversing field strength by using an adjustable resistor.
AC/TIME… it is adjusted to determine the acceleration speed.
(1) The adjustment of the current limit and confirmation. To test the current,
please use a D.C. ammeter. And set the gravity of the electrolyte at above 1.25.
In addition, it needs to be under all normal conditions and the controller can
work well, the test can be proceeded then.
a) Place the ammeter onto the device.

b) Confirm and adjust.
b1) Prepare a 500A D.C. ammeter.
b2) Place forks against a wall and make them not moveable, with handbrake
pulled up.
b3) Change the direction switch, step down the brake pedal and step down the
acceleration pedal to the maximal.
b4) Read now the maximal value of the ammeter.
※ The test time needs to be within 3 seconds. If the reading is not in

compliance with 350A, please adjust again in the following sequence.
◎ The way to adjust.

Adjust the value of the CL (VR1) on the printed circuit board with a screwdriver
to the required range. To increase, turn clockwise. In case the value difference is
over 15A, please check and adjust the assembly angel of the accelerator
plywood.
(2) Adjusting the plugging.

The distance standard of the plugging is under no load condition, the truck
moves forwards with full speed and can reverse, without any impact, the
traction direction in 3.5 to 4.5 meters.
◎ The way to adjust.
Adjust the plugging current resistor (VR2) on the printed
circuit electrical board.
To increase the plugging effect, turn VR2 clockwise.
For safety reason, please make sure at the beginning with the
lowest speed that there is no rush impact.
(3) Confirming the action of the control circuit.

a) With mast tilt back and blocks placed between the mast
and the floor, let the mast tilt forwards and the front wheel
float above the floor.
※ Install a safety guard on the front wheel.

b) Operate the switch to move the truck back- and forwards. Step on the
acceleration switch to see whether the acceleration is good and confirm that the
controller can work normally.
5-7 The acceleration assembly-GE
1. Disassembly.
a) Disassemble the flat plate.
b) Unplug the wiring to the accelerator.
c) Remove the assembly screws on the
accelerator and the accelerator.
※ Before replacing the printed circuit board, be
sure to unplug the wiring from the battery. If
replace it with wiring to the battery, once the
printed circuit board shorts, it will burn up or
can not work normally.
※ After replacing the printed circuit board, please make sure that it doesn’t
contact the open gap plate.
d) Disassemble the acceleration push rod.
d1) Remove the spring.
d2) Remove the cotter pin, gasket and the pedal-linking rod.
d3) Remove the roller.
2. The sequence to disassemble and notes:

(1) Disassemble the micro switch.
a) Remove the switch cover, unplug the micro switch wiring.
b) Remove the fixing bolts under the condition that the micro switch is still
open.
(2) Remove the printed circuit board and the open gap plate.
a) Remove the acceleration case lid.
b) Withdraw the printed circuit board.
c) Loosen the fastening bolts and removes the axle end.
d) Disassemble the acceleration bracket.
e) Loosen the fastening bolts and remove the open gap plate.
f) Pull out the cam.
3. Check.
(1) The cam.
a) Check it for wearing.
b) Check it for slanted wearing.
(2) Spring.
Check it for deformation or cracks.
(3) The open gap plate.
Check it for damage or loosened rivets.
(4) The printed circuit board.
Check the copper coat for peeling off or getting rusty. If it appears peeled or
rusty, replace it.
4. Assembly and notes:
(1) Grease the cam and the bush springs during the assembly.
(2) Assembly of the open gap plate and the printed circuit board.
a) Align the centerlines of the open gap plate and the acceleration case.
b) Apply a fixing paint after securing the fastening bolts.
※1 After securing, turn the cam smoothly and make sure there is no gap
between the acceleration case and the cam.
※2 After installing the printed circuit board, be sure that the open gap plate can
turn back smoothly.
※3 In case that it can’t turn back smoothly, the cause is the open gap plate and
the printed circuit board is not parallel. Please correct the open gap plate not to
slant.
※4 Turn the cam till it touches the thrust screws. Make sure that the open gap
plate won’t touch the acceleration case.
(3) Assembly of the micro switch.
◎ The adjustment of the micro switch.
a) Turn the cam after the micro switch is assembled.
b) Turn the position of the micro switch bracket, to make the micro switch move
freely. (No idle situation during movement)
c) Move again the bracket position of the micro switch, to make the play have
0.3~0.5mm gap, and then secure it squarely.
d) After adjustment, apply a fixing paint on the screws.
(4) Assembly of the acceleration push rod.
a) Install the roller onto the acceleration arm.
b) Install the acceleration arm to the acceleration bracket.
c) Install the spring.
(5) Adjustment of the acceleration push rod.
◎ Tips to adjust.
(I) Adjust the length of the thrust screw, to make the truck move with full speed
when the acceleration pedal is pressed down before it touches the thrust screw.
(Ⅱ) To ensure the full speed traction during the adjustment, a shim of about 1
mm is suggested to insert into between the pedal and the thrust screw, to make
sure of the gap.
5-8 The direction switch-GE

1. Disassembly.
a) Remove the wiring of the direction
switch.
※ Cut the wiring band.
b) Remove the retainer and the direction
switch.
※ Please write down the assembly place
of the direction switch.
2. The sequence to disassembly and noted:

a) Un-install the direction rod.
b) Remove the switch case.
c) Remove the wiring clip and the retainer while the micro switch is still in
assembled situation.
d) Remove the micro switch.
e) Remove the screws first, then the cam.
f) Remove the revolving axle, the steel ball and the spring.
3. Assembly and notes:

(1) The assembly of the spring and the steel ball. Grease first then assemble.
(2) The assembly of the micro switch.
◎ The adjustment of the micro switch.
a) Finish the assembly of the micro switch, turn the cam forwards or backwards.
b) Move the bracket position of the micro switch till it can move freely. (till that
play has no gap.)
c) Adjust the play to be within 0.3~0.5mm from the totally free one. Then
secure the bracket position.
d) Apply fixing paint after securing the screws.
5-9 The contactor assembly-GE

1. Remove the assembly.
(1) Remove traction contactors.
a) Open the left side cover.
b) Open the contactor guard.
c) Remove the wiring and plug connecting the
contactor to the main circuit.
d) Remove the assembly screws on the contactor
bracket, then the contactor assembly.
(d1) forward contactor.
(d2) backward contactor.
(d3) by-pass contactor.
(2) Remove the hydraulic contactor.
(a) Remove the left side frame cover.
(b) Remove the wiring and plug connecting the
contactor and the main circuit.
(c) Remove the contactor guard and the contactor assembly.
2. The disassembly of the contactor.

(1) The disassembly of the traction contactor.
a) Remove the contacting rod and linking rod.
b) Remove the round-headed assembly screws, then the contactor.
c) Remove the wiring to the auxiliary circuit. Please pay attention to the wiring
terminals, not to damage them.
(2) The un-install of the hydraulic contactor.
a) Remove the assembly screws of the contactor, then the contactor from the
bracket.
b) Remove the auxiliary circuit wiring. Please be careful not damage the wiring
terminals.
3. Check up.
(1) The contact point.
Check if for wearing and injury.
※ 1 While the contactor is still mounted on the
truck, you have to unplug the wiring to the battery
when fixing or replacing the contact points.
※2 Please grind it with a fine file or sand paper of
#400, when correction needed.
(2) The remover.
Check for injury.
※ In case it is injured, big current flows through the contactors’ contacting
points, it makes the contacting points rugged for it causes arching during cutting
down.
(3) The field coil.
Check the securing part for loosening. If loosened, tighten the screws squarely.
4. The assembly and notes:

(1) The spacing of the contacting point’s surface.
The contacting point’s contacting surface cannot allow a deviation of above 1
mm during assembly.
The contact intervals of the contactor (unit:mm)

Item Intervals
Traction contactor 5.5~6.5
Hydraulic contactor 7.0~8.5
(2) The measuring and adjustment of the

contactor’s attracting voltage and the breaking
voltage.
※ The criteria of the attracting and breaking voltage value (the coil temperature
at 20∘C).
Attracting, breaking voltage Unit: V

Item Attracting Breaking
Traction contactor 24~32 4~15
Hydraulic contactor 26~32 4~14
Steering contactor 26.5 2.0
◎ The way to measure.

a) The attracting voltage
a1) Connect the field coil with two wires of the dial. 1.25mm2.
a2) Change the battery voltage. Read out the contacting point’s the status of
loosening by trio meter or a voltmeter.
b) The breaking voltage.
b1) Press the armature band with hand to joint the contacting points.
b2) Apply a voltage close to the breaking one to the field coil and confirm the
breaking voltage.
(3) Confirm the connection and securing of the wiring to be tight and not loose
at all.
※ In the condition of poor securing, it will cause breakdown due to the poor
contact.
5-10 The dash display- SME

1. The disassembly.
a) Remove the assembly screws of the dash display.
b) Remove the connecting plugs and the dash display.
c) Remove the wires connecting to each component.
d) Remove the locknuts, every component, and the attracting voltage.
b) The breaking voltage
b1) Press against the armature with hand, joint the contacting points together.
b2) Apply a voltage close to the breaking voltage to the field coils and confirm
the breaking voltage.
b3) Make sure of the connection and securing of all wiring. If truck not used,
unplug the battery connection.
2. All information given by the display
Figure 1：SME Panel
2.1 Display Segments：
Panel shows the information of current status of system. Below are the main
function：
Forklift traveling speed（expressed in km/h or mph）.
Handbrake active, indicated by the warning symbol.
Safety contact open, indicated both by EE blinking message visualized in time

meter area and by relative symbol.
With any directional switch active and safety contact still open, lift truck can’t
be moved, even after seat switch is closed; in such a case, after safety contact is
closed, the symbol disappears. EE code disappears
only after active directional switch is turned off.
Time meter or, otherwise, odometer or weight present on the forks,
expressed in kg.
Steering angle
Maintenance time expiry, indicated by warning symbol.
Slow speed operation, indicated by
Lift truck speed level, range from 0（NO speed）to 9（MAXIMUM

speed）segment, as in symbol.
Battery level, indicated by a 9 segments symbol.

Display signals with alarm code 12 the fact battery is completely discharged.
Over temperature alarm, indicated by the warning light.
※ In following Table 1, you can read the relation between battery charge level
and number of visualized bars; refer to table second column in case of a
charge level indicated by percentage, to third column in case of a 36V
system , to fourth in case of a 48V system and to fifth column in case of an
80V system.
Table 1 Relation between battery charge level and number of
Visualized bars.
Forklift Energy Mode

Pressing E-S-H button, you can set energetic operating mode for your
system. The function is enabled using EYE software menu named
Calibration – ESH to select desired operating mode. In particular you can
choose between E-S-H or PROGRAMMABLE WORKING.
＊ Pressing E-S-H (economic, standard, high) button, you change energetic

mode and update related parameters with a value, corresponding to selected
operating mode, that operator can’t modify.
★ Notice: This function can be enabled also via display, using calibration
parameter 97.
★ Notice: Percent values can be modified only with EYE Calibration－

E-S-H menu.
★ Notice: Pressing PROGRAMMABLE WORKING you can manage

economic, standard or high operating mode too.
★Notice: COMPACT display shows different symbols in function of

selected energetic mode:
E-S-H management disabled: no symbol visualized.
E-S-H management enabled: active mode is indicated by symbol
★ Notice: as usual, if lift truck is moving, symbol

indicates speed level.
※ Alarm message, indicated by an alpha-numerical code in the display area

where usually lift truck speed appears. See Table 2 for the meaning of
alarm codes.
Table2 Meaning of alarm codes

ALARM ALARM DESCRIPTION ALARM ALARM DESCRIPTION
CODE CODE
1 Maximum battery voltage 25 Left drive module
Desat/overcurrent
2 Minimum battery voltage 36 12V voltage is exported and
warned
3 Pedal trimmer fault 37 The encoder 5V voltage
warning
5 EEPROM alarm 38 12V voltage is exported and
warned
6 Capacitors not charged 50 Pump input on at the start
8 Right drive module Desat/overcurrent 63 Seat switch
9 Capacitor not charged: fast fast 64 Wrong start
10 Pump module overtemperature 74 Right drive motor encoder
11 Trans. Precharge in short / Capacitor 75 Left drive motor encoder
too charged at start
12 Low battery alarm 77 Wrong right drive motor
thermal probe
13 Right drive motor overtemperature 78 Wrong left drive motor thermal
probe
14 Pump motor overtemperature 79 Wrong pump motor thermal
probe
15 Right drive motor current offse 80 Wrong right drive motor
module thermal probe
16 Left drive motor loss current 81 Wrong left drive motor module
thermal probe
17 Main breaker fault 82 Wrong pump module thermal
probe
18 Watchdog timer alarm 83 CRC fault
19 Left drive motor over temperature 84 Bank CRC restored
20 Right drive module overtemperature 91 Steering sensor alarm
21 Bunches of communication warning 98 Capacitor not charged: slow
charge
22 Left drive motor module over 99 Capacitor not charged: time out
temperature
24 Pump module Desat/overcurrent
Hour meter separation point, usually blinking, stops in following cases:

- Seat switch open.
- Serial communication between display and control unit not active
- Main breaker open
Some alphanumeric codes, are visible for 3 seconds, when you turn your
lift truck on. They appear where usually is visualized speed indicator symbol;
those codes help operator to identify system in use. Where usually is visualized
hour meter, on left side appears battery voltage in V DC, and on right side,
maximum weight industrial truck can lift, expressed in quintals.
2.2 LED INDICATORS: description

On left side, COMPACT display has four LED indicators which, when
switched on, give information as follows:
Alarm message; red colour LED.

Message of lamps; green colour LED.
Indicator lights activated; green colour LED.
Low oil level of the brakes; red colour LED.
★ Notice: Alarm LED is managed as follows:

- Display normally working: LED lights up briefly switching on /off your
System.
- Display not communicating with control board: after 3 seconds from the
moment in which the communication stops, alarm LED brightens.
- Display board microprocessor not working: alarm LED brightens.
3. DISPLAY KEYS UTILIZATION

As you can see in Fig.1, on right side of display front there are four keys: E-S-H,
UP (TURTLE), DOWN and ENTER. The function of each of them is
described as follows:
ENTER key
◎ When you switch your device on, this key, pressed for 3 consecutive
seconds, allows entering both to parameter calibration and to diagnostic
mode.
◎ During usual operations, this key, pressed for 3 consecutive s, allows
you to access merely to diagnostic mode.
Remember that if the display is operating in diagnostic mode during typical
operations, you can exit this procedure pressing once ENTER key. Moreover,
ENTER key is used to confirm the new value of the parameter in calibration
procedure.
UP key
◎ Pressing of this key, in calibration and diagnostic mode, you increase
the number of the parameter displayed.
◎ In calibration phase, you increase the numeric value of the parameter
displayed.
TURTLE key
◎ Remember that pressing this key you can toggle between slow running
and normal working condition (if the lift truck is already in speed
limitation mode).
DOWN key
◎ Pressing of this key, in calibration and diagnostic mode, you decrease the
number of the parameter displayed.
◎ In calibration phase, you decrease the numeric value of the parameter
displayed.
◎ Pressing this key (for1 second), you can visualize time meter or, otherwise,
odometer or, in case of calibrated lift sensor, weight present on the forks .
E-S-H key
◎With this key, you can modify the device operating condition, in a
circular sequence, as described in Table 3.
CURRENT WORKING WORKING CONDITION AFTER

CONDITION THE KEY PRESSURE
Economic (E) Standard (S)
Standard (S) High (H)
High (H) Economic (E)
Table 3
◎ In calibration phase, you can use this key to adjust initial variation (see
Table 4 ) relative to displayed parameter.
★ Notice: You can modify system operating modes only after enabling their
management with EYE applicative software or with display using
calibration parameter 97 (in such a case you can select only
among economic, standard or high mode);
★ Notice: Pressing this key when you are in diagnostic mode, you can see a
circular list of 10 latest alarms.
4. PROGRAMMABLE PARAMETER
This chapter describes the way to adjust the main operating parameters of the
system. You inhibit the access to this menu with EYE submenu named “Lift
truck setup”.
◎ ADJUSTABLE PARAMETERS: calibration procedure
To calibrate your parameters, read following instructions:
Only after this procedure, it’s possible to modify parameters value.

See Table 4 for the list of all adjustable parameters and relative initial available
variations.
To enter calibration mode:

1. Switching on your system and pressing ENTER key (for 3 seconds)
appears a numeric code identifying control unit software release.
2. Press UP key: the entry to the chosen calibration mode is indicated by “C”;
this symbol persists until the first parameter will be selected.
★Notice: If calibration procedure is not enabled using EYE “Lift truck setup”
menu, UP key pressure has no effect.
★ Notice: You can exit this operating mode only switching off your system.
To execute the calibration:

1. Slect parameter 10 using UP and DOWN keys, and confirm your choice
pressing ENTER key.
2. Use UP and DOWN keys to set at 4 the value of this parameter, and confirm
with ENTER key.
3. Repeat the above operations to fix parameter 17 value at 6
★Notice: it doesn’t matter if you first modify parameter 10 and then 17,
or vice versa.
To change the value of other parameters:
1. Select the parameter to change, using UP or DOWN key; press ENTER to
confirm.
2. Now adjust the value of the selected parameter with UP and DOWN keys;
confirm your choice typing ENTER key.
★ Notice: The parameter number appears on the display area usually reserved
to lift truck speed and alarm codes, and its value is shown in the
time-meter area. Moreover, appear a number of segments
proportional to the parameter value.
★ Notice: If you see that the numeric data have been modified in the time
meter area, it means that the value of the chosen parameter has
really been updated into control board memory.
★ Notice: Once entered in calibration mode, pressing E-S-H key, you can
adjust initial variation relative to each parameter of Table 4.
◎CALIBRATION PARAMETER: describe

Table 4: CALIBRATION PARAMETER TABLE
PARAMETER PARAMETER INITIAL
PARAMETER DESCRIPTION
ORDER NUMBER VARIATIO
1 5 Deceleration steering ramp 1 [rpm / s] 100
2 6 Deceleration steering ramp 2 [rpm / s] 1
3 9 Battery reset value [V·10] 1
4 10 First parameter for calibration enable 1
5 11 Seat switch delay [s] 1
6 12 Chat time [s] 1
7 13 Hydro time [s] 1
8 14 Maintenance time inserting enable [digit] 1
9 17 Second parameter for calibration enable 1
Steering sensor value with the wheels turned on the
10 18 right [mV]
1000
Steering sensor value with the wheels
11 19 1000
turned on the left [mV]
Steering sensor value with the wheels on straight
12 20 position [mV]
1000
13 23 Accelerator pedal minimum value [mV] 1000

14 24 Accelerator pedal maximum value [mV] 1000
15 26 Stop on slop timer [s] 1
16 27 Lift priority for speed reference [digit] 1
17 32 Lift sensor maximum value [mV] 1000
18 33 Lift sensor minimum value [mV] 1000
19 34 Lift sensor middle value [mV] 1000
20 36 Weight of the load on the forks [kg] 1000
21 37 No load pressure [bar．10] 100
22 38 Load pressure [bar．10] 100
23 39 Limitation temperature [ºC / ºF] 1
24 41 Drive maximum current [%] 10
25 42 Forward maximum speed [rpm] 100
26 43 Reverse maximum speed [rpm] 100
27 44 Drive Limitation max speed [rpm] 100
28 46 High lift switch 1 drive max speed[rpm] 100
29 47 Steer limitation drive max speed [rpm] 100
30 48 Drive acceleration ramp [rpm/s] 100
31 49 Drive inversion ramp [rpm/s] 100
32 50 Drive release ramp [rpm/s] 100
33 51 Pedal brake ramp [rpm/s] 100
34 52 Creep speed [rpm/s] 100
35 53 Diameter of drive tyres [mm] 10
36 54 High lift switch 2 drive max speed [rmp] 100
37 59 Partial release ramp [rpm/s] 10
38 61 Lift max current [%] 10
39 62 Auxiliary max current [%] 10
40 63 Lift max speed [rpm] 100
41 64 Tilt speed [rpm] 100
42 65 Lateral shift speed [rpm] 100
43 66 Auxiliary 2 function speed [rpm] 100
44 67 Auxiliary 3 function speed [rpm] 100
45 68 Lift min speed [rpm] 100
46 69 High lift 1 switch lift max speed [rpm] 100
47 70 Hydro speed [rpm] 10
48 71 Hydro idle speed [rpm] 10
49 72 Pump accelerator ramp [rpm/s] 1000
50 73 Pump deceleration ramp [rpm/s] 1000
51 74 High lift 2 switch lift max speed [rpm] 100
52 75 High lift 1 switch tilt max speed [rpm] 100
53 76 High lift 2 switch tilt max speed [rpm] 100
High lift 1 switch side shift max speed
54 77 100
[rpm]
High lift 2 switch side shift max speed
55 78 100
[rpm]
High lift 1 switch auxiliary 2 function max
56 79 100
speed [rpm]
High lift 2 switch auxiliary 2 function max
57 80 100
speed [rpm]
High lift 1 switch auxiliary 3 function
58 83 100
max speed [rpm]
High lift 2 switch auxiliary 3 function
59 84 100
max speed [rpm]
60 94 Slow speed [digit] 1
61 95 British unit [digit] 1
62 96 Display brightness 1
63 97 E-S-H enable [digit] 1
Time meter (par. 98 = 0) / odometer
64 98 (par.98 = 1 ) / weight of the load on the 1
forks (par. 98 = 2) on display
65 99 Maintenance time [h] 1000
Table 4: List of adjustable parameters
In following Table 5 is shown the meaning of each adjustable parameters, divided
by functional groups.
DRIVE MOTOR
PARAMETER NAME PARAMETER DESCRIPTION
Drive acceleration ramp Lift truck acceleration with accelerator pedal pressed
Drive release ramp Lift truck deceleration with accelerator pedal released
Drive inversion ramp Lift truck deceleration in inversion
Pedal brake ramp Lift truck deceleration with pedal brake pressed
Drive limitation maximum Maximum lift truck speed with speed limitation
speed (turtle active)
Maximum forward lift truck speed with no speed limitation
Forward maximum speed
(no alarms present and turtle not active)
Maximum reverse lift truck speed with no speed limitation
Reverse limitation speed
(no alarms present and turtle not active)
If the truck speed is greater then this threshold, the speed
Creep speed reference becomes a parabolic function of the accelerator
potentiometer voltage.
Steer limitation maximum Maximum speed reference in the angle in which the internal
speed wheel is mechanically still.
Drive motors maximum current (expressed in per cent of
Drive maximum current
high energetic mode value)
Parameter that softens the drive inversion ramp if the traction
Partial release ramp
motors are working with low rpm
If this parameter is set to 1, it is possible to change the value
E-S-H enable
of the power mode with the display
If parameter is set to1, speed limitation is active; otherwise
Slow speed
lift truck speed is managed as usual.
Table 5: Description of adjustable parameters relative to drive motor
DRIVE MOTOR
If parameter is set to 1, values are expressed in
British unit
british unit, otherwise in international ones.
If parameter value is 0, display shows the hour
Time meter / odometer / weight of the meter. If parameter is set to 1, odometer
load on the forks on display indication appears . If parameter value is 2,
display shows weight on the forks .
Max.lift truck speed when the forks are above
High lift switch 1 drive maximum speed
the1st critical height
Max. lift truck speed when the forks are above
High lift switch 2 drive maximum speed
the 2nd critical height
This parameter gives drive tyres diameter
Diameter of drive tyres
measure (expressed in mm)
If a motor temperature is above this value,
Limitation temperature
acceleration, inversion, re-
lease ramps and max torque are reduced in
function of temperature
If parameter is set to 1 program service function
Maintenance time inserting enable
is enabled
Table 5: Description of adjustable parameters relative to drive motor
TIMERS
Time interval between seat switch opening and drive and
Seat switch delay
pump motors stopping
Time interval when pump motor works (with hydro
Hydro time
speed) after the end of a command
Time delay between last command given to a drive or
Chat time
pump motor and chat mode signalling
If operator stops on slop, after this time interval lift truck
Stop on slope time
begins to slowly move
Table 5: Description of adjustable parameters relative to timers
BATTERY
Minimum battery voltage necessary to reset battery
Battery reset value
discharged voltage alarm
Table 5: List of adjustable parameters relative to battery
SENSORS AND POTENTIOMETERS

Accelerator pedal minimum value Accelerator sensor voltage with pedal released
Accelerator sensor voltage with pedal completely
Accelerator pedal maximum value
pressed
Lift sensor minimum value Lift sensor voltage with lift lever released
Lift lever potentiometer voltage to which the lifting
Lift sensor middle value
becomes proportional to the shift of the lever
Lift sensor maximum value Lift sensor voltage with lift lever completely pressed
Steering sensor minimum value Steering sensor voltage with wheels turned on left
Steering sensor middle value Steering voltage with wheels straight ahead
Steering sensor maximum value Steering sensor voltage with wheels turned on right
This parameter is used to calibrate lift sensor to
Weight of the load on the forks [kg]
calculate the weight of load present on forks
No load pressure [bar · 10]
Load pressure [bar · 10]
Table 5: Description of adjustable parameters relative to sensors and
potentiometers
PUMP MOTOR
Minimum lift speed Minimum lift speed
Maximum lift speed Maximum lift speed
Tilt speed Pump motor speed with speed function active
Lateral shift (AUX 1 function) st
Pump motor speed with lateral shift function (1 auxiliary) active
speed
nd
AUX 2 function speed Pump motor speed with 2 auxiliary function active
rd
AUX 3 function speed Pump motor speed with 3 auxiliary function active
Pump acceleration ramp Lift acceleration
Pump deceleration ramp Pump motor deceleration after the end of a command
Hydro speed Pump motor speed when steering
Pump motor speed with direction command lever not in neutral, accel-
Hydro idle speed
erator pressed and no pump command active
Lift maximum current Pump motor maximum current with lift function active
Auxiliary maximum current Pump motor maximum current with lift lever released
High lift switch 1 lift maximum st
Max. lift speed when the forks are above the1 critical height
speed
High lift switch 2 lift maximum nd
Max. lift speed when the forks are above the 2 critical height
speed
High lift switch 1 tilt maximum st
Max. tilt speed when the forks are above the1 critical height
speed
High lift switch 2 tilt maximum nd
Max. tilt speed when the forks are above the 2 critical height
speed
High lift switch 1 AUX1 function
Max. side shift speed when the forks are above the1st critical height
max. speed
High lift switch 2 AUX1 function nd
Max. side shift speed when the forks are above the 2 critical height
max. speed
High lift switch1 AUX2 function st
AUX2 function speed when the forks are above the 1 critical height
max .speed
max. speed
High lift switch1 AUX3 function st
max. speed
max. speed
Lift priority for speed reference In case of simultaneous activation of lift and any other pump function
if parameter is set to 1, pump motor works at auxiliary function speed;
if parameter value is set to 0, pump motor works at lift speed
Table 5: Description of adjustable parameters relative to pump motor
◎ADJUSTABLE PARAMETERS: limits
In following tables are listed maximum, minimum, default programmable
values, and relative measure unit too for all adjustable parameters.
In particulars see Table 6 for two drive motors, 48v system.
DRIVE MOTOR
PARAMETER UNIT MINIMUM MAXIMUM
Drive acceleration ramp rpm/s 400 2000
Drive release ramp rpm/s 400 2000
Drive inversion ramp rpm/s 400 2000
Pedal brake ramp rpm/s 400 2000
Drive limitation maximum speed rpm 500 3500
Forward maximum speed rpm 1000 4500
Reverse maximum speed rpm 1000 4500
Creep speed rpm 100 2000
Steer limitation maximum speed rpm 400 2000
Drive maximum current ％ 20 100
Partial release ramp rpm/s 10 500
High lift switch 1 drive maximum speed rpm 0 4500
High lift switch 2 drive maximum speed rpm 0 4500
Diameter of drive tyres mm 300 700
Limitation temperature 。C/。F 50 155
Deceleration steering ramp 1 rpm/s 0 5000
Deceleration steering ramp 2 rpm/s 0 10
Table 6: Limits of adjustable parameters relative to drive motor
BATTERY
Battery reset value V 46 49.5
Table 6: Limits of adjustable parameters relative to battery
SENSORS AND POTENTIOMETERS
Accelerator pedal minimum value mV 200 4500
Accelerator pedal maximum value mV 3000 12000
Lift sensor minimum value mV 0 12000
Lift sensor maximum value mV 3000 12000
Lift sensor middle value mV 1000 12000
Steering sensor minimum value mV 500 11500
Steering sensor maximum value mV 500 11500
Steering sensor middle value mV 500 11500
No load pressure bar.10 0 2200
Load pressure bar.10 0 2200
Weight of the load on the forks kg 0 20000
Table 6: Limits of adjustable parameters relative to sensors and potentiometers
TIMERS
Seat switch delay s 1 9
Hydro time s 10 20
Chat time s 3 9
Stop on slope time s 1 10
Table 6: Limits of adjustable parameters relative to timers
PUMP MOTOR
Minimum lift speed rpm 500 1500
Maximum lift speed rpm 1500 4500
Tilt speed rpm 500 2000
Lateral shift (AUX 1 function) speed rpm 500 2800
AUX 2 function speed rpm 500 2800
AUX 3 function speed rpm 500 2800
Pump acceleration ramp rpm/s 1000 10000
Pump deceleration ramp rpm/s 1000 10000
Hydro speed rpm 400 800
Hydro idle speed rpm 200 500
Lift maximum current % 20 100
Auxiliary maximum current % 10 100
High lift switch 1 lift maximum speed rpm 0 3500
High lift switch 2 lift maximum speed rpm 0 3500
High lift switch 1 tilt maximum speed rpm 0 2000
High lift switch 2 tilt maximum speed rpm 0 2000
High lift switch 1 AUX1 function maximum speed rpm 0 2800
Table 6: Limits of adjustable parameters relative to pump motor
It is also possible to update all the parameters with their default values.
As for the procedure explained before, use UP, DOWN and ENTER keys to set
parameter10 value to 5 and parameter 17 value 2. Once more, the order you
adopt to change the two parameters is not important.
The loading of default data is indicated by the symbols dS(default set)
★ Notice: All parameters whose value is related to selected energetic operating

mode (economic, standard, high, limitation 1, limitation 2, limitation
3) are updated with default values corresponding to the active one.
Pressing E-S-H key on display (unless you are operating in

diagnostic or calibration mode), and selecting a different working
mode, you immediately change the value of all parameters related.
Table 7 for a 48V system.
Default values for ESH operating mode Two drive motors, 48V system
PARAMETER UNIT ECONOMIC MODE STANDARD MODE HIGH MODE
Maximum drive current % 62 76 100
Maximum forward speed rpm 3300 3800 4500
Maximum reverse speed rpm 2700 3300 3600
Drive acceleration ramp rpm/s 700 850 1000
Drive inversion ramp rpm/s 700 1000 1100
Drive release ramp rpm/s 680 800 900
Lift maximum current % 85 90 95
Maximum lift speed rpm 1550 2550 2700
Table 7: Default values for ESH operating mode
★ Notice: Once default data have been loaded, if you further need to modify
parameters value, you have to switch your system off, before entering
calibration mode again.
★ Notice: Parameter 99 appears only if maintenance time management is

enabled via EYE software, using relative PROGRAM SERVICE menu, or
via Compact display calibration parameter 14.
◎ADJUSTABLE PARAMETERS: notable parameters
In particular you can calibrate those parameters:
＊ STEERING SENSOR (parameter 12): enter diagnostic mode to visualize

steering sensor voltage.
(1). Minimum value calibration: turn wheels completely on left and read
sensor voltage value from display; enter calibration mode and set
parameter 19 to the value measured.
(2). Maximum value calibration: turn wheels completely on right and read
sensor voltage value from display; enter calibration mode and set
parameter 18 to the value measured.
(3). Central value calibration: put wheels straight and read sensor voltage
value from display; enter calibration mode and set parameter 20 to the
value measured.
＊ ACCELERATOR SENSOR (parameter 11): enter diagnostic mode to

visualize speed sensor voltage.
(1). Minimum value calibration: read from display sensor voltage
corresponding to start switch closure (when all segments dedicated to speed
level visualisation are active); enter calibration mode and set parameter 23
to the value measured.
(2). Maximum value calibration: read sensor voltage value from display,
with pedal completely pressed; enter calibration mode and set parameter
24 to the value measured.
＊ LIFT LEVER SENSOR (parameter 5): enter diagnostic mode to visualize

lift lever voltage.
(1). Minimum value calibration: read from display sensor voltage with lift
lever released; enter calibration mode and set parameter 33 to the value
read.
(2). Maximum value calibration: read from display sensor voltage with lift
lever completely pressed; enter calibration mode and set parameter 32 to
the value measured.
(3). Central value calibration: enter calibration mode and modify parameter
34.
＊ WEIGHT SENSOR (parameter 51): enter diagnostic mode to visualize lift

pressure .
(1). No load pressure calibration: hoist the forks till 50 cm height; after 5 s
set parameter 37 to the value of the pressure.
(2). Load pressure calibration: put on the forks a known value load, hoist the
forks till 50 cm height and, after 5 s, set parameter 38 to the value of
the pressure.
(3). Weight on the forks calibration: fix parameter 36 to the value of the
weight on the forks.
5. DIAGNOSTIC MODE
Diagnostic operating mode enables you to test main analogical and digital
signals managed by your system.
Operator can enter diagnostic mode executing following procedures:
if you are switching on your lift truck:
＊ Press ENTER key (for 3 consecutive s) until appears a numeric

code identifying control unit software release.
＊ Press DOWN key to enter diagnostic mode; the symbol “d” is visualized
and it persists.
until the first parameter has been selected. if you are working as usual with your
lift truck:
＊ Press ENTER key (for 3 consecutive s) until symbol “d” appears; it will
persist as long as the first parameter has been selected.
After diagnostic mode has been enabled, you can choose the parameter to be
analysed:
a. Use UP key to increase parameter number.
b. Use DOWN key to decrease parameter number.
In following Table 8 listed accessible parameters with their respective

displaying order and measure unit.
Selected parameter is visualized as follows:
＊ parameter number (flashing) appears in the area dedicated to speed /
alarm signals
＊ parameter actual value is displayed in the area reserved to the
time meter.
In particular, if the selected parameter is:

＊ Analogue input: COMPACT display shows its value, in the unit of Table
8. If the selected parameter is a temperature, also thermal alarm

symbol is visualized.
※ Digital input: if the command activated by the operator corresponds to the

parameter selected, the value of the quantity is visualized.
Other way the symbol e (error) appears, except in following case:
(1). Seat switch active, for any selected digital input.
(2). If you select a parameter relative to one of the high switches, and the other
high switch is active
★ Notice: If an alarm occurs when diagnostic mode is enabled, and the

system is working as usual, display returns automatically to its
typical visualization mode. However you can enter diagnostic
mode again, pressing ENTER key (for 3 consecutive s), until the
last parameter displayed before exiting is visualized.
Table 8-1 DIAGNOSTIC TABLE
PARAMETER NUMBER PARAMETER DESCRIPTION
1 Right traction motor speed [rpm]
2 Right traction motor speed reference [rpm]
3 Left traction motor speed [rpm]
4 Left traction motor speed reference [rpm]
5 Lift voltage [mV]
6 Battery voltage [V-10]
7 Right traction motor power module temperature [ºC / ºF]
8 Pump motor power module temperature [ºC / ºF]
9 Pump motor speed [rpm]
10 Pump motor speed reference [rpm]
11 Accelerator potentiometer voltage [mV]
12 Steering sensor voltage [mV]
13 Left traction motor power module temperature [ºC / ºF]
14 Right traction motor phase current U [A rms]
15 Right traction motor phase current V [A rms]
16 Right traction motor phase current W [A rms]
17 Left traction motor phase current U [A rms]
18 Left traction motor phase current V [A rms]
19 Left traction motor phase current W [A rms]
20 Pump motor phase current U [A rms]
21 Pump motor phase current V [A rms]
22 Pump motor phase current W [A rms]
23 Right traction motor temperature [ºC / ºF]
24 Left traction motor temperature [ºC / ºF]
25 Pump motor temperature [ºC / ºF]
26 Seat switch hour meter [h]
Table 8-2 DIAGNOSTIC TABLE

PARAMETER NUMBER PARAMETER DESCRIPTION
27 Drive motor hour meter [h]
28 Pump motor hour heter [h]
29 Seat switch [digit]
30 Park brake switch [digit]
31 Start switch [digit]
32 Reverse traction direction switch [digit]
33 Forward traction direction switch [digit]
34 Pedal brake switch [digit]
35 3 / 4 wheels selection switch [digit]
36 Side shift switch [digit]
37 Auxiliary 2 function switch [digit]
38 Auxiliary 3 function switch [digit]
39 High lift switch 1 [digit]
40 Tilt switch [digit]
41 High lift switch 2 [digit]
42 Main breaker command [digit]
43 5V out [digit]
44 12V out [mV]
45 24V out [digit]
46 Buzzer command [digit]
47 Fans command [digit]
48 Lift pressure [bar. 10]
49 Pressure sensor voltage [mV]
50 Weight of the load on the forks [kg]
5-11 Charger-GE&DANAHER
1. Disassembly.
(1) Remove the charger assembly.
a) Remove the wiring and the connecting plugs.
b) Remove the assembly bolts and takes out the charger assembly.
(2) Remove the transformer assembly.
a) Remove the battery plugs and hook out the battery.
b) Remove the transformer cover.
c) Remove the wiring.
d) Remove the transformer assembly.
5-12 The handset-GE

1. Insert the plug of the handset to the place shown below.
2. Proceed the relevant setting. (Please refer to P.151)
EV100 controller relevant settings:
TRACTION CARD
Parameters Default Setting
STORED FAULT CODE 1 0
CREEP SPEED 2 136
CONTROLLED ACCELERATION AND 1A TIME 3 10
CURRENT limit 4 255
PLUGGNING DISTANCE 5 70
1A DROP OUT CURRENT 6 76
FIELD WEAKENING PICK UP 7 0
FIELD WEAKENING DROP OUT 8 0
REGEN BRAKING C/L 9 0
REGEN START 10 0
SPEED LIMIT 1 11 79
SPEED LIMIT 2 12 120
SPEED LIMIT 3 13 120
INTERNAL RESISTANCE 14 12
BATTERY VOLTS 15 52
REDAL POSITION PLUG 16 14
CARD TYPE SELECTION 17 0
STEER PUMP TIME DELAY 18 134
5-13 Fuse-GE&SME&ZAPI
1. Disassembly and notes during the replacement.
The main fuse case.
a) Remove the floor plate & Remove the plate on
left side.
b) Open the fuse case lid, then take out the fuse.
※ Notes during the replacement.
b1) Be sure to unplug the battery connection.
b2) Be sure to replace according to the
specifications.
b3) Secure nuts tightly after replacement.
2. The capacity of the fuse.

The regulated capacity of the fuse (unit: A)
Fuse Cap (GE). Cap (SME).&ZAPI
Traction 355
Hydraulic 300 700
Control 20 10
Auxiliary 20 5
5-14 The controller-SME &ZAPI
1. Disassembly.
(1) Lift the counter weight. After taking apart the fixed bolts (2), lift up the
counter weight (1).
(2) Take apart the mounting bolts (16)(13). Take the counter weight cover (17)
and waterproof plate(12).
(3) Disassemble the wire harness of controller.
(4) Take apart mounting bolts. Take out the controller (20).
5-15 The accelerator assembly-SME
1.Remove the step:
Footboard cushion will be picked up (1) first, running-board after and then
picking up (2), and then (3) dismantle (4) the bolt on the running-board, can
pick up the accelerator.
5-16 One yard of forms of trouble-SME
Warn and tabulate
The largest voltage of the battery
● EYE warns codes: 1
● Warn the rank: 1
● Warn the reason: Through the inside measurement of the controller, have
found the voltage of the battery and gone beyond the level following:
63V, and the working voltage of system is 36V
If the controller finds this kind of mistake, please consult the following wrong
solution:
1. This warning may be caused by recycled electric current. It in not releasing at
machine not high of piling or it overturn it apply the brake When, work at
generator way, may exceed electrical machinery it if pressing, limit battery
voltage. In this case, the battery is being defeated by extremely wrong wiring.
2. Check whether the battery is normal.
3. Replace the control panel.
Minimum voltage of the battery.

● Warn the reason: Through the inside measurement of the controller, find the
voltage of the battery and is lower than the level following:
If the minimum voltage of the battery happens to warn, please consult the
following wrong solution:
1. Battery wiring mistake, or straight negative electrode connects corrosion.
2. Check the state of the battery: If the electrolytic liquid part of the battery is
exhausted, sometimes the controller will send out the low-voltage warning; It
run into battery it is electric for level the getting lower very (<10%) situation, if
at this time job the getting heavier very in electric current (analogy, electrical
machineries are full-load while working to improve the electrical machinery and
draw), warn low-voltagly that may send out, especially when the battery
electricity is close exhaustedly.
3. Change the control panel.
Regulator mistake of the footboard.

● Warn the reason: The voltage measurement value of the accelerator circuit
has exceeded through regulating the voltage range calculated; In addition,
Move the switch and seem to open a way too.
While presenting this kind of warning, please consult the following step:
1. Check that it is correct that the voltage counts and initializes setting up; if
incorrect, recalibrate once. (Can use the computer to communicate through one
bunch of mouths, can use the instrument).
2. Check whether 68 stitch wiring end son and corresponding input end of
counting the circuit of the voltage are joining correctly:
K1-11 (12V)
K1-15 (ground)
K1-10 (the signal of footboard imports)
3. If it is OK to wire, change the voltage to count.
It is warned that the storing device will flash soon.

● Warn the reason: It can't work to make mistakes normally that the storing
device will flash soon, or some store the materials and go beyond the correct
range.
While presenting this warning, according to the following step:

1. Flash storing device middle soon and is loaded the preserving value, can use
the computer to be linked to realizing with pile the high machine through a
bunch of materials line, can realize through the instrument too.
Charge the condenser and warn low-voltagly (the condenser has not been
charged in advance).
● Warn the reason: 70% that the voltage level of charging the condenser in
advance is less than the normal battery level, but the situation that the mould
group of the power works may happen in this and open a way in the main
circuit breaker.
This warning appears, can deal with as follows:

1. Check whether to stand intact in the main circuit breaker coil and power
street place or not.
2. Check whether the power fuse is damaged.
3. Check whether the main circuit breaker coil is a correct connection:
K1-18 (positive pole +)
K1-19 (negative pole-)
4. Replace the main circuit breaker.
The mould group of the power is unsaturated or passes and flows and warns.
● EYE warns codes:
8 is Drive the mould group of the power of the electrical machinery in right.
24 is Improve the mould group of the power of the electrical machinery.
25 is Drive the mould group of the power of the electrical machinery on the
left.
● Warn the reason: The real electric current of mould group of power has
exceeded limit 929A.
This warning appears, according to the step:

If present this warning message while starting the machine, close the system
first, then the broken power mould group that opens by mistake and cable of the
corresponding electrical machinery join, then start the machine again, if warn at
this moment that disappeared, that:
1. Replace the connecting wire between the control panel and this power mould
group.
2. Replace the mould group of the power.
If after starting the machine again, the warning message still exists, that:
1. Replace the mould group of the power.
2. Replace the electrical machinery.
The condenser of mould group of the power is charged in advance too fast.
● Warn the reason: Charge the voltage of the condenser to increase too fast in
advance when the system starts the machine.
This warning message appears, deal with as follows:

2. Replace CN1 outputting and connection cable between the corresponding
power mould groups of the control panel.
3. Replace and output the corresponding power mould group connected with
control panel CN1.
It is overheated to improve the mould group of the power of the electrical

machinery.
● Warn the reason: Group's temperature of the power mould (through a
temperature detector measurement) has exceeded 100°C, exceed 30 seconds
between being here.
This warning appears, deal with as follows:

1. This warning message may be caused by heat dissipation not so effective,
checking between the mould group of the power and aluminium board and
coupling situation of heat dissipation among aluminium board and vehicle. The
coupling heat dissipation glue of enough quantity is the essential assurance
dispelling the heat effectively.
2. Replace control panel CN4 and output and improve the connection cable
between the mould groups of the power.
3. If power mould group temperature relative to pile high plane service time say
that seem too high, replacing should improve the mould group of the power.
Can read the temperature survey materials through the instrument or EYE
procedure.
The condenser is charged while moving.

● Warn the reason: When the system starts the machine, the condenser is not
improved the electrical machinery to totally discharge. In fact, if you
suddenly start the machine, then shutdown, the level of voltage of the
condenser is too high at this moment. Must put the electric charge, which
lose the condenser before checking any mistake.
This warning message appears, the following is dealt with:
1. Check that it is correct that the cable which improves the electrical machinery
and its corresponding power mould group is joined.
2. Replace the connection cable of CN4 outputting and corresponding power
mould group of the control panel.
3. Replace the power mould group connected with control panel CN4.
4. This situation of appearance of checking the main circuit breaker replaces
this circuit breaker.
5. Replace connection cable CN1 that control panel and right drove the mould
group of the power of the electrical machinery; This cable is problematic may
cause the condenser voltage measurement to make mistakes.
6. Replace right and drive the mould group of the power of the electrical
machinery.
The battery is warned low-voltagly.
● Warn the reason: Battery voltage level lower than low voltage of charging
most, concrete number value please consult the service manual of instrument,
36V system sees forms 2, 48V system sees forms 3.
This warning appears, the following is dealt with:

1. Use the tester to measure the voltage of the battery, if measurement value is
different from display number value of the instrument, that replace the control
panel.
2. Besides the above situation, charge the battery again.
It is overheated to drive the electrical machinery.

13 is Drive the electrical machinery in right.
19 is Drive the electrical machinery on the left.
● Warn the reason: Urge the electrical machinery temperature survey value to
exceed 155°C.
This warning message appears, the following is operated:
This warning appears when the electrical machinery is not hot:
1. Use a type on the palm universal meter, put and measure the way in the
resistance, in the environment temperature measure the resistance value
between two lines of the temperature detector of electrical machinery under 25°
C situation, if measurement value is not about 10,000 ohms, that? Replace this
resistance detector.
2. Disconnection temperature detector, measures the resistance value between
its signal line and control panel ground wire.
This warning appears when the electrical machinery is very hot:

1. If it is correct from the instrument or the temperature value, which the
computer linking with main board reads, check whether the stator chassis of the
electrical machinery is clean.
It is overheated to improve the electrical machinery.

● Warn the reason: Improve the electrical machinery temperature survey value
and exceed 155°C.
This warning appears, the following is operated:
1. Use a type on the palm universal meter, put and measure the way in the
resistance, in the environment temperature Measure the resistance value
between two lines of the temperature detector of electrical machinery under 25°
C situation, if measurement value is not about 10,000 ohms, that? Replace this
resistance detector.
2. Disconnection temperature detector, measures the resistance value between
its signal line and control panel ground wire.
This warning appears when the electrical machinery is very hot:

1. If it is correct from the instrument or the temperature value, which the
computer linking with main board reads, check whether the stator chassis of the
electrical machinery is clean.
It is warned that loss flows in the electric electro mechanics.
15 is Drive the electrical machinery in right.
16 is Drive the electrical machinery on the left.
36 is Improve the electrical machinery.
● Warn the reason: Looks electric current of electrical machinery when the
system start the machine no zero.
This warning message appears, the following is operated:

1. Replaces the connection cable making mistakes between the mould group of
the power and control panel.
2. Replaces the mould group of the power.
3. Replaces the control panel.
Main circuit breaker mistake

● Warn the reason: The main circuit breaker coil is overheated.
This warning message appears, carry out the following step:

Monitor the time-recorder to warn.

● Warn the reason: Wrong communication of microprocessor of control panel,
or control panel make mistakes.
This warning appears, carry out the following step:
1. Using the programming interface of EYE, new programming will flash and
store thinking highly of to the control panel soon.
Urge the mould group of the power of the electrical machinery to be overheated.
20 is Drive the mould group of the power of the electrical machinery in
right.
22 is Drive the mould group of the power of the electrical machinery on the
left.
● Warn the reason: Group's temperature of the power mould (through a
temperature detector measurement) has exceeded 100°C, exceed 30 seconds
between being here.
This warning appears, carry out and operate as follows:

1. This warning message may be caused by heat dissipation not so effective,
checking between the mould group of the power and aluminium board and
coupling situation of heat dissipation among aluminium board and vehicle. The
coupling heat dissipation glue of enough quantity is the essential assurance
dispelling the heat effectively.
2. Replace outputting or CN2 (drives the electrical machinery to the left) and
connection cable between the corresponding power mould groups of control
panel CN1 (drives the electrical machinery in right correctly).
3. If power mould group temperature relative to pile high plane service time say
that seem too high, replace this power mould group, can read the temperature
survey materials through the instrument or EYE procedure.
Bunches of communication warning.

● Warn the reason: A bunch of communication of arranging between two
DSPs (several signal processors) presents the mistake, DSP on the control
panel controls the mutual software, so as to ensure that discerns this mistake
fast.
Present to the warning message, deal with as follows:

1. To improving and urging DSP to be programmed again, the reason? It has
been already destroyed that perhaps the procedure inside of the storing device
will flash soon.
The encoder 5V voltage warning.

● Warn the reason: Control panel K1-14 is connected (5V is outputted) the
voltage is lower than 4.3V.

1. Check that 5V is exported and has been grounded.
12V voltage is exported and warned.

● Warn the reason: Control panel K1-12 is connected (12V is outputted) the
voltage is lower than 10.5V.

1. Check that 12V is exported and has been grounded, therefore may cause the
following wrong wiring:
The voltage of the accelerator is counted.
Changing direction and detecting device.
Buzzer.
Instrument.
2. Replace wrong part.
Improve the electrical machinery while moving and order the pole to be in the
state of starting.
● Warn the rank: Warn; as the wrong condition, all improvement functions
(except hydraulic pressure function) are forbidden.

1. Before beginning to operate, close all orders (included control lever and
switch) that had already started.
2. Confirm improving, slope and the auxiliary function switches are all closed.
The seat switch opens and shuts while moving.

● Warn the rank: Warn; the main circuit breaker opens and shuts improve and
urge the electrical machineries to all stop running.
● Warn the reason: When is it work to start the machining, find seat switch be
opened and shut, or when close the main circuit breaker, the seat switch
keeps holding and shutting the time when " the seat switch is postponed " at
least of state.

1. Check whether the seat switch is damaged.
The mistake Move.

● Warn the rank: Warn; the main circuit breaker opens and shuts improve and
urge the electrical machineries to all stop running.
● Warn the reason: While starting the machine and working, have found the
accelerator pedal and already pushed or advanced / gone backwards switch
already arrival.

1. Check whether have switches that have already been started while moving
and piling the high machine or the accelerator pedal has already been pushed.
2. Check move, advance or go backwards the switch?
3. Check that it exceeds 1/3 of the maximum to accelerate the value of voltage
of the circuit.
The encoder warning.

74 is Drive the electrical machinery encoder in right.
75 is Drive the electrical machinery encoder on the left.
● Warn the reason: An encoder pass way disconnection, and the electrical
machinery is working.

1. Check whether this encoder is connected correctly to:
Electrical machinery itself.
Grounded: K1-15 connecting.
+5V: K1-14 connecting.
A pass way:
K1-37 connect, is drive the electrical machinery encoder in right.
K1-17 connect, is drive the electrical machinery encoder on the left.
B pass way:
K1-36 connect, is drive the electrical machinery encoder in right.
K1-16 connect, is drive the electrical machinery encoder on the left.
2. If it is correct to wire, replace this encoder.
Temperature detector warns the electrical machinery.

77 is Drive the temperature detector of electrical machinery in right.
78 is Drive the temperature detector of electrical machinery on the left.
79 is Improve the temperature detector of electrical machinery.
● Warn the reason: The wanton temperature of two of three electrical
machineries has exceeded 70°C badly.
This warning appears, can deal with as follows:

1. Confirm whether wiring is correct.
2. Replace this temperature detector.
Temperature detector of mould group warns the power.

80 is Drive the temperature detector of mould group of power of the
electrical machinery in right.
81 is Drive the temperature detector of mould group of power of the
electrical machinery on the left.
82 is Improve the temperature detector of mould group of power of the
electrical machinery.
● Warn and the quilt: 7
● Warn the reason: The wanton temperature of two of the mould group of
three powers has exceeded 70°C badly.

1. Check the temperature detector connecting wire between the control panel
and mould group of the power.
2. Replace the corresponding power mould group.
3. If warn that still exists, replace the control panel.
CRC mistake is warned.

● Warn the reason: EEPROM makes mistakes or it makes mistakes that the
software is matched.
1. Use " RESTORE " function form on EYE software homepage to resume
EEPROM again.
2. If the warning message still exists, replace the control panel.
Bank CRC resuming.

● Warn the rank: Warn
● Warn the reason: One is warned EEPROM RESTORE caused by CRC.
The detecting device is warned to change direction.

● Warn the reason: Have turned to the voltage of the circuit and gone beyond
the normal range.
This warning appears, but the following is operated:

1. Check whether the following line is correct:
K1-11 (12V)
K1-15 (ground)
K1-10 (turn to the signal of the detecting device and input)
2. If the line does not have question, replacing and changing direction and
detecting device.
It is too slow that the condenser is charged in advance.

● Warn the reason: After starting the machine, it is too slow to charge the
voltage of the condenser and increase in advance.

1. Replace CN1 cable, which connects the control panel and mould group of the
power.
2. Replace the power mould group connected with CN1 cable.
The condenser is charged the overtime in advance.

● Warn the reason: After starting the machine, it is too slow to charge the
voltage of the condenser and increase in advance.
5-17 The battery and the plugs.
1. Check up.
(1) Check the solution and compensate the water.
◎ The way to check.
a) Remove the battery plug.
b) Open the battery cover lid, get it hooked on the top rod.
c) Check the floating status from the outside.
※The way to judge is when the red floating mark is available, it indicates
equivalent. If not available, it indicates insufficient water. You need to refill it
with the distilled water.
d) The level mark lamp lights up. Green means normal and red means a refill
needed. If both don’t light up, it means a immediate refill is needed.
◎ The way to refill water.

(a) Open the container lid. Insert the plastic hose, with the middle lid, into it (to
the bottom). The middle lid is close to the container open.
(b) Open the solution cover; insert the plastic hose, which is attached with
spring clip.
(c) Loosen the spring clip. Press the center part of the polyester container with
fingers. Suck out the refined water.
(d) Refill water till the floating mark appears in the equivalent volume
indication area (white color).
(e) Screw the spring clip tight when the volume is adequate.
(2) Measure the gravity of the electrolyte of each set battery.

※ The way to read the gravity scale is the scale on the scale tube where the
solution level contacts.
Check the electrolyte gravity in each cell for deviation. It should be within the
basic value of 0.05.
◎ The way to correct.

a) Proceed the balance charging.
b) After charging, measure the gravity again and check it for deviation from one
cell to another. The electrolyte gravity is based on the temperature 20∘c. So,
you have to include the environmental temperature in your calculation of the
gravity.
◎ The way to calculate.

a) Measure the electrolyte temperature.
※ Please use tube-shaped alcohol thermometer to measure.
b) Measure the electrolyte gravity.
c) Change the measured gravity into the one calculated in the standard
temperature 20∘C.
※ The formula is
S20=St+0.0007(t-20)
S20…the measured gravity at 20∘C.
St… The measured gravity at the normal temperature.
t…..the temperature in Celsius.
2. Clean up.
(1) The cell, coupling and connectors.
a) Always keep the battery clean. Please use a
clean rag or compressed air to clean.
b) If it occurs rust, please use a file or a sand
paper to get rid of it.
(2) The solution cell cap.

a) Turn it counter clockwise to loosen.
b) Wash it with neutral solution and keep the cap and label clear.
c) To assemble, the cap and the solution plug have to be tightly secured.
※ If the solution plug thread is injured, please replace it.
(3) Check the battery plug.

a) Check the contacting plate for injury.
◎ The way to fix.

a1) Remove the assembly screw of the plug and the contacting plate.
a2) Correct it with a fine file or a sand paper.
◎ The way to remove the battery side contacting plate.

a) Press downs the spring plate with an insulated screw blade and pulls the
wiring to get out the contacting plate.
b) When at assembly, have the contacting plate pushed to embed in the grub and
till the front of the spring plate.
※ Please confirm the polarity of the contacting plate.
Chapter 6 The routine check, maintenance and lubrication.
6-1 The routine check and maintenance:
Before operation of the truck, one is supposed to proceed the「the routine checks
before the operation」, In addition, for the sake of the safety and assuring the
parts’ service life, performance and efficiency, one should conduct the routine
checks to the truck.
★Note:
1. Please read all the matters needing your attention in the book 「Safe
maintenance」.
2. When you run unto questions, please consult your superior or discuss them
with technician. Never conduct fixing yourself to insure your and the
machine safety.
3. Please give the job of the maintenance, which require more precise skill, to
the technical persons and professionals to handle it.
The replacement schedule table for oils and its pipe parts.
1. The kind of the grease and coolant.
Unit: Hour
Items Month 2 6 12
Hour 300 1200 2400
Transmission box oil. ○
Hydraulic oil. ○
Hydraulic oil filter. ○
Brake fluid. ○
Grease for the bearing in the front / rear ○
wheels.
2. Plastic piping, oil seals and chains.

Items Month 2 6 12
Hour 300 1200 2400
Plastic assembly in the brake system (in the ○
assembly and subassembly pumps).
Plastic oil tubes in the steering system. Every two-year.
Plastic oil assembly in the steering system. Every three-year.
Plastic oil tubes in the hydraulic system. Every three-year.
Chain. Every three-year.
6-2 Advised schedule for checks and maintenance:
1.The electric system:
Unit: Hour
Items Hours 200 600 1200 2400
◆Battery.
1. Check the electrolyte and refill it,
○
plus distilled water.
2. Clean the top of the battery. ○
3. Check the specific gravity of the
electrolyte. If necessary, refill, plus ○
distilled water.
4. Recharge evenly. ○
5.Check the exposed for insulation. ○
◆ Motor.
6. Check the brush for wearing.
○
Replace it if necessary.
7. Check the commutator for
○
wearing. If necessary, replace it.
8. Check the operation for in a good
○
condition.
9. Check for having a noise. ○
10. Check the insulation for being
○
effective.
11. Check for pollution. ○
◆ The controller.
12. Connecting is correct? ○
13. Check the contact for being
○
good.
14. Check its surface for being not
○
polluted. If necessary, clean it.
15. Check the contacting point for
○
wearing.
16. Check the insulation for being
○
effective.
◆ Circuit and terminals.
17. Check for wearing. ○
18. Check for loosening? Secure it if
○
necessary.
19. Check for getting dirty. ○
2. Torque converting system.
Items Hours 200 600 1200 2400
◆ Transmission.
1. Check the Transmission for ○
leaking.
2. Check for noisy. ○
◆ The front driving axle.
3. Check its bolts for loosening. ○
3. Moving mechanism.
Items Hours 200 600 1200 2400
◆ Tire pressure.
1. Tire pressure. ○
2. Check tires for slashing? Broken? ○
3. Check wearing depth and surface
○
for even.
4. Check the rim and hub for
○
loosening.
5. Check the tire threads for foreign
○
matter.
6. Check the front / rear wheel
○
bearing for loosening, noise?
4. The steering system.

Items Hours 200 600 1200 2400
◆ The steering wheel.
1. The operation condition. ○
2. Check the steering wheel for
○
loosening.
◆ The steering motor assembly.
3. Check it for leakage. ○
4. Check the piping for leakage. ○
◆ Transmission linking shaft.
5. Check it for loosening or
○
deforming.
6. Check the kingpin for loosening
○
or deforming.
7. Check the dual-arm crank for
○
wearing or deforming.
◆ The transmission shaft of the steering motor.
8. Check for it’s positioning. ○
5. The brake system.
Items Hours 200 600 1200 2400
◆ The brake pedal.
1. Check its stepping and returning
○
action.
2. Check its braking effect. ○
◆ The parking.
3. Check for the parking strength. ○
4. Check for the braking effect. ○
5. Check the parking cable and the
○
linking shaft for loosening.
◆ The brake fluid.
6. Check for the brake fluid level. ○
◆ The braking fluid circuit.
7. Check the piping and joints for
○
leakage.
◆ The brake assembly and subassembly pumps.
8. Check them for wearing or
○
breaking.
◆ The braking hub and the brake shoes.
9. The gap between the braking hub
○
and shoes.
10. Check the shoes for wearing. ○
11. Check the brake hub for wearing
○
or breaking.
12. Check the return spring for
○
wearing.
13. Check the self-adjusting
mechanism for its activating ○
condition.
6. Lift system.
Items Hours 200 600 1200 2400
◆ Forks.
1. Check forks and stopper for
○
function.
2. Check its welding heel and
○
welding joint for crack.
◆ The mast and load bracket.
3. Check for deforming and it’s ○
welding for crack.
4. Check the mast bushing for
○
breaking and wearing.
5. Check the supporting axle for
○
wearing or breaking.
6. Check the roller for breaking or
○
wearing.
7. Check the roller pin for breaking
○
or wearing.
◆ The chain and the chain shaft bearing.
8. Check its tension for being
○
enough and deforming or deforming.
9. Check the chain for lubrication. ○
10. Check the adjusting bolt for
○
securing.
11. Check the bearing ring for its
○
rolling condition.
7. The hydraulic system.

Items Hours 200 600 1200 2400
◆ The starting motor.
1. Check for leaking oil. ○
2. Check the cylinder pin for
○
wearing or injuring.
3. Check for its lifting speed. ○
4. Check it’s moving for smoothness. ○
◆ The hydraulic pump
5. Check for leakage or noise. ○
◆ The hydraulic oil tank.
6. Check the oil level and the oil for
○
changing or being polluted.
7. Check the oil tank and the oil
○
filter.
8. Check for leakage. ○
◆ The control levers.
9. Check for is operation condition. ○
10. Check its oil level and its quality
○
for any changing or being polluted.
11. Check the oil tank and the oil
○
filter.
◆ The controlling valve assembly.
14. Check its pressure releasing
○
strength and measure it.
◆ The hydraulic piping.
15. Check for leakage, deforming or
○
breaking.
16. Check its joint for loosening. ○
8. The safety devices.
Items Hours 200 600 1200 2400
◆ The overhead guard.
1. Check it’s welding for any
○
cracking.
2. Check for deforming or Injury. ○
◆ The load bracket.
3. Check the fastening part for
○
loosening.
4. Check for deforming, cracking or
○
injury.
◆ The lights.
5. Check its connecting and lighting
○
function.
◆ The horn.
6. Check its circuit connecting and
○
its function.
◆ The monitoring system of the display panel.
7. Check its functions. ○
◆ The seat.
8. Check its fastening positions for
○
loosening.
◆ The chassis.
9. Check for cracking or breaking. ○
10. Check its fastening positions for
○
loosening.
6-3 Instruction of the charger:
1. Every 10~12 hours charging, it will adjust the discharge depth automatically.
2. It will detect and delay 8 seconds before start-up.
3. Confirming DIN41774, the charging model.
4. It can be converted to 3 phases 380 V or 3 phases 220V according to

different needs.
5. The method of operation:

c Connect the battery plugs with the charger.
d Open the AC power source.
e It will detect automatically after 8 seconds delay.
f After charging finished, the power will shut down automatically.
g If you wanna stop charging middle way, you have to press down the STOP
switch before you unplug the battery from the charging terminals.
6. You can realize whether the battery is fully charged from the indicator on the
display panel. More close to the top means more close to finish the charging.
6-4 Operational maintenance:

Please read the manual “The safe maintenance” first before maintenance.
1. Refill the hydraulic oil:

c Open the lid of the hydraulic oil tank and refill the hydraulic oil.
d After finishing refill, confirm if the oil level is at normal position.
★ Note:
A. Please be sure first that the truck is parked safely on a stable level before you
go to check the oil volume.
B. The hydraulic oil is very dangerous under high heat or pressure, particularly
it will inject into skin and cause serious injury.
C. Check the oil quality for deterioration, discolor or being stagnant.
D. Clean the refill inlet before refill. Please avoid letting dust from entering.
E. Please don’t over refill the hydraulic oil. Clean the overflowed hydraulic oil
after refill.
2. The adjustment of the parking:

c The normal strength of the parking should be within 28~35 kg. If it is not, a
suitable adjustment is needed.
d Turning the grip on the top of the lever clockwise to increase the strength.
Vise verse.
e The braking strength a parking should have is able to stop a truck full of load
on a slope of 10％ ~ 15％. If it doesn’t reach that strength, then adjusting
the strength of the parking lever is necessary.
3. Check the hydraulic system and the mast assembly:

c Keep the hydraulic pump running while checking the hydraulic system.
Operate the tilt control lever to slant backwards and at a steady speed till the
mast reaches its limit then operate it forwards to its original position. Repeat
this operation several times to check the hydraulic system for any leakage or
abnormal.
d Operate the lift control lever to its most top. While the mast at lifting, check
the mast and the forks for any interference or vibration. Then operate it to
lower for the same checking.
e If the forks can’t reach its designed height at checking, the possible cause
may be the oil in the tank is not enough or there is a very serious interference
between the rollers and the mast rails. This kind of problems needs to be
solved by the professional person.
4. The forks:
For sake of the operation convenience, the level height difference between the
two forks can’t be over 6mm and if their wearing is over 10% of their thickness,
they must be replaced.
6-5 Tire Pressure:

c If both side tire pressure is not at its balance or not within its designated
value, it will reduce the stability of the truck, particularly when the truck is
fully loaded, it will be very difficult for turning. In order to assure the truck’s
traction performance and reduce its tire wearing, the tire pressure should be
always kept at the following value.
Items Tire pressure
Front wheel 8.0kgf/cm2
d When at checking the tire pressure, please use a tire pressure gauge, which
has a long handle, and face to the tire while measuring. At mean time, keep
yourself as far as possible away from the flank side of the tire.
e Due to the used tires being kind of a high-pressure one, if the rim or tire
itself even gets only slight hurt, it will cause a possible explosion.
f If the truck always operate at the rated load capacity, the tire tube should be
replaced every 1000 hours.
g The wearing of the tire surface can easily lead to a turnover or slide of the
truck. If this phenomenon exists, the tires should be replaced immediately.
h Please check the wheels and the tires for any injury and remove all the
foreign matters on the tire surface.
i Check anytime all the wheel hub bolts for loosening and tighten them if
necessary. When at fastening them, be sure to do it one by one diagonally.
★ Warning
The air inside of the tires must be completely released before any tires or rims
are changed. You can begin to dismantle the tires after that. Otherwise it could
hurt someone during the replacement. This job is bettered proceeded by a
professional person. Who has been trained for it?
The brake pedal:

c Before each start, be sure to check the brake pedal for working successfully.
d The truck, which has no stop mechanism, will do harm to person and the
truck.
e If the free distance of the brake pedal is not correct, please adjust it to the
standard value, which is 10 ~ 15 mm.
6-6 Lubrication chart:
1. Chain.
2. Mast. c Grease
3. The tilt cylinder pin. d Engine oil
4. The front wheel bearing. e Gear oil
5. The universal joint of the steering motor. f The hydraulic oil
6. The transmission box.
7. The brake assembly. g The brake fluid
8. The front axle of the rear wheel beam.
9. The steering kingpin.
10. The rear wheel bearing. ○：Check, refill
11.The rear crank pin. ◇：Replacement
12. The rear axle of the rear wheel beam.
6-7 Lubricant table:
Places to be lubricated. The hydraulic system.The differential gear.
The transmission box.
Lubricant specification. Consistency ISO VG46 API GL-4
Viscosity index 95/100 SAE 80W
Lubricating method. Forced circulation Oil shower
Capacity. About 20 liters. About 0.55~0.65 liters.
Replacement periodic. 2400 hours (yearly) 1000 hours (half year)
Recommended lubricant. cKo-guan hydraulic oil cMobil HD90
46AW dShell Spirax HD80
dMobil DTE25 eWithstanding
eShell Tellus 46 high-press
fEsso Nuto H46
The lubrication spots. Outer and inner mast The brake system.
channels.
Tilt cylinder-fastening
seat.
Front wheel bearing.
Rear wheel bearing.
Steering axle.
All fastening axle
bushing.
The lubrication specific. Molybdenum. JIS DOT-4
The lubricating method. Grease.
Capacity. Up to the situation.
Check periodic. Refer the lubrication Every 1200 hours (half
chart. year)
Recommended lubricants. cKo-gung multi-purpose cKo-gung brake fluid
grease dBP Brake Fluid
dEsso Multi-purpose Wanger-21
Grease H eMobil Brake Fluid
eBP Energrease LS-EP2 Wanger-21
fShell Alvania EP2 fAPOLLO BRAKE
FULID.
6-8 The maintenance standard:
Items Unit Standard value
1. Tire pressure. (Front \ rear) Kg/cm2 7.0\7.0
2. The fastening torque for the wheels. (Front \ rear) Kg-m 20~25\10~15
3. The fastening bolts torque for the rims (Front \ Kg-m 5~7\3~5
rear)
4. The strength of the parking. Kg 20~25
5. The setup pressure of the release valve. Kg/ cm2 135~140
6-9 The hydraulic circuit chart:
1. Tilt cylinder. 5. Lift cylinder.

2. Steering valve. 6. Safety valve.
3. Steering cylinder. 7. Throttle.
4. Hydraulic switch.
6-10 The electric system diagram-GE&DANAHER
6-11 The electric system diagram-SME
(SME) Controller electric system
(SME) Lamp electric system

Chapter 7 Troubleshooting.
Troubleshooting for the mechanism.
7-1 The transmission system.
Phenomenon Cause Policy
Too noisy. The bearings or gears broken, gear Replace.
spine groove worn out. Refill or replace.
Lubricant not enough or
deteriorated.
Leakage. Oil or seal broken. Replace.
Can’t move. Front wheel axle broken or the Replace.
fastening bolts broken.
7-2 The steering system.
Steering not valid. Oil level too low or no oil at all. Refill and tighten
The oil pipe joint for the steering again.
control valve loosened.
Slow steering. Oil level too low or no oil at all. Refill.
Hard to turn steering Oil pipes broken. Replace.
wheel. Steering valve or pump parts worn Replace.
out.
The wheel keeps turning The steering valve broken. Replace.
after the steering wheel
being stopped still.
Free movement too Accumulated space, include. Gear Adjust or replace.
large. gap, too large.
7-3 The hydraulic system.

Pump runs but no The hydraulic oil in tank not Refill.
hydraulic oil flows out. enough. Replace.
The hydraulic pump out of order. Replace or clean.
The inlet of the tank or the strainer
clogged. Replace.
Draining setup not adequate.
Can’t lift or can’t lift toOil volume not enough. Refill.
the top.
Forks can’t lift / lower or The drain setup not adequate. Reset.
tilt.
Lift or tilt cylinder Seal broken. Replace.
leaking.
7-4 The chain and forks.
Load center not correct. The chain tension not adequate. Adjust.
Not stable at lifting. Forks loosened. Secure.
7-5 The brake system.
Brake strength not Shoes stained with oil. Dismantle and
sufficient. clean.
Shoes worn out. Replace.
Shoes broken. Replace.
Brake pump assembly or Replace.
sub-assembly broken.
Brake drum not perfectly round or Replace or clean.
stained with oil.
Brake piping clogged or broken. Replace.
Air immersed in the brake pipes. Bleeding the air.
Can’t return after Returning spring broken. Replace.
parking released. Brake shoes too tight. Adjust.
Free movements of the brake pedal Adjust.
not enough.
Brake sub-assembly broken. Replace.
Hard to step down the Free movement of the pedal not Adjust.
brake pedal. enough.
Brake pump assembly or Replace.
sub-assembly broken.
Return spring of the pedal poor. Replace.
Need to step down Air found in the brake piping. Bleed air.
deeply to stop. Brake shoes wrong adjusted. Adjust.
Brake shoes worn out. Replace.
Free movement of the pedal too Adjust.

large.
Poor parking. Parking cable not properly Adjust.
adjusted. Replace.
Parking cable poor. Replace.
Brake shoes worn out.
7-6 The electric system.
No action. Poor connection. Check and adjust.
Battery terminals out of order. Replace terminals.
Can’t light up. Poor connection. Check and adjust.
Switch out of order. Replace switch.
Fuse broken. Replace fuse.
Light bulb burns out. Replace light
bulb.
Horn won’t “horn”. Poor connection. Check and adjust.
Fuse burn out. Replace fuse.
Key switch out of order. Replace switch.
Horn out of order. Replace horn.
Battery indicator not Poor connection. Check and adjust.
working. Fuse burn out. Replace fuse.
Key switch out of order. Replace switch.
Battery indicator out of order. Replace indicator.
Pump contact has no Poor connection. Check and adjust.
movement. Fuse burn out. Check and fix.
Contact out of order. Replace contact.
Traction contact has no Poor connection. Check and adjust.
movement. Fuse burn out. Replace fuse.
Main contact wiring poor. Check and adjust.
Accelerator switch out of order. Check and fix.
Motor out of order. Check and fix.
Speed controller out of order. Replace circuit
board.
Traction motor cannot Accelerator switch out of order. Check and fix.
rotate at high speed. Connection between the Check and adjust.
Accelerator and speed control
circuit board. Replace the
Control board connection poor. circuit board.
Check and
Speed control circuit board out of replace.
order.
Motor rotation sensor out of order. Check and
replace.
The charger.
Phenomenon Cause Find out Remedy
1. Even it starts to (1) Bulb filament To test the bulb for If it electrifies,
charge, the broken (except its electricity. replace the bulb.
indication lamp neon one).
won’t light up. (2) The circuit of To test the circuit Fix the bad part.
the lamp broken. for its
electrification.
2. It starts to charge (1) Bad To test it runs If The fuse in the
but at the same transformer. charging without AC side burns,
time the fuse in the load. replace it.
AC side breaks. (2) Bad diode. Test the diode for If the plus number
its resistance in is above 10Ω or the
plus and minus minus number is
direction good: the under 10kΩ,
plus number under replace it.
10Ω, minus
number above
10kΩ.
(3) Short inside of Measure the volt Replace the shorted
the battery. on the battery battery.
terminals.
(4) Other main Check each circuit Fix the bad part.
circuits short. respectively.
3. It cannot start (1) The supply Test the volt on the If it exist missing
charging even after power stops. supply power phase, find the
power on. socket. cause and fix it.
(2) Wire broken Test the volt on the If missing phase or
inside of the plug. AC fuse. volt exists, fix the
plug.
(3) The fuse in the Test the fuse for its If there is no
AC side breaks. electrification. electricity, replace
the fuse.
(4) MgS coil Test the coil for its If there is no
shorted. resistance value. electricity, replace
the MgS coils.
Phenomenon Cause Find out Remedy

4. Insufficient (1) The connecting Test it by inputting
Change the
charging. point of the AC volt. connecting point to
transformer is be in compliance
wrong. with the input
voltage.
(2) Missing phase Test the voltage on If missing phase
on the input the input socket. exists, find the
electricity. cause and fix it.
(3) The fuse in the Check the fuse for If it doesn’t
AC side burns out. its electrification. electrify, replace
the fuse.
(4) Bad diode. Refer to the item Same as the left.
2.2 on this table.
(5) Bad Check it for its If the voltage is too
transformer coils. electrification. low, fix or replace
it.
(6) Bad locking of Check its locking If loosened, tighten
the transformer condition. it.
terminals.
(7) Bad connection Check every Fix the bad part
on the other locking condition. and tighten again.
charging circuit.
(8) The battery Check the gravity, If the battery is
capacity reduces. the voltage, and the bad, replace it.
solution level.
5. Overcharging. (1) The connection Check the AC Change the
point to the input voltage. connection point in
transformer is compliance with
wrong. the input voltage.
(2) The set up time Confirm the set up Charging time
in the timer is too time. Check it regularly needs
long. regularly. 4 hours equal
charging needs 6
hours. If they are
not the same,
change it.
7-7 Wearing parts list.
The wearing parts list.
Name Where used Numbers Specification
18x7-8 / 15x4
Wheel tires. Wheel. 2x2
1/2-8
Gear oil. Gearbox. 0.55~0.65L 80W
Hydraulic oil. Hydraulic tank. 20L VG46
Brake fluid. Fluid reservoir. V DOT4
Brake shoes. Brake hub. 4 PMP
Parking cable. Parking. 1 TAILIFT
Brake light and rear
48v light bulb. 2 48V 10/25W
lamp.
48v25w light bulb. Direction light. 4 48V 25W
48v25w light bulb. Small lamp. 2 48V 25W
48v10w light bulb. Reverse lamp. 2 48V 10W
48v light bulb. Big lamp. 2
EN
User Manual
GRAPHIC
SMART
DISPLAY
Copyright © 1975-2008 Zapi S.p.A.
All rights reserved
The contents of this publication is a ZAPI S.p.A. property; all related authorizations are covered
by Copyright. Any partial or total reproduction is prohibited.
Under no circumstances will Zapi S.p.A. be held responsible to third parties for damage caused
by the improper use of the present publication and of the device/devices described in it.
Zapi spa reserves the right to make changes or improvements to its products at any time and
without notice.
The present publication reflects the characteristics of the product described at the moment of
distribution. The publication therefore does not reflect any changes in the characteristics of the
product as a result of updating.
NOTES LEGEND
4 The symbol aboard is used inside this publication to indicate an annotation or a

suggestion you should pay attention.
U The symbol aboard is used inside this publication to indicate an action or a

characteristic very important as for security. Pay special attention to the
annotations pointed out with this symbol.
Page - 2/43 AF4ZP0AA - GRAPHIC SMART DISPLAY - User Manual

Contents
1 INTRODUCTION ...................................................................................................................5
2 GENERAL CHARACTERISTICS ..........................................................................................6
2.1Technical specifications..............................................................................................6
2.1.1Dashboard ....................................................................................................6
2.1.2Alphanumeric LCD (Liquid Crystal Display)..................................................6
2.2Functional descriptions ...............................................................................................7
2.2.1LED function .................................................................................................7
2.2.2Display function.............................................................................................8
INSTALLATION HINTS.......................................................................................................10
3.1Material overview......................................................................................................10
3 3.1.1Connection cables ......................................................................................10
3.1.2Fuses ..........................................................................................................10
3.2Installation of the hardware.......................................................................................10
3.2.1Dashboard heating......................................................................................11
3.2.2Wirings: CAN connections and possible interferences ...............................11
3.2.3Wirings: I/O connections .............................................................................13
3.2.4Insulation of truck frame..............................................................................14
3.3Protection and safety features ..................................................................................14
3.3.1Protection features......................................................................................14
3.3.2Safety Features...........................................................................................14
3.4EMC..........................................................................................................................15
DIAGNOSIS.........................................................................................................................17
DESCRIPTION OF CONNECTORS....................................................................................18
5.1CNA connector: Molex Minifit 6 pins .........................................................................18
5.2CNB connector: Molex Minifit 4 pins .........................................................................18
5.3CNC connector: Molex Minifit 12 pins.......................................................................18
4 DRAWINGS .........................................................................................................................20
5 6.1Mechanical drawing ..................................................................................................20
6.2Connection drawing ..................................................................................................21
PROGRAMMING AND ADJUSTMENTS USING ZAPI HANDSET ....................................22
7.1Adjustment via console.............................................................................................22
7.2Description of standard console menu .....................................................................23
7.3Description of programmable functions ....................................................................24
6 7.4Special Adjustment menu .........................................................................................26
7.5Hardware Setting .....................................................................................................26
7.6Tester menu..............................................................................................................27
7 7.7Description of console using.....................................................................................29
7.8Other functions .........................................................................................................31
7.9Description of Alarm menu .......................................................................................32
STRUCTURE OF DISPLAY MENU.....................................................................................33
8.1Performance rolling...................................................................................................35
8.2Using of Password menu..........................................................................................35
8.3Using dashboard like a console................................................................................36
8.4Set Date/Hour menu .................................................................................................36
ANALYSIS OF GRAPHIC SMART DISPLAY RELATED ALARMS ..................................37
9.1Graphic Smart Display alarms ..................................................................................37
9.2Graphic Smart Display warnings ..............................................................................38
AF4ZP0AA - GRAPHIC SMART DISPLAY - User Manual Page - 3/43

9.3Alarms visualisation.................................................................................................. 38
10 RECOMMENDED SPARE PARTS ..................................................................................... 42
11 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED......................... 43
APPROVAL SIGNS
COMPANY FUNCTION INIZIALS SIGN
GRAPHIC AND LAYOUT FF
PROJECT MANAGER FG
TECHNICAL ELECTRONIC
PP
MANAGER VISA
SALES MANAGER VISA MC
Publication N°: AF4ZP0AA

Edition: June 2007

1 INTRODUCTION
Graphic Smart Display is an intelligent dashboard connected to the truck system
by CAN-BUS line.
This dashboard provides the diagnostic and set-up of the whole truck system:
Graphic Smart Display itself, Traction controller, Pump controller, Valves
controller.
It has an alphanumeric liquid crystal display (LCD) and a built-in backlight.
Access to Graphic Smart Display menu structure is provided by six operator
buttons integrated in a membrane keyboard.
Furthermore this dashboard has six built-in red LED, which provide the operator
with a easy information about the status of some truck devices.

2 GENERAL CHARACTERISTICS
2.1 Technical specifications
2.1.1 Dashboard
Voltage:..............................................................................................24/36/48/80 V
Can interface [n°]: .................................................................................................. 1
Keyboard buttons [n°]: ........................................................................................... 6
LED [n°]: ................................................................................................................ 6
Protection:…………………………………………………IP65 (Front); IP55 (Bottom)
External temperature range: standard version ........................................-10÷50 °C
External temperature range: frozen cell version ......................................-30÷50 °C
2.1.2 Alphanumeric LCD (Liquid Crystal Display)

Viewing area (WxH).......................................................................... 67.0x46.0 mm
Number of pixels [n°] ................................................................................. 240x160
Pixel size........................................................................................... 0.28x0.28 mm
Yellow-green backlight: number of LED .............................................................. 12

2.2 Functional descriptions
2.2.1 LED function
1 2 3 4 5 6
The Graphic Smart Display has six built-in red LED, which provide the operator
with an easy information about the status of some truck devices.
Battery(1)
This led lights when the measured battery voltage is equal or less than 40%
nominal battery voltage.
Wrench (2)
This led blinks when truck is in alarm condition.
Thermometer (3)
This led blinks when one truck’s controller is in alarm due IMS high temperature.
Seat (4)
This led lights when the operator is not on the seat.
Handbrake (5)
This led lights when the handbrake is activated.
Seat belt (6)

This led lights to signal that the seat belt is not correctly fastened. The Seat belt
sensor must be connected to the Analogue Input #2 (CNC#8).
4 When the Key Switch is closed, the Graphic Smart Display makes a general test
lighting and switching off all the LED in sequence.

2.2.2 Display function
6 2
1
7
3
8 4 5
Battery’s state of charge

The battery's state of charge indication (number 1 in figure) is displayed on the
left side of the unit; it is shown by ten notches. Each notch represents the 10% of
the battery charge. As the battery becomes discharged, the notches turn off
progressively, one after the other, in proportion to the value of the residual
battery charge. When the residual battery charge is ≤ 40 % the notches displayed
start to blink. When Battery Low alarm appears on the traction controller, the
battery symbol wich is near the notches also blinks.
Performance
The letter which appears in the rectangle displayed in the top right side of the unit
(number 2 in figure) shows the performance mode which is being used in the
controller.
Performances can be scrolled pressing button ESC . When one performance is
selected, the related information will be sent via can-bus to traction and pump
controllers that will manage this data. The standard functioning reduces truck
performance passing from the high to economic performance.
The real meaning, in terms of parameters level of these performances, depends
on software present on pump and traction controllers:
- “H” corresponds to highest performance;
-
Turtle
The turtle symbol (number 3 in figure) is normally off; when it appears (fixed) it
shows activation of the “soft” mode of the truck, in which maximum speed and

acceleration are reduced. The “soft” mode can be activated pressing button
(↓).
Hour meter
The number displayed on the bottom right side of the unit (number 4 in figure)
shows the Hours Worked.
The letter present near the hour meter(number 5 in figure) shows which hour
meter is displayed:
- K: the key hour meter is displayed;
- T: the traction hour meter is displayed;
- P: the pump hour meter is displayed; it increases if pump control is working.
Accelerator
The accelerator level indication (number 6 in figure) is displayed on the central
top side of the unit; it is shown by ten notches. When the accelerator level is
minimum only a notch is displayed, when the accelerator level is maximum all the
ten notches are displayed. Each notch represents 1/10 of the difference between
maximum and minimum accelerator level.
Speed
The number displayed under the accelerator notches on the center of the unit
(number 7 in figure) shows the truck speed. The unit can be km/h or mph
depending on the SPEED UNIT parameter setting (see 7.4).
Wheel position and running direction

The notch displayed on the left of the hour meter (number 8 in figure) represents
the wheel (only one of the nine notches is displayed) and shows the steering
angle (it corresponds to the relative truck direction if the truck is running).
The arrow (number 9 in figure) shows the set truck running direction. The arrow
point is up when the truck is forward running; the arrow point is down when the
truck is reverse running. If the truck doesn’t run a dot is displayed instead of the
arrow.

3 INSTALLATION HINTS
In the description of these installation suggestions you will find some boxes of
different colours, they mean:
4 These are information useful for anyone is working on the installation, or a

deeper examination of the content
U These are Warning boxes, they describe:

- operations that can lead to a failure of the electronic device or can be
dangerous or harmful for the operator;
- items which are important to guarantee system performance and safety
3.1 Material overview
Before starting it is necessary to have the required material for a correct

installation. Otherwise a wrong choice of cables or other parts could lead to
failures/ misbehaviour/ bad performances.
3.1.1 Connection cables

For the auxiliary connections, use cables of 0.5-1.0 mm² section.
3.1.2 Fuses
- Use a 10A Fuse for protection of the card.
- For Safety reasons, we recommend the use of protected fuses in order to
prevent the spread of fused particles in case the fuse blow.
3.2 Installation of the hardware
U 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.
Do not connect the module to a battery with a nominal voltage different

than the value indicated on the label. A higher battery voltage may cause a
logic failure. A lower voltage may prevent the logic from operating.

3.2.1 Dashboard heating
Graphic Smart Display does not need any means of heat dissipation. The frozen-
cell version, provided with a built-in heater, is strongly recommended for frozen-
cell applications.
3.2.2 Wirings: CAN connections and possible interferences
4 CAN stands for Controller Area Network. It is a communication protocol for real
time control applications. CAN operates at data rate of up to 1 Megabits per
second.
It was invented by the German company Bosch to be used in the car industry to
permit communication among the various electronic modules of a vehicle,
connected as illustrated in this image:
- The best cable for can connections is the twisted pair; if it is necessary to
increase the immunity of the system to disturbances, a good choice would be
to use a cable with a shield connected to the frame of the truck. Sometimes it
is sufficient a simple double wire cable or a duplex cable not shielded.
- In a system like an industrial truck, where power cables carry hundreds of
Ampere, there are voltage drops due to the impedance of the cables, and
that could cause errors on the data transmitted through the can wires. In the
following figures there is an overview of wrong and right layouts of the cables
routing.

U Wrong Layout:
R
Can Bus
Power cables
Module
Module
1
2
Module
3
R
The red lines are can wires.

The black boxes are different modules, for example traction controller, pump
controller and display connected by canbus.
The black lines are the power cables.
This is apparently a good layout, but can bring to errors in the can line.
The best solution depends on the type of nodes (modules) connected in the
network.
If the modules are very different in terms of power, then the preferable
connection is the daisy chain.
U Correct Layout:
R
Can Bus
Power cables
Module
Module
1
2
Module
3
R
Note: Module 1 power > Module 2 power > Module 3 power
The chain starts from the –BATT post of the controller that works with the highest
current, and the others are connected in a decreasing order of power.
Otherwise, if two controllers are similar in power (for example a traction and a
pump motor controller) and a third module works with less current, the best way
to deal this configuration is to create a common ground point (star configuration).

U Correct Layout:
R
Can Bus
Power cables
Module
Module
1
2
Center of the Ground connection
Module
3
R
Note: Module 1 power ≈ Module 2 power > Module 3 power
In this case the power cables starting from the two similar controllers must be as
short as possible. Of course also the diameter of the cable concurs in the voltage
drops described before (higher diameter means lower impedance), so in this last
example the cable between the minus of the Battery and the common ground
point (pointed by the arrow in the image) must be dimensioned taking into
account thermal and voltage drop problems.
4 Can advantages
The complexity of today systems needs more and more data, signal and
information must flow from a node to another. CAN is the solution to different
problems that arise from this complexity
- simplified design (readily available, multi sourced components and tools)
- lower costs (less and smaller cables)
- improved reliability (fewer connections)
- analysis of problems improved (easy connection with a pc to read the data
flowing through the cable).
3.2.3 Wirings: I/O connections

- After crimping the cable, verify that all strands are entrapped in the wire
barrel.
- Verify that all the crimped contacts are completely inserted on the connector
cavities.
U A cable connected to the wrong pin can lead to short circuits and failure;
so, before turning on the truck for the first time, verify with a multimeter the
continuity between the starting point and the end of a signal wire.
- For information about the mating connector pin assignment see the
paragraph “description of the connectors”.

3.2.4 Insulation of truck frame
U As stated by EN-1175 “Safety of machinery – Industrial truck”, chapter 5.7,

“there shall be no electrical connection to the truck frame”. So the truck
frame has to be isolated from any electrical potential of the truck power
line.
3.3 Protection and safety features
3.3.1 Protection features

- Connection Errors:
All inputs are protected against connection errors.
- External agents:
The dashboard is protected against dust and the spray of liquid to a degree
of protection meeting IP55.
3.3.2 Safety Features
U ZAPI devices are designed according to the prEN954-1 specifications for

safety related parts of control system and to UNI EN1175-1 norm.
The safety of the machine is strongly related to installation; length, layout

and screening of electrical connections have to be carefully designed.
ZAPI is always available to cooperate with the customer in order to evaluate
installation and connection solutions. Furthermore, ZAPI is available to
develop new SW or HW solutions to improve the safety of the machine,
according to customer requirements.
Machine manufacturer holds the responsibility for the truck safety features
and related approval.

3.4 EMC
U EMC and ESD performances of an electronic system are strongly

influenced by the installation. Special attention must be given to the
lengths and the paths of the electric connections and the shields. This
situation is beyond ZAPI's control. Zapi can offer assistance and
suggestions, based on its years experience, on EMC related items.
However, ZAPI declines any responsibility for non-compliance,
malfunctions and failures, if correct testing is not made. The machine
manufacturer holds the responsibility to carry out machine validation,
based on existing norms (EN12895 for industrial truck; EN50081-2 for other
applications).
EMC stands for Electromagnetic Compatibility, and it represents the studies and
the tests on the electromagnetic energy generated or received by an electrical
device.
So the analysis works in two directions:
1) The study of the emission problems, the disturbances generated by the
device and the possible countermeasure to prevent the propagation of that
energy; we talk about “conduction” issues when guiding structures such as
wires and cables are involved, “radiated emissions” issues when it is studied
the propagation of electromagnetic energy through the open space. In our
case the origin of the disturbances can be found inside the controller with the
switching of the mosfets which are working at high frequency and generate
RF energy, but wires and cables have the key role to propagate the
disturbs because they works as antennas, so a good layout of the cables
and their shielding can solve the majority of the emission problems.
2) The study of the immunity can be divided in two main branches: protection
from electromagnetic fields and from electrostatic discharge.
The electromagnetic immunity concern the susceptibility of the controller
with regard to electromagnetic fields and their influence on the correct work
made by the electronic device.
There are well defined tests which the machine has to be exposed to.
These tests are carried out at determined levels of electromagnetic fields, to
simulate external undesired disturbances and verify the electronic devices
response.
3) The second type of immunity, ESD, concerns the prevention of the effects of
electric current due to excessive electric charge stored in an object. In fact,
when a charge is created on a material and it remains there, it becomes an
“electrostatic charge”; ESD happens when there is a rapid transfer from a
charged object to another. This rapid transfer has, in turn, two important
effects:
this rapid charge transfer can determine, by induction, disturbs on the
signal wiring and thus create malfunctions; this effect is particularly
critical in modern machines, with serial communications (canbus)
which are spread everywhere on the truck and which carry critical
information.
in the worst case and when the amount of charge is very high, the

discharge process can determine failures in the electronic devices; the
type of failure can vary from an intermittently malfunction to a completely
failure of the electronic device.
U IMPORTANT NOTE: it is always much easier and cheaper to avoid ESD

from being generated, than to increase the level of immunity of the
electronic devices.
There are different solutions for EMC issues, depending on level of

emissions/ immunity required, the type of controller, materials and position
of the wires and electronic components.
4) EMISSIONS. Three ways can be followed to reduce the emissions:
SOURCE OF EMISSIONS: finding the main source of disturb and work

on it.
SHIELDING: enclosing contactor and controller in a shielded box; using
shielded cables;
LAYOUT: a good layout of the cables can minimize the antenna effect;
cables running nearby the truck frame or in iron channels connected to
truck frames is generally a suggested not expensive solution to reduce
the emission level.
5) ELECTROMAGNETIC IMMUNITY. The considerations made for emissions

are valid also for immunity. Additionally, further protection can be achieved
with ferrite beads and bypass capacitors.
6) ELECTROSTATIC IMMUNITY. Three ways can be followed to prevent

damages from ESD:
PREVENTION: when handling ESD-sensitive electronic parts, ensure the

operator is grounded; test grounding devices on a daily basis for correct
functioning; this precaution is particularly important during controller
handling in the storing and installation phase.
ISOLATION: use anti-static containers when transferring ESD-sensitive
material.
GROUNDING: when a complete isolation cannot be achieved, a good
grounding can divert the discharge current through a “safe” path; the
frame of a truck can works like a “local earth ground”, absorbing excess
charge. So it is strongly suggested to connect to truck frame all the
parts of the truck which can be touched by the operator, who is
most of the time the source of ESD.

4 DIAGNOSIS
Graphic Smart Display microcontroller continuously monitors the output stages
and carries out a diagnostic procedure on the main functions.
Main fault diagnostic function concern: parameter and password memory, canbus
interface, output drivers.

5 DESCRIPTION OF CONNECTORS
5.1 CNA connector: Molex Minifit 6 pins
A1 -BATT Power supply negative reference

A2 -BATT Power supply negative reference
A3 CAN H Can signal high
A4 CAN L Can signal low
A5 HEATER+ Heater positive power supply. This input must be
connected to +BATT before the key switch.
A6 KEY Key input
5.2 CNB connector: Molex Minifit 4 pins
B1 NAUX Auxiliary load output. The external load is driven to –

Batt.
B2 PAUX Auxiliary load positive supply. This output is internally
connected to the key through a diode (cathode
connected to CNB#2)
B3 CANT Internally connected to CNA#4 through a Can-Bus 120
Ohm termination resistance. Connecting CNB#3 to
CNA#3 the termination resistance is inserted between
CAN L and CAN H.
B4 +BATT Power supply positive reference. This input must be

connected to +BATT before the key switch. CNB#4
supplies Graphic Smart Display also after the Key is
switched OFF for a programmable service time.
5.3 CNC connector: Molex Minifit 12 pins
C1 FLASH BOOT This input is used for the software download through
the microcontroller Asynchronous Serial Interface. To
connect the input to CNC#6 during this operation
otherwise leave it open.
C2 NCLRXD Serial reception negative

C3 PCLTXD Serial transmission positive
C4 NCLTXD Serial transmission negative
C5 GND Console negative power supply
C6 +12 Console positive power supply
C7 AN/DI 1 Analogue/digital input #1

C11 NPOT Power supply negative reference. It is used as
potentiometer negative.
C12 PAN-IN Potentiometer positive: 12 V / 5 V output;
keep load > 1kW / 0,5 KW

6 DRAWINGS
6.1 Mechanical drawing

6.2 Connection drawing

7 PROGRAMMING AND ADJUSTMENTS
USING ZAPI HANDSET
7.1 Adjustment via console
Adjustment of Parameters and changes to the display configuration are made

using the Digital Console.
Description of console and connection

7.2 Description of standard console menu

7.3 Description of programmable functions
MENU SET MODEL
1) CONNECT TO
Using CANBUS link, every module connected to can net can act as the
“access node” to the canbus net for the external world.
For example the ZAPI hand console (or the PC-Win console) can be
physically connected to one module and, by the canbus, virtually
connected to any other module of the net.
This parameter is used to select the module to which the user wishes to
be connected.
Following the numbers associated to each module in Zapi canbus system
are showed.
Number associated in canbus net MODULE

01 SICOS
02 TRACTION
03 TRACTION MASTER
04 TRACTION SLAVE
05 PUMP
06 EPS-AC
09 MHYRIO/HVC
16 GRAPHIC SMART DISPLAY
MENU SET OPTIONS
1) PERFORM. ENABLE
It can enable or disable operator changing the truck performances using
button 5
- ON: Enabled operator
- OFF: Not enabled operator
2) PERFORMANCE TYPE
It sets the truck performances.
LEVEL 0 : E (Economic performance)
LEVEL 1 : N (Normal performance)
LEVEL 2 : H (High performance)
3) USER PWD
It sets using of the starting password to main page access.
- ON: Starting password requeste
- OFF: Starting password not requested
4) CONSOLE ENABLE
It can active or disable using of console function
- ON: Console function active

- OFF: Console function disable
5) SPEED UNIT
It sets the speed unit:
OPTION #1: the speed unit is km/h
OPTION #2: the speed unit is mph
6) HOUR COUNTER
It sets the hour counter displayed.
OPTION #1: the traction hours are displayed
OPTION #2: the displayed hours represent the machine hour counter
managed by the display
7) BRAKE ACT CLS

It sets active logic level of handbrake input (C7)
- ON: Active high input
- OFF: Active low input
8) SEATBELT ACT CLS

It sets active logic level of seat input (C8)
- ON: Active high input
- OFF: Active low input
9) AUX OUTPUT#1
The options are:
PRESENT: An external load is connected between PAUX and
NAUX. The related diagnosis are enabled.
ABSENT: No external load is connected between PAUX and NAUX.
The related diagnosis are disabled.
MENU ADJUSTMENTS
1) DELAY DISPLAY OFF

This parameter sets the display ON “Service time”. If the CNB#4 is
connected to +Batt after Key-Off the display is still supplied for a
programmable time, follow the table below to choose your temporization:
DELAY DISPLAY 0 1 2 3 4 5 6 7 8 9
OFF LEVEL
SERVICE TIME 1 3 5 7 9 11 13 15 17 20
[Sec]
2) SPEED FACTOR
It adjusts speed coefficient to have the correct truck speed value shown on
the display. This coefficient has to be regulated depending on truck mechanic
characteristics. It is the result of following formula:
Speed Factor = (88 * rr * p) / Ø
Where:
rr = total gearbox reduction ratio
p = number of pair pole of the motor
Ø = traction wheel diameter expressed in centimeters (cm)

3) AUX VOLTAGE#1
It specifies the percentage of battery voltage supplied to AUX coil to close
the AUXILIARY electro valve. This parameter can be changed in the
range 0% to 100%.
4) CHECK UP TYPE
It defines the truck behaviour when a maintenance is required.
LEVEL 0: the “SERVICE REQUIRED” alarm doesn’t appear
LEVEL 1: the “SERVICE REQUIRED” alarm appears after a time equal to
the hours set in the CHECK UP HOURS parameter
LEVEL 2: the “SERVICE REQUIRED” alarm appears after a time equal to
the hours set in the CHECK UP HOURS parameter and after 50
additional hours the truck speed is reduced
5) CHECK UP HOURS
It defines the hours after which a maintenance is required. It can be adjusted
in the 100 to 1000 hours. The resolution is 100 hours (it can be adjusted in
steps of 100 hours).
6) CHECK UP DONE
It can be ON/OFF. This parameter is normally off. Setting this parameter on
at next key-on, the last maintenance hour-counter resets. This operation
erases the “SERVICE REQUIRED” warnig if it is present and disable
possible reductions.
7.4 Special Adjustment menu
To enter this Zapi hidden menu a special procedure is required. Ask this
procedure directly to a Zapi technician.
Following parameter can be configured in this menu:
1) RESET HOURMETER
It can be ON/OFF. If it is ON it is possible to reset the machine hour-counter.
7.5 Hardware Setting
To enter this Zapi hidden menu a special procedure is required. Ask this
procedure directly to a Zapi technician.
Following parameter can be configured in this menu:
1) DISPLAY CONTRAST
It is used to better the display contrast.

7.6 Tester menu
Status of keyboard buttons can be monitored in real time in the TESTER menu.
Key #1 Key #2
Key #4
Key #3
Key #6
Key #5
2) KEY 1
Status ofkeyboard button:
ON = Input active, button pushed
OFF = Input not active, button released
3) KEY 2
Status of- TURTLE keyboard button:
4) KEY 3
Status of keyboard button:
5) KEY 4
Status of keyboard button:
6) KEY 5
Status of PERFORMANCE - ESC keyboard button:

7) KEY 6
Status of (Enter) keyboard button:
OFF = Input not active, button release
8) ANALOGUE INPUT#1
It display the voltage, in the range [0V, 5V], read on AN1 (CNC#7)
9) ANALOGUE INPUT#2
10) ANALOGUE INPUT#3

11) ANALOGUE INPUT#4


7.7 Description of console using
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.
DISP GRPH ZP0.00

1) Opening Zapi Menu 0V0A 00000
2) Press ROLL UP & SET UP Buttons to enter %'%

CONFIG MENU '''
3) The Display will show: SET MODEL. If another

menu is displayed, press ROLL UP or ROLL CONFIG MENU
SET MODEL
DOWN until SET MODEL appears
'%'
4) Press ENTER to go into the SET MODEL
'''
5) The display will shows the first option, only

CONNECTED TO option is present in this CONNECTED TO
16
menu
6) Press SET UP or SET DOWN buttons in order ''%

to select the desired value for selected option ''%
CONNECTED TO
7) New desired value appears 9
'''
8) Press OUT to exit the menu
'%'
ARE YOU SURE?

9) The Display will ask “ARE YOU SURE?” YES=ENTER NO=OUT
10) Press ENTER for YES, or OUT if you do not '%' '''
accept the changes ''' '%'
CONFIG MENU
11) SET MODEL menu appears SET MODEL
12) Press OUT again. Console now disconnects '''

and reconnects '%'
13) Display now shows the Opening Zapi Menu of

the ZAPI product corresponding to option MHYRIO CB ZP 0.00
48V 0A 00000
selected at point 7)

Flow chart showing how to make changes to Option Menu:
DISP GRPH ZP0.00

2) Press ROLL UP & SET UP Buttons to enter %'%

CONFIG MENU '''
CONFIG MENU
3) The Display will show: SET MODEL SET MODEL
4) Press ROLL UP or ROLL DOWN until SET %''

OPTIONS appears %''
CONFIG MENU
5) SET OPTIONS menu appears SET OPTIONS
6) Press ENTER to go into the SET OPTIONS '%'

menu '''
POWER SELECTOR
7) The Display will show the first option 1
8) Press ROLL UP or ROLL DOWN buttons until %''

desired option appears %''
USER PASSWORD
9) Desired option appears ON
10) Press SET UP or SET DOWN buttons in order ''%

to modify the value for selected option ''%
USER PASSWORD
11) New value for selected option appears OFF
'''
12) Press OUT to exit the menu
'%'
ARE YOU SURE?

13) Confirmation request appears YES=ENTER NO=OUT
14) Press ENTER to accept the changes, or press '%' '''

OUT if you do not accept the changes ''' '%'
CONFIG MENU
15) SET OPTIONS menu appears SET OPTIONS
16) Press OUT again. Display now shows the '''

Opening Zapi Menu '%'

Flow chart showing how to use the TESTER function of the Digital Console:
DISP GRPH ZP0.00

'%'
2) Press ENTER to go into the MAIN MENU
'''
MAIN MENU
3) The Display will show: PARAMETER CHANGE PARAMETER CHANGE
4) Press ROLL UP or ROLL DOWN until %''

TESTER menu appears on the display %''
MAIN MENU
5) The Display will show: TESTER TESTER
'%'
6) Press ENTER to go into the TESTER function
'''
7) The first variable to be tested is shown on the KEY 1

display OFFGND
8) Press either ROLL UP or ROLL DOWN %''

buttons %''
KEY 2
9) Next variable for measurement appears OFFGND
'''
10) When you have finished press OUT
'%'
MAIN MENU
11) The Display will show: TESTER TESTER
12) Press OUT again and return to Opening Zapi '''

Menu '%'
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.
7.8 Other functions
SAVE function allows to transfer dashboard parameters to the Pc console

memory (using Zapi PcWin console). With this function, a copy of the display set
of parameters can be retained in a Pc and downloaded to another dashboard
(see RESTORE).
RESTORE function allows to download display parameters from the Pc console
memory to the Graphic Smart Display Eeprom. Thus, a copy of the parameters
stored in a Pc can be downloaded in a dashboard avoiding the parameter setting
operation.

7.9 Description of Alarm 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 and the Hour Meter count. This
function permits 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:
DISP GRPH ZP0.00

'%'
2) Press ENTER to go into the MAIN MENU
'''
MAIN MENU
3) The Display will show: PARAMETER CHANGE
4) Press ROLL UP or ROLL DOWN until %''

ALARMS menu appears on the display %''
MAIN MENU
5) The Display will show: ALARMS
'%'
6) Press ENTER to go into the ALARMS menu
'''
CODE
7) The display will show the most recent alarm 00005h #02 20°C
8) Each press of 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 NONE

show: NONE 00000h #00 0°C
10) When you have finished looking at the alarms, '''

press OUT to exit the ALARMS menu '%'
11) The Display will ask: “CLEAR LOGBOOK?” CLEAR LOGBOOK?

Press ENTER for Yes, or OUT for No YES=ENTER NO=OUT
12) Press OUT again and return to Opening Zapi '''

Menu '%'

8 STRUCTURE OF DISPLAY MENU
Graphic Smart Display present a software structure made by menus and
submenus. It is possible to have access to Graphic Smart Display menu structure
by the six operator buttons integrated in a membrane keyboard.
At turn on the display asks the starting password to have access to the main
page (if “USER PASSWORD” option is ON), otherwise it shows directly the main
page (if “USER PASSWORD” option is OFF).
The main page, if there aren’t alarms, shows battery charge, truck speed (in
Km/h or mph, it depends on “SPEED UNIT” parameter) and key/traction/pump
hour meter (see “HOUR COUNTER” option); if alarms are present it will show
alarm code and node number in which alarm has occurred.
From the main page it is possible to have access to the ALARM page (if alarms
occur) and to MENUS page, that may be USER or SERVICE MENU, it depends
on which password is used.
To enter a password is necessary to push the fourth button (M) of membrane
keyboard when the main page is showed; this will show a entering password
page.
By using user password it’s possible to enter USER MENU which will be
customized depending on customer requests.
By using service password it’s possible to enter SERVICE MENU which presents
three items: “password”, “zapi console” and “date/hour”.
The “password” submenu allows to manage passwords of Graphic Smart Display
software structure. It’s possible to edit, add and delete passwords.
All passwords are optional (ON/OFF option).
The “zapi console” submenu can be accessible only if CONSOLE ENABLE
option is ON. This menu allow user to use dashboard as a real Zapi digital
console connected to one module of canbus net.
The “date/hour” submenu allows to modify and watch the display hour and the
calendar (used for future customized functions).
It follows flow chart diagram of software structure.

START
Starting Password (if option on)

ALARMS PAGE
If alarms occur It shows alarm code and
node number in which
alarm has occurred
PERFORMANCE
CHOICE
The display send the
Button 5 MAIN PAGE Button 6
chosen performance to It shows battery charge, hourmeter, trac
traaction and pump speed and active performance.
Button 5
controllers via can; they
will manage this
information
Button 6
PASSWORD REQUEST
Service password User password
SERVICE MENU USER MENU

It is possibile to scroll items of service menu by (to be customized)
using buttons 1 and 2. these submenus
PASSWORD, DATE/HOUR and ZAPI
CONSOLE.
Push button 6 to enter the desired menu
(If Console Enable = ON)
ZAPI CONSOLE PASSWORD DATE/HOUR

The display will act like a Zapi digital (for future applications)
console.
- USER PASSWORD
BUTTON 1 = ROLL UP - ADD PASSWORD
BUTTON 2 = ROLL DOWN - EDIT PASSWORD
BUTTON 3 = SET DOWN - DELETE PASSWORD
BUTTON 4 = SET UP
BUTTON 5 = OUT
BUTTON 6 = ENTER

8.1 Performance rolling
From MAIN PAGE using membrane keyboard numbers, it is possible to select

the performance mode which must be used in traction and pump controllers.
Performance can be chosen with button 4, and it is displayed in the top right side
of the unit.
When one performance is selected, the related information will be sent via
canbus to traction and pump controllers that will manage this data. The standard
functioning reduces truck performance passing from high performance mode (H)
to economy performance mode (E).
This is possible only if “PERFORM. ENABLE” option is ON.
The real meaning, in terms of parameters level of these performances, depends

on software present on pump and traction controllers.
Button 4 selects in sequence the truck performance (H → N → E).
8.2 Using of Password menu
By entering the service password from MAIN PAGE it’s possible to have access
to SERVICE MENU. Here with roll buttons (button 1 and 2 of membrane
keyboard) it’s possible to scroll the submenu items.
With ENTER button (button 6 of membrane keyboard) it is possible to enter
PASSWORD submenu where the operator can manage Graphic Smart Display
passwords. In particular it could enable/disable password entering, enter, edit
and remove passwords.
Inside the PASSWORD menu, use buttons ENTER (6) and OUT (5) to enter or
exit submenus and to confirm or cancel operations.
When new password is added, insert:
- the 5 digits password in place of “11111” that appear on the left side of
screen;
- the alphanumeric user id in place of “--------“;
- the performance type 0/1/2 (M) related to the password.
- password type (U): S-service / O-user.
To edit or add passwords use these buttons:
Button 1 / Button 2 change the digit marked by cursor

Button 3 shifts cursor on previous digit
Button 4 shifts cursor on following digit
Button 5 cancels all changing
Button 6 saves all changing
When there isn’t service password in eeprom, it can be used default password
“55555” that is deactivated when at least one service password is saved, and it is
reactivated when all service passwords are deleted, then it is not possible save
the default password.

8.3 Using dashboard like a console
By entering the service password, from MAIN PAGE it’s possible to have access
If option CONSOLE ENABLE is ON, with ENTER button, it is possible to enter
ZAPI CONSOLE submenu, which allows user to use dashboard as a real Zapi
digital console connected to one module of canbus net.
Here with roll buttons (button 1 and 2 of membrane keyboard) and enter button
(button 6), it is possible to choose which module of canbus net has to be
connected to the display.
When the display has been connected, it works exactly like a Zapi digital console.
Buttons of membrane keyboard do the same functions of Zapi console keys.
Button 1 performs function of the ROLL UP console key

Button 2 performs function of the ROLL DOWN console key
Button 3 performs function of the SET DOWN console key
Button 4 performs function of the SET UP console key
Button 5 performs function of the OUT console key
Button 6 performs function of the ENTER console key
8.4 Set Date/Hour menu
By entering the service password from MAIN PAGE it’s possible to have access
With ENTER button (button 6 of membrane keyboard) is possible to enter
DATE/HOUR submenu where the operator can watch and modify the date and
the calendar.
Inside the DATE/HOUR menu use buttons ENTER (6) and OUT (5) to enter or
exit submenus and to confirm or cancel operations.
To modify hour and date use these buttons:
Button 1 / Button 2 change the digit marked by cursor

Button 3 shifts cursor on previous digit
Button 4 shifts cursor on following digit
Button 5 cancels all changing
Button 6 saves all changing

9 ANALYSIS OF GRAPHIC SMART DISPLAY
RELATED ALARMS
9.1 Graphic Smart Display alarms
1) WATCHDOG
Cause:
At start-up the watch dog signal is already active before the software has
generated it. At standby or running condition the watch dog signal is not
active (in alarm status).
Troubleshooting:
The WD hardware circuit or microcontroller output port are damaged. In both
cases no external component are involved. Replace the logic board.
2) COIL SHORTED
Cause:
This alarm occurs when there is a short circuit of the AUXILIARY coil
connected to CNB#1 output. After the overload condition has been removed,
the alarm exits automatically by releasing and then enabling a travel demand.
Troubleshooting:
The typical root cause for this error code to be displayed is in the harness or
in the load coil. So the very first check to carry out concerns connections
between dashboard outputs and loads.
In case no failures/problems have been found externally, the problem is in
the logic card, which has to be replaced.
3) DRIVER SHORTED
Cause:
The driver of the auxiliary electro valve coil is shorted.
Troubleshooting:
Check if there is a short or a low impedance pull-down between NAUX
(CNB#1) and –BATT.
The driver circuit is damaged in the logic board, which has to be replaced.
4) AUX DRIVER OPEN

Cause:
The AUX coil driver is not able to drive the load. The device itself or its
driving circuit is damaged.
Troubleshooting:
This type of fault is not related to external components; replace the logic
board.
5) HARDWARE FAULT
Cause:
At Key-on the dashboard checks if the AUX driver is turned off by a not
active (alarm status) Watch-dog signal. If it is not turned off then the alarm is
generated.
Troubleshooting:
The problem is inside the logic, no external component are involved, replace
the logic board.

6) CAN BUS KO
Cause:
Graphic Smart Display doesn’t receive messages from canbus line or the
hour meter synchronization at Key-on fails.
Troubleshooting:
If this fault code is displayed together with other alarm messages, the fault is
probably to be looked for in the Graphic Smart Display can interface,
since the Display seems to be unable to receive any can message. So it
is suggested to check Graphic Smart Display canbus wiring and
connection.
Otherwise, the fault is in the can interface of other modules present on
canbus network.
9.2 Graphic Smart Display warnings
1) EEPROM KO
Cause:
It’s due to an HW or SW defect of the non-volatile embedded memory
supporting the dashboard parameters. This alarm does not inhibit the
machine operations, but the truck will work with the Graphic Display
parameters default values.
Troubleshooting:
Try to execute a CLEAR EEPROM operation (refer to Console manual).
Switch the key off and on to check the result. If the alarm occurs
permanently, it is necessary to replace the logic. If the alarm disappears, the
previously stored parameters will have been replaced by the default
parameters.
2) MAINTENANCE NEEDED
Cause:
This is just a warning to call for the time programmed maintenance.
Troubleshooting:
It is just enough to turn the MAINTENANCE DONE option to level ON after
the maintenance is executed.
9.3 Alarms visualisation
When an alarm condition occurs, Graphic Smart Display gives the information
showing the initial of module in which the alarm occurred, the alarm code and
description.
For example, the information:
245 ON PUMP
means that the alarm 245 occurred in the pump controller (M).
Here the table with the alarm codes and the respective meaning is shown.

The meaning of alarms with a code higher than 99 can change depending on the
purpose of the application (see following tables).
00 NONE
01 CHOPPER RUNNING
02 NO COMMUNICATION
03 UNKNOWN CHOPPER
04 CONSOLE EEPROM
05 SERIAL ERROR #2
06 SERIAL ERROR #1
07 CHOPPER NOT CONF
08 WATCHDOG
09 FIELD FF FAILURE
10 EEPROM DATA KO
11 EEPROM PAR. KO
12 EEPROM CONF. KO
13 EEPROM KO
14 EEPROM OFFLINE
15 LOGIC FAILURE #5
16 LOGIC FAILURE #4
17 LOGIC FAILURE #3
18 LOGIC FAILURE #2
19 LOGIC FAILURE #1
20 FORW VMN LOW
21 FORW VMN HIGH
22 BACK VMN LOW
23 BACK VMN HIGH
24 LEFT VMN LOW
25 LEFT VMN HIGH
26 RIGHT VMN LOW
27 RIGHT VMN HIGH
28 PUMP VMN LOW
29 PUMP VMN HIGH
30 VMN LOW
31 VMN HIGH
32 VMN NOT OK
33 NO FULL COND.
34 RGT NO FULL COND
35 LFT NO FULL COND
36 PU NO FULL COND
37 CONTACTOR CLOSED
38 CONTACTOR OPEN
39 BRAKE CON CLOSED

40 BRAKE CONT. OPEN
41 DIR CONT. CLOSED
42 DIR CONT. OPEN
43 RIGHT CON CLOSED
44 RIGHT CONT. OPEN
45 LEFT CONT CLOSED
46 LEFT CONT. OPEN
47 MAIN CONT CLOSED
48 MAIN CONT. OPEN
49 I=0 EVER
50 LEFT I=0 EVER
51 RIGHT I=0 EVER
52 PUMP I=0 EVER
53 STBY I HIGH
54 LEFT STBY I HIGH
55 RGT STBY I HIGH
56 PUMP STBY I HIGH
57 HIGH FIELD CUR.
58 NO FIELD CUR.
59 HIGH BRAKING I
60 CAPACITOR CHARGE
61 HIGH TEMPERATURE
62 TH. PROTECTION
63 THERMIC LEVEL #2
64 PUMP TEMPERATURE
65 MOTOR TEMPERAT.
66 BATTERY LOW
67 BATTERY LEVEL #2
68 BATTERY LEVEL #1
69 CURRENT SENS. KO
70 HIGH CURRENT
71 POWER FAILURE #3
72 POWER FAILURE #2
73 POWER FAILURE #1
74 DRIVER SHORTED
75 CONTACTOR DRIVER
76 COIL SHORTED
77 COIL INTERRUPTED
78 VACC NOT OK
79 INCORRECT START
80 FORW + BACK
81 BAD STEER 0-SET

82 ENCODER ERROR
83 BAD ENCODER SIGN
84 STEER SENSOR KO
85 STEER HAZARD
86 PEDAL WIRE KO
87 PEDAL FAILURE
88 TRACTION BRUSHES
89 PUMP BRUSHES
90 DRIVER 1 KO
91 DRIVER 2 KO
92 DRIVER 1 SIC. KO
93 DRIVER 2 SIC. KO
94 INPUT ERROR #6
95 INPUT ERROR #5
96 INVERTION
97 POSITION HANDLE
98 INPUT ERROR #2
99 INPUT ERROR #1

10 RECOMMENDED SPARE PARTS
Part number Description
C12359 Molex Minifit Connector 6 pins Female
C12777 Female Molex Minifit pin harness side

User Manual
ACE2 350-450
INVERTE
Copyright © 1975-2007 Zapi S.p.A.
All rights reserved
The contents of this publication is a ZAPI S.p.A. property; all related authorizations are covered
by Copyright. Any partial or total reproduction is prohibited.
Under no circumstances will Zapi S.p.A. be held responsible to third parties for damage caused
by the improper use of the present publication and of the device/devices described in it.
Zapi spa reserves the right to make changes or improvements to its products at any time and
without notice.
The present publication reflects the characteristics of the product described at the moment of
distribution. The publication therefore does not reflect any changes in the characteristics of the
product as a result of updating.
is a registered trademark property of Zapi S.p.A.
NOTES LEGEND
4 The symbol aboard is used inside this publication to indicate an annotation or a

suggestion you should pay attention.
U The symbol aboard is used inside this publication to indicate an action or a

characteristic very important as for security. Pay special attention to the
annotations pointed out with this symbol.
Page - 2 /79 AF2ZP0CB - ACE2 350/450 - User Manual

Contents
1 INTRODUCTION ...................................................................................................................5
2 SPECIFICATION ...................................................................................................................6
2.1 Technical specifications ..............................................................................................6
2.2 Block diagram .............................................................................................................6
3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT.......7
3.1 Microswitches .............................................................................................................7
3.2 Accelerator unit ...........................................................................................................7
3.3 Other analog control unit ............................................................................................8
3.4 Speed feedback ..........................................................................................................9
4 INSTALLATION HINTS .......................................................................................................10
4.1 Material overview ......................................................................................................10
4.1.1 Connection cables ......................................................................................10
4.1.2 Contactors...................................................................................................10
4.1.3 Fuses ..........................................................................................................10
4.2 Installation of the hardware.......................................................................................11
4.2.1 Positioning and cooling of the controller .....................................................11
4.2.2 Wirings: power cables.................................................................................11
4.2.3 Wirings: CAN connections and possible interferences ...............................12
4.2.4 Wirings: I/O connections .............................................................................14
4.2.5 Connection of the encoder..........................................................................14
4.2.6 Main contactor and key connection ............................................................15
4.2.7 Insulation of truck frame..............................................................................15
4.3 Protection and safety features ..................................................................................16
4.3.1 Protection features......................................................................................16
4.3.2 Safety Features...........................................................................................16
4.4 EMC ..........................................................................................................................17
4.5 Various suggestions .................................................................................................19
5 OPERATIONAL FEATURES ..............................................................................................20
5.1 Diagnosis ..................................................................................................................21
6 DESCRIPTION OF THE CONNECTORS ............................................................................22
6.1 Connectors of the logic - Traction configuration .....................................................22
6.2 Connectors of the logic - Pump configuration ...........................................................23
6.3 Description of power connections .............................................................................24
7 DRAWING ...........................................................................................................................25
7.1 Mechanical drawing ..................................................................................................25
7.2 Connection drawing - Traction configuration ............................................................26
7.3 Connection drawing - Pump configuration ................................................................27
7.4 Connection drawing - Combi configuration ...............................................................28
8 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE ...................................29
8.1 Adjustments via Console ..........................................................................................29
8.2 Description of Console & Connection .......................................................................29
8.3 Description of Standard Console Menu ....................................................................30
8.3.1 Traction configuration .................................................................................30
8.3.2 Pump configuration .....................................................................................31
8.4 Function configuration ..............................................................................................32
8.4.1 Traction .......................................................................................................32
8.4.2 Pump...........................................................................................................36
AF2ZP0CB - ACE2 350/450 - User Manual Page - 3 /79

8.5Parameter regulation ................................................................................................ 43
8.5.1 Traction....................................................................................................... 43
8.5.2 Pump .......................................................................................................... 46
8.6 Programming console functions ............................................................................... 50
8.7 Sequence for Ac Inverter Traction setting ................................................................ 51
8.8 Sequence for Ac Inverter Pump setting.................................................................... 52
8.9 Tester: description of the function ............................................................................ 53
8.9.1 Traction....................................................................................................... 53
8.9.2 Pump .......................................................................................................... 54
8.10 Description of the Console “SAVE” function............................................................. 57
8.11 Description of Console “RESTORE” function ........................................................... 58
8.12 Description of Console “PROGRAM VACC” function ............................................... 59
8.13 Description of the battery charge detection setting .................................................. 61
8.14 Description of “ALARMS” menu ............................................................................... 62
8.15 Faults diagnostic system .......................................................................................... 63
8.16 Microcontroller alarms overview ............................................................................... 64
8.17 Analysis and troubleshooting of alarms displayed on console ................................. 67
8.18 Microcontroller warning overview ............................................................................. 74
8.19 Analysis and troubleshooting of warnings displayed on console ............................. 75
9 RECOMMENDED SPARE PARTS FOR INVERTER ......................................................... 78
10 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED ......................... 79
APPROVAL SIGNS
COMPANY FUNCTION INIZIALS SIGN
GRAPHIC AND LAYOUT FF
PROJECT MANAGER FG
TECHNICAL ELECTRONIC
PP
MANAGER VISA
SALES MANAGER VISA PN
Publication N°: AF2ZP0CB

Edition: September 2007

1 INTRODUCTION
Within the ZAPIMOS family, the ACE-2 inverter (E stands for evolution) is the
model suitable for control of 4.0 kW to 9.0 kW motors. It has been expressly
designed for battery electric traction.
It is fit for electric truck, material handling: order pickers, reach truck, CB 2,0 tons,
tractors, boom lift and scissors lift.
The ACE-2 can be supplied in three versions:
1) Sensored version: using an Encoder (Sensor Bearing) in the Motor axle is

realised an extremely precise and reliable motor speed and torque control
2) SenseCoils version: using special auxiliary windings inside the motor instead
of an encoder is realised the motor speed and torque control.
3) Sensorless version: using only the phase voltage feedback is implemented

the motor speed and torque control with the Zapi patented sensor-less
control software.
Here the Sensored Version is descripted: it adopts an Encoder integrated in the

Ball Bearing (Sensor Bearing). The Encoder fills up the truck performance, respect
to the Sensorless and Sense Coils versions, with lower minimum speed, the “stop
on the ramp” service and a smoother inversion; on the other hand the reliability
gets penalized by the fragile mechanics and inaccessible position of the Sensor
Bearing.

2 SPECIFICATION
2.1 Technical specifications

Inverter for AC asynchronous 3-phase motors
Regenerative braking functions
Can-bus interface
Flash memory (128 Kbytes On-Chip Program Memory) Digital control based upon
a microcontroller
Voltage:.............................................................................................. 24 - 36 - 48 V
Maximum current ACE2 24V/400: ............................................. 400 A (RMS) for 3'
Maximum current ACE2 36-48V/350: ........................................ 350 A (RMS) for 3'
Maximum current ACE2 24V/500: ............................................. 500 A (RMS) for 3'
Maximum current ACE2 36-48V/450: ........................................ 450 A (RMS) for 3'
1 hour current rating ACE 24V/400:................................................... 200 A (RMS)
1 hour current rating ACE 36-48V/350: ............................................. 170 A (RMS)
1 hour current rating ACE 24V/500:................................................... 250 A (RMS)
1 hour current rating ACE 36-48V/450: ............................................. 225 A (RMS)
Operating frequency: ......................................................................................8 kHz
External temperature range: .............................................................-30 °C ÷ 40 °C
Maximum inverter temperature (at full power): ............................................... 85 °C
2.2 Block diagram

3 SPECIFICATION FOR THE INPUT
DEVICES FILLING UP THE INSTALLATION
KIT
The ACE2 inverter needs some external parts in order to work. The following
devices complete the kit for the ACE2 installation.
3.1 Microswitches
- The microswitches must have a contact resistance lower than 0.1 Ω and a
leakage current lower than 100 µA.
- When full load connected, the voltage drop between the key switch contacts
must be lower than 0.1 V.
- The microswitches send a voltage signal to the microprocessor when a
function request (for ex.: running request) is made.
3.2 Accelerator unit

The accelerator unit can consist of a potentiometer or an Hall effect device. It
should be in a 3-wire configuration. The potentiometer is supplied through
CNA#2.
Potentiometer output signal must be input to CPOT (CNA#3), signal range is
from 0 to 10 V.
The negative supply of the potentiometer has to be taken from CNA#9 (GND), or
from CNA-5 (REV/ 1ST SPEED) if the diagnosis PEDAL WIRE KO is done. In this
case the hardware must be configured closing a jumper on the logic card.
Potentiometer value should be in the 0.5 – 10 kΩ range; generally, the load
should be in the 1.5 mA to 30 mA range. Faults can occur if it is outside this
range.
The standard connection for the potentiometer is the one in the Left side of next
figure (potentiometer on one end at rest) in combination with a couple of Travel
demand switches. On request it is also possible the handling in the Right side of
next figure (potentiometer in the middle at rest) still in combination with a couple
of Travel demand switches.
The Procedure for automatic potentiometer signal acquisition is carried out using
the Console. This enables adjustment of the minimum and maximum useful

signal level (PROGRAM VACC function), in either direction. This function is
unique when it is necessary to compensate for asymmetry with the mechanical
elements associated with the potentiometer, especially relating to the minimum
level.
The sequence of procedure is described in the programming console manual.
The two graphs show the output voltage from a non-calibrated potentiometer with
respect to the mechanical “zero” of the control lever. MI and MA indicate the point
where the direction switches close. 0 represents the mechanical zero of the
rotation.
The Left Hand graph shows the relationship of the motor voltage without signal
acquisition being made. The Right Hand Graph shows the same relationship after
signal acquisition of the potentiometer.
3.3 Other analog control unit

1) Input A10 is an analog input, whose typical application is for proportional
braking. It should be in a 3 wire configuration. Potentiometer value should be
in the 0.5-10 kΩ range. Generally, the load should be in the 1.5 mA to 30 mA
range. The CPOTB (A10) signal range is from 0 to 10 V.
2) Connections A22 (PTHERM) and A23 (NTHERM) are used for a motor
thermal sensor. It can be digital (on/off sensor, normally closed) or analog.
See also chapter 8.4 for more explanation.

3.4 Speed feedback
The motor control is based upon the motor speed feedback. The speed
transducer is an incremental encoder, with two phases shifted at 90°. The
encoder can be of different types:
- power supply: +5 V or +12 V.
- electric output: open collector ( NPN), push-pull
- standard (A and B) output.
For more details about encoder installation see also chapter 4.2.5.
4 Note: The encoder resolution and the motor poles pair (the controller can handle),
is specified in the home page display of the handset showing following headline:
AE2T2B ZP1.13
That means:
AE2T= ACE-2 traction controller
(AE2P= ACE-2 pump controller)
2 = motor’s poles pair number
B = 64 pulses/rev encoder
The encoder resolution is given by the last letter in the following list:
A = 32 pulses/rev
B = 64 pulses/rev
C = 80 pulses/rev
D = 128 pulses/rev

4 INSTALLATION HINTS
In the description of these installation suggestions you will find some boxes of
different colors, they mean:
4 These are information useful for anyone is working on the installation, or a

deeper examination of the content
U These are Warning boxes, they describe:

- operations that can lead to a failure of the electronic device or can be
dangerous or harmful for the operator;
- items which are important to guarantee system performance and safety
4.1 Material overview

Before to start it is necessary to have the required material for a correct
installation. Otherwise a wrong choice of cables or other parts could lead to
failures/ misbehaviour/ bad performances.
4.1.1 Connection cables
For the auxiliary circuits, use cables of 0.5 mm² section.
For power connections to the motor and to the battery, use cables having section
of at least 50 mm². The screwing torque for the controller power connection must
be comprised in the range 13 Nm÷15Nm.
For the optimum inverter performance, the cables to the battery should be run
side by side and be as short as possible.
4.1.2 Contactors
The main contactor must be installed. Depending on the setting two parameters
in the controller (MAIN CONT VOLT [V%] and MAIN CONT V RID [%] ; see
chapter 8.4.1, 8.4.2):
- the output which drives the main contactor coil is modulated with a PWM at
high frequency (1 kHz). After an initial delay of about 1 sec in which the coil is
driven with a percentage of Vbatt set by MAIN CONT. VOLT. parameter, the
PWM reduces the voltage down to a percentage which is set by the MAIN
CONT V RID parameter. This feature is useful to decrease the power
dissipation of the contactor coil.
4.1.3
Fuses - Use a 10 A Fuse for protection of the auxiliary circuits.
- For protection of the power unit, refer to chapter 9 (Recommended
spare parts for inverter). The Fuse value shown is the maximum allowable.
For special applications or requirements these values can be reduced.
- For Safety reasons, we recommend the use of protected fuses in order
to prevent the spread of fused particles should the fuse blow.

4.2 Installation of the hardware
U 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.
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 Resistor
between 10 ohm and 100 ohm.
4.2.1 Positioning and cooling of the controller

Install the inverter with the base-plate on a flat metallic surface that is clean and
unpainted.
- Apply a light layer of thermo-conductive grease between the two surfaces to
permit better heat dissipation.
- Ensure that the wiring of the cable terminals and connectors is carried out
correctly.
- Fit transient suppression devices to the horn, solenoid valves, and contactors
not connected to the controller.
- The heat generated by the power block must be dissipated. For this to
be possible, the compartment must be ventilated and the heat sink
materials ample.
- The heat sink material and system should be sized on the performance
requirement of the machine. Abnormal ambient air temperatures should be
considered. In situations where either ventilation is poor, or heat exchange is
difficult, forced air ventilation should be used.
- The thermal energy dissipated by the power block module varies and is
dependent on the current drawn and the duty cycle.
4.2.2 Wirings: power cables
- The power cables length must be as short as possible to minimize power
losses.
- They must be tightened on controller power posts with a Torque of 13-15
Nm.
- The ACE2 module should only be connected to a traction battery. Do not
use converters outputs or power supplies. For special applications please
contact the nearest Zapi Service Centre.
U 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.

4.2.3 Wirings: CAN connections and possible interferences
4 CAN stands for Controller Area Network. It is a communication protocol for real
time control applications. CAN operates at data rate of up to 1 Megabits per
second.
It was invented by the German company Bosch to be used in the car industry to
permit communication among the various electronic modules of a vehicle,
connected as illustrated in this image:
- The best cable for can connections is the twisted pair; if it is necessary to
increase the immunity of the system to disturbances, a good choice would
be to use a cable with a shield connected to the frame of the truck.
Sometimes it is sufficient a simple double wire cable or a duplex cable not
shielded.
- In a system like an industrial truck, where power cables carry hundreds of
Ampere, there are voltage drops due to the impedance of the cables, and that
could cause errors on the data transmitted through the can wires. In the
following figures there is an overview of wrong and right layouts of the cables
routing.
U Wrong Layout:
R
Can
Bus
Power cables
Module Module
1
2
Module
3
R
The red lines are can wires.

The black boxes are different modules, for example traction controller, pump
controller and display connected by canbus.

The black lines are the power cables.
This is apparently a good layout, but can bring to errors in the can line.
The best solution depends on the type of nodes (modules) connected in the
network.
If the modules are very different in terms of power, then the preferable
connection is the daisy chain.
U Correct Layout:
R
Can Bus
Power cables
Module
Module
1
2
Module
3
R
Note: Module 1 power > Module 2 power > Module 3 power
The chain starts from the –BATT post of the controller that works with the highest
current, and the others are connected in a decreasing order of power. Otherwise,
if two controllers are similar in power (for example a traction and a pump motor
controller) and a third module works with less current, the best way to deal this
configuration is to create a common ground point (star configuration).
U Correct Layout:
R
Can Bus
Power cables
Module
Module
1
2
Center of the Ground connection
Module
3
R
Note: Module 1 power ≈ Module 2 power > Module 3 power
In this case the power cables starting from the two similar controllers must be as
short as possible. Of course also the diameter of the cable concurs in the voltage
drops described before (higher diameter means lower impedance), so in this last
example the cable between the minus of the Battery and the common ground point
(pointed by the arrow in the image) must be dimensioned taking into

account thermal and voltage drop problems.
4 Can advantages:
The complexity of today systems needs more and more data, signal and
information must flow from a node to another. CAN is the solution to different
problems that arise from this complexity
- simplified design (readily available, multi sourced components and tools)
- lower costs (less and smaller cables )
- improved reliability (fewer connections)
- analysis of problems improved (easy connection with a pc to read the data
flowing through the cable).
4.2.4 Wirings: I/O connections

- After crimping the cable, verify that all strands are entrapped in the wire
barrel.
- Verify that all the crimped contacts are completely inserted on the connector
cavities.
U A cable connected to the wrong pin can lead to short circuits and failure;
so, before turning on the truck for the first time, verify with a multimeter the
continuity between the starting point and the end of a signal wire.
- For information about the mating connector pin assignment see the
paragraph “description of the connectors”.
4.2.5 Connection of the encoder
1) ACE2 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 +5 or +12 V. It can have
different electronic output.
A8 +5V/+12V positive of encoder power

supply. A15 GND negative of encoder power
supply. A7 ENC A phase A of encoder.
A14 ENC B phase B of encoder.
2) Connection of encoder with +5 V power supply.

Connection of encoder with +12 V power supply.
U VERY IMPORTANT
It is necessary to specify in the order the type of encoder used, in terms of
power supply, electronic output and n° of pulses for revolution, because
the logic unit must be set in the correct way by Zapi.
4.2.6 Main contactor and key connection

- The connection of the main contactor can be carried out following the
drawing in the figure
- The connection of the battery line switches must be carried out following
ZAPI instructions.
- If a mechanical battery line switch is installed, it is necessary that the key
supply to the inverter is open together with power battery line; if not, the
inverter may be damaged if the switch is opened during a regenerative
braking.
- An intrinsic protection is present inside the logic when the voltage on the
battery power connection overtakes 40% more than the battery nominal
voltage or if the key is switched off before the battery power line is
disconnected.
4.2.7 Insulation of truck frame
U As stated by EN-1175 “Safety of machinery – Industrial truck”, chapter 5.7,

“there shall be no electrical connection to the truck frame”. So the truck
frame has to be isolated from any electrical potential of the truck power line.

4.3 Protection and safety features
4.3.1 Protection features
The ACE-2 is protected against some controller injuries and malfunctions:
- Battery polarity inversion
It is necessary to fit a MAIN CONTACTOR to protect the inverter against
reverse battery polarity and for safety reasons.
- Connection Errors
All inputs are protected against connection errors.
- Thermal protection
If the controller temperature exceeds 75 °C, the maximum current is reduced
in proportion to the thermal increase. The temperature can never exceed 100
°C.
- External agents
The inverter is protected against dust and the spray of liquid to a degree of
protection meeting IP65.
- Protection against uncontrolled movements
The main contactor will not close if:
- The Power unit is not functioning.
- The Logic is not functioning perfectly.
- The output voltage of the accelerator does not fall below the minimum
voltage value stored, with 1 V added.
- Running microswitch in closed position.
- Low battery charge
When the battery charge is low, the maximum current is reduced to the half
of the maximum current programmed.
- Protection against accidental Start up
A precise sequence of operations are necessary before the machine will
start.
Operation cannot begin if these operations are not carried out correctly.
Requests for drive, must be made after closing the key switch.
4.3.2 Safety Features
U ZAPI controllers are designed according to the prEN954-1 specifications for

safety related parts of control system and to UNI EN1175-1 norm. The
safety of the machine is strongly related to installation; length, layout and
screening of electrical connections have to be carefully designed.
ZAPI is always available to cooperate with the customer in order to evaluate
installation and connection solutions. Furthermore, ZAPI is available to
develop new SW or HW solutions to improve the safety of the machine,
according to customer requirements.
Machine manufacturer holds the responsibility for the truck safety features
and related approval.
ACE-2 inverter electronic implements an hardware safety circuit, which is able to

open the Line Contactor (LC) and the Electric Brake (EB) - and therefore to cut
the power line stopping the machine via HARDWARE, that is bypassing the
software control of the LC and EB. This safety circuit is driven by "SAFETY"
input. If safety input is connected to -BATT, the "SAFETY" circuit is inactive; if the
input is open, the "SAFETY" circuit becomes active and, within a timeout, it is
able to open the drivers of LC coil and EB coil. The safety circuit is also periodically
checked by the ACE-2 microcontroller; if the microcontroller detects a

failure in the "SAFETY" circuit, the microcontroller itself will bring the machine in
a safe status.
Suggested connection of "SAFETY" circuit:
- STANDALONE CONFIGURATION: it is suggested to connect safety input to
the "SEAT" microswitch or to the "DEADMAN" microswitch (it depends on the
application); in this way the machine will be brought to a safe status as soon as
the operator leaves the machine.
- COMBI CONFIGURATION: in this case the pump controller acts as
supervisor, checking the traction controller functionality by the CANBUS. So
it is suggested to connect the "SAFETY" input of traction controller to a
dedicated output of pump controller "SAFETY OUT", so that the pump
controller can drive the traction safety input and open the power line in case
of malfunctioning of traction controller.
4.4 EMC
U EMC and ESD performances of an electronic system are strongly

influenced by the installation. Special attention must be given to the
lengths and the paths of the electric connections and the shields. This
situation is beyond ZAPI's control. Zapi can offer assistance and
suggestions, based on its years experience, on EMC related items. However,
ZAPI declines any responsibility for non-compliance, malfunctions and
failures, if correct testing is not made. The machine manufacturer holds the
responsibility to carry out machine validation, based on existing norms
(EN12895 for industrial truck; EN50081-2 for other applications).
EMC stands for Electromagnetic Compatibility, and it represents the studies and
the tests on the electromagnetic energy generated or received by an electrical
device.
So the analysis works in two directions:
1) The study of the emission problems, the disturbances generated by the device
and the possible countermeasure to prevent the propagation of that energy;
we talk about “conduction” issues when guiding structures such as wires and
cables are involved, “radiated emissions” issues when it is studied the
propagation of electromagnetic energy through the open space. In our case
the origin of the disturbances can be found inside the controller with the
switching of the mosfets which are working at high frequency and generate RF
energy, but wires and cables have the key role to propagate the disturbs
because they works as antennas, so a good layout of the cables and their
shielding can solve the majority of the emission problems.
2) The study of the immunity can be divided in two main branches: protection
from electromagnetic fields and from electrostatic discharge.
The electromagnetic immunity concern the susceptibility of the controller with
regard to electromagnetic fields and their influence on the correct work made
by the electronic device.
There are well defined tests which the machine has to be exposed to.
These tests are carried out at determined levels of electromagnetic fields, to

simulate external undesired disturbances and verify the electronic devices
response.
3) The second type of immunity, ESD, concerns the prevention of the effects of
electric current due to excessive electric charge stored in an object. In fact,
when a charge is created on a material and it remains there, it becomes an
“electrostatic charge”; ESD happens when there is a rapid transfer from a
charged object to another. This rapid transfer has, in turn, two important
effects:
A) this rapid charge transfer can determine, by induction, disturbs on the
signal wiring and thus create malfunctions; this effect is particularly
critical in modern machines, with serial communications (canbus) which
are spread everywhere on the truck and which carry critical information.
B) in the worst case and when the amount of charge is very high, the
discharge process can determine failures in the electronic devices; the
type of failure can vary from an intermittently malfunction to a completely
failure of the electronic device.
4 IMPORTANT NOTE: it is always much easier and cheaper to avoid ESD from
being generated, than to increase the level of immunity of the electronic devices.
There are different solutions for EMC issues, depending on level of emissions/
immunity required, the type of controller, materials and position of the wires and
electronic components.
1) EMISSIONS. Three ways can be followed to reduce the emissions:
A) SOURCE OF EMISSIONS: finding the main source of disturb and

work on it.
B) SHIELDING: enclosing contactor and controller in a shielded box;
using shielded cables;
C) LAYOUT: a good layout of the cables can minimize the antenna effect;
cables running nearby the truck frame or in iron channels connected to
truck frames is generally a suggested not expensive solution to reduce
the emission level.
2) ELECTROMAGNETIC IMMUNITY. The considerations made for emissions

are valid also for immunity. Additionally, further protection can be achieved
with ferrite beads and bypass capacitors.
3) ELECTROSTATIC IMMUNITY. Three ways can be followed to prevent

damages from ESD:
A) PREVENTION: when handling ESD-sensitive electronic parts, ensure

the operator is grounded; test grounding devices on a daily basis for
correct functioning; this precaution is particularly important during
controller handling in the storing and installation phase.
B) ISOLATION: use anti-static containers when transferring
ESD-sensitive material.
C) GROUNDING: when a complete isolation cannot be achieved, a good
grounding can divert the discharge current trough a “safe” path; the frame
of a truck can works like a “local earth ground”, absorbing excess charge.
So it is strongly suggested to connect to truck frame all the parts of the
truck which can be touched by the operator, who is most of the

time the source of ESD.
4.5 Various suggestions

- Never connect SCR low frequency chopper with ASYNCHRONOUS
INVERTER because the ASYNCHRONOUS filter capacitors alter the SCR
choppers' work. If it is necessary to use two or more control units (traction +
lift. for ex.), they must belong to the ZAPIMOS family.
- During battery charge, disconnect ASYNCHRONOUS from the battery.

5 OPERATIONAL FEATURES
- Speed control (three versions available: sensored, sense coil and sensorless
as explained in the introduction section) .
- Optimum behaviour on a slope due to the speed feedback:
- the motor 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 (see also chapter 8.4).
- Stable speed in every position of the accelerator.
- Regenerative release braking based upon deceleration ramps.
- Regenerative braking when the accelerator pedal is partially released
(deceleration).
- Direction inversion with regenerative braking based upon deceleration ramp.
- Regenerative braking and direction inversion without contactors: only the
main contactor is present.
- The release braking ramp can be modulated by an analog input, so that a
proportional brake feature is obtained.
- Optimum sensitivity at low speeds.
- Voltage boost at the start and with overload to obtain more torque (with
current control).
- The inverter can drive an electromechanical brake.
- Hydraulic steering function:
a) traction inverter
- the traction inverter sends a "hydraulic steering function" request to
the pump inverter on the can-bus line (see also OPTIONS chapter
8.4).
- moreover, if the pump inverter is not present (for ex: tractor
application), the traction inverter can manage an "hydraulic steering
function" by driving a hydro contactor which drive an hydraulic
steering motor (output A18), see also OPTIONS chapter.
b) pump inverter
the pump inverter manage an "hydraulic steering function". That is, it
drives the pump motor at the programmed speed for the programmed
time.
- High efficiency of motor and battery due to high frequency commutations.
- Self diagnosis, the faults can be displayed through the console or Zapi’s
MDI/Display.
- Modification of parameters through the programming console.
- Internal hour-meter with values that can be displayed on the console.
- Memory of the last five alarms with relative hour-meter and temperature
displayed on the console.
- Test function within console for checking main parameters.

5.1 Diagnosis
The microcontroller continually monitors the inverter and carries 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 drives, can-bus
interface, if the switch sequence for operation is correct and if the output of
accelerator unit is correct.
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 check: 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.

6 DESCRIPTION OF THE CONNECTORS
6.1 Connectors of the logic - Traction configuration

A1 KEY Connected to the power supply through a microswitch
(CH) with a 10 A fuse in series.
A2 PPOT Potentiometer positive: 12 V / 5 V output; keep load >
1 kohm / 0.5 kohm.
A3 CPOT Accelerator potentiometer wiper.
A4 FORW Forward direction request input. It must be connected
to the forward direction microswitch, active high.
A5 REV Backward direction request input. It must be connected
to the backward direction microswitch, active high.
It can also be used as NPOT (potentiometer negative
reference) with the PEDAL WIRE KO diagnosis
implemented.
A6 SEAT SEAT input; it must be connected to the SEAT
microswitch; it is active when connected to -BATT.
A7 ENCA Incremental encoder phase A input.
A8 PENC Incremental encoder positive supply 12 V / 5 V
A9 -BATT Negative power supply. It is used as NPOT, without
PEDAL WIRE KO diagnosis, for acceleration
potentiometer and brake potentiometer
A10 CPOTBR Brake potentiometer wiper.
A11 SAFETY IN If not connected to -Batt the MC and EB coil power
output will be disabled. In the COMBI configuration it is
connected to SAFETY OUT (CNA#19) of pump
controller. This input can also be used as a general
purpose digital input.
A12 CAN-T If it is connected with A21 (CAN H) it introduces the
120 Ohm termination resistance between CAN-L and
CAN-H.
A13 SR/HB Speed reduction (handbrake) input. Active with switch
opened. Not active with switch closed to -Batt.
A14 ENCB Incremental encoder phase B input.
A15 ENC GND Encoder negative power supply.
A16 NLC Main contactor coil output. The coil is driven to
negative reference.
A17 PLC/PB Positive of the main contactor and electromechanical
brake coil.
A18 NEB Electro mechanic brake coil output. The coil is driven
to negative reference.
A19 SAFETY OUT It drives the external load to negative reference when
the REV input is active. It can be used for a flashing light
or acoustic indicator. The maximum current load is
1 A. In case of inductive load it is suggested to use a
free-wheeling diode across the load (with cathode

connected to +Batt)
A20 CAN-L Low level CAN-BUS voltage I/O.
A21 CAN-H High level CAN-BUS voltage I/O.
A22 PTHERM Input for motor temperature sensor. It is possible to
use a digital or analogue (PTC) sensor.
A23 NTHERM -Batt.
B1 PCLRXD Positive serial reception (Not used: it can be

disconnected).
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 It must be connected to B8 for the Flash memory
programming.
programming.
6.2 Connectors of the logic - Pump configuration

A1 KEY Connected to the power supply through a microswitch
(CH) with a 10 A fuse in series.
A2 PPOT Potentiometer positive: 12 V / 5 V output; keep load >
1 kohm / 0.5 kohm.
A3 CPOT Lifting potentiometer wiper.
A4 LIFT ENABLE Input for potentiometer lifting enable input; it is active
HIGH.
A5 SPEED1 Input for first speed request; it is active HIGH.
It can also be used as NPOT (potentiometer negative
reference) with the PEDAL WIRE KO diagnosis
implemented.
A6 SEAT SEAT input; it must be connected to the SEAT
microswitch; it is active when connected to -BATT.
A7 ENCA Incremental encoder phase A input.
A8 PENC Incremental encoder positive supply 12 V / 5 V
A9 -BATT Negative power supply. It is used as NPOT, without
PEDAL WIRE KO diagnosis, for lifting potentiometer
A10 SPEED2 Input for second speed request; it is active HIGH.
A11 SAFETY IN If not connected to -Batt the AUX1 and AUX2 coil
power output will be disabled. It can also be used as a
general purpose digital input.
A12 CAN-T If it is connected with A21 (CAN H) it introduces the
120 Ohm termination resistance between CAN-L and
CAN-H.
A13 SPEED3 Input for third speed request; it is active when

connected to -Batt.
A14 ENCB Incremental encoder phase B input.
A15 ENC GND Encoder negative power supply.
A16 NLC Main contactor coil output. The coil is driven to
negative reference.
A17 PLC/PAUX Positive of the LC and Auxiliary coil.
A18 NAUX Auxiliary coil output. The coil is driven to negative
reference.
A19 SAFETY OUT In the COMBI configuration it is connected to SAFETY
IN (CNA#11) of traction controller.
It can also be used to drive an external load to
negative reference when the pump motor is driven.
The maximum current load is 1 A. In case of inductive
load it is suggested to use a free-wheeling diode
across the load (with cathode connected to +Batt)
A20 CAN-L Low level CAN-BUS voltage I/O.
A21 CAN-H High level CAN-BUS voltage I/O.
A22 PTHERM Input for motor temperature sensor. It is possible to
use a digital or analogue (PTC) sensor.
A23 NTHERM -Batt.
B1 PCLRXD Positive serial reception (Not used: it can be

disconnected).
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.
programming.
programming.
6.3 Description of power connections

View of the power bars:
-BATT Negative of the battery.

+BATT Positive of the battery.
U; V; W Connection bars of the three motor phases; follow this
sequence and the indication on the motor.

7 DRAWING
7.1 Mechanical drawing
Existing others versions (with or without power fuse):

- With heat sink 200x40x150mm
- With heat sink 200x40x200mm

7.2 Connection drawing - Traction configuration

7.3 Connection drawing - Pump configuration

7.4 Connection drawing - Combi configuration

8 PROGRAMMING & ADJUSTMENTS USING
DIGITAL CONSOLE
8.1 Adjustments via Console

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.
8.2 Description of Console & Connection
Digital consoles used to communicate with AC inverter controllers must be fitted

with EPROM CK ULTRA, minimum "Release Number 3.02".

8.3 Description of Standard Console Menu
8.3.1 Traction configuration

8.3.2 Pump configuration

8.4 Function configuration
8.4.1 Traction
Using the CONFIG MENU of the programming console, the user can configure
the following functions (see "OPERATIONAL FEATURE" chapter for an
explanation of "hydraulic steering function"):
SUBMENU "SET OPTIONS"
1) TILLER SWITCH
This option handles the input CNA#6 . This input opens when the operator
leaves the truck. It is connected to a key voltage when the operator is
present. There are two levels:
- HANDLE: CNA#6 is managed as tiller input (no delay when released).
- SEAT: CNA#6 is managed as seat input (with a delay when released -
debouncing function)
2) HOUR COUNTER
- RUNNING: the counter registers travel time only.
- KEY ON: the counter registers when the "key" switch is closed.
3) CUTBACK MODE
- PRESENT: input A13 is managed as a cutback speed input.
- ABSENT: input A13 is managed as an handbrake input.
4) 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.
5) STOP ON RAMP
- ON: the stop on ramp feature (truck electrically hold on a ramp) is
managed for a time established by "auxiliary time" parameter. After this
time, the behaviour depends on the "aux output #1" option programming
(see also the following table).
- OFF: the stop on ramp feature is not performed.
6) AUX OUTPUT #1
- HYDRO CONT.: the inverter manages an hydraulic steering function
when the direction input or brake pedal input are active or a movement of
the truck is detected.
- EXCLUSIVE HYDRO: the inverter manages an hydraulic
steering function when the exclusive hydro input is active.
- BRAKE: output A18 drives an electromagnetic brake coil which is
activated every time the traction motor is driven.
7) SET TEMPERATURE
- DIGITAL: a digital (ON/OFF) motor thermal sensor is connected
between A22 and A23 inputs.
- ANALOG: an analogue motor thermal sensor is connected between

A22 and A23 (the curve can be customized on a customer request).
- NONE: no motor thermal sensor switch is connected.
SUBMENU "ADJUSTMENTS"
1) SET POT BRK MIN

It records the minimum value of braking pedal potentiometer when the
braking switch is closed; the procedure is similar to the "Program Vacc"
function (see chapter 9.4). This procedure must be carried out only if the
"Pedal braking" option is programmed as "Analog".
2) SET POT BRK MAX

It records the maximum value of braking pedal potentiometer when the
braking pedal is fully pressed; the procedure is similar to the "Program Vacc"
function (see chapter 9.4). This procedure must be carried out only if the
"Pedal braking" option is programmed as "Analog".
3) SET BATTERY TYPE

It selects the nominal battery voltage.
4) ADJUST BATTERY
Fine adjustment of the battery voltage measured by the controller.
5) THROTTLE 0 ZONE
It establishes a deadband in the accelerator input curve (see also curve
below).
6) THROTTLE X POINT
This parameter changes the characteristic of the accelerator input curve.
7) THROTTLE Y POINT
This parameter changes the characteristic of the accelerator input curve.
VACC MIN and VACC MAX are values programmable by the "Program Vacc"
function.

8) BATT. MIN. ADJ.
It adjusts the lower level of the battery discharge table. It is used to calibrate
the discharge algorithm with the battery of the application. See chapter 9.5
for more information.
9) BATT. MAX. ADJ.

It adjusts the upper level of the battery discharge table. It is used to calibrate
the discharge algorithm with the battery of the application. See chapter 9.5 for
more information.
10) ADJUSTMENT #03

This parameter adjusts the updating of battery charge after Key-On.
Decreasing this parameter the difference between the battery voltage
measured after Key-On and the last stored value necessary to update the
charge with the new value measured decrease. It is used to calibrate the
discharge algorithm with the battery of the application. See chapter 9.5 for
more information.
11) LOAD HM FROM MDI

When set On, the HourMeter of the Controller is transferred and recorded on
the HourMeter of the Standard MDI (connected on the Serial Link).
12) CHECK UP DONE

Turn it On when the required Maintenance service has been executed to
cancel the CHECK UP NEEDED warning.
13) CHECK UP TYPE

It specifies the handling of the CHECK UP NEEDED warning:
- NONE: No CHECK UP NEENED warning
- OPTION#1: CHECK UP NEENED warning shown on the hand set and
- MDI after 300 hours
- OPTION#2: Equal to OPTION#1 but Speed reduction after 340 hours
- OPTION#3: Equal to OPTION#2 but the truck definitively stops after 380
hours
14) MAIN CONT VOLT

It specifies the percentage of battery voltage supplied to MC coil to close the
contactor.
15) AUX OUT VOLT

It specifies the percentage of battery voltage supplied to EB coil to apply the
electro mechanic brake.
16) MAIN CONT. V RID

It specifies the percentage of battery voltage supplied to MC coil to keep the
contactor closed. This percentage is lower than the MAIN CONT VOLT value.
17) AUX OUTPUT V RID

It specifies the percentage of battery voltage supplied to EB coil to keep the
electro mechanic brake applied. This percentage is lower than the AUX OUT
VOLT value.

AUX STOP A18
OUTPUT ON OUTPUT BEHAVIOUR ON A SLOPE
RAMP
The truck is electrically hold on a
-It drives the coil of a slope; when the time set by
electromagnetic brake. "auxiliary time" parameter is
BRAKE ON -The hydraulic steering function elapsed the brake is applied and
request is sent to the pump the 3-phase bridge is released.
inverter by the can-bus link. Do not use this combination if
the negative brake is not
installed.
The truck is not electrically hold
on a slope, but comes down
-It drives the coil of a very slowly; when the time set
electromagnetic brake. by "auxiliary time" parameter is
BRAKE OFF -The hydraulic steering function elapsed, the brake is applied
request is sent to the pump and the 3-phase bridge is
inverter by the can-bus link. opened. Do not use this
combination if the negative
brake is not installed.
-It drives the coil of a hydraulic The truck is electrically hold on
HYDRO steering contactor when the a slope; when the time set by
CONT. ON direction input or brake pedal "auxiliary time" parameter is
input are active or a movement of elapsed, the truck comes down
the truck is detected.-The very slowly, till the flat is
hydraulic steering function reached.
request is also sent to the pump
inverter by the can-bus link.
-It drives the coil of a hydraulic
HYDRO OFF steering contactor when the The truck is not electrically hold
CONT. direction input or brake pedal on a slope, but comes down
input are active or a movement of very slowly till the flat is
the truck is detected. reached.
-The hydraulic steering function
request is also sent to the pump
-It drives the coil of a hydraulic The truck is electrically hold on
EXCL. ON steering contactor when the a slope; when the time set by
HYDRO exclusive hydro input is active. "auxiliary time" parameter is
-The hydraulic steering function elapsed, the truck comes down
request is also sent to the pump very slowly, till the flat is
inverter by the can-bus link. reached.
-It drives the coil of a hydraulic
EXCL. OFF steering contactor when the The truck is not electrically hold
HYDRO exclusive hydro input is active. on a slope, but comes down
-The hydraulic steering function very slowly till the flat is
request is also sent to the pump reached.

8.4.2
Pump Using the config menu of the programming console, the user can configure the
following functions.
SUBMENU "SET OPTIONS"
1) TILLER SWITCH
This option handles the input CNA#6 . This input opens when the operator
leaves the truck. It is connected to a key voltage when the operator is
present. There are two levels:
- HANDLE: CNA#6 is managed as tiller input (no delay when released).
- SEAT: CNA#6 is managed as seat input (with a delay when released -
debouncing function)
2) HOUR COUNTER
- RUNNING: the counter registers travel time only.
- KEY ON: the counter registers when the "key" switch is closed.
3) 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.
Very important:
In the combi system (pump + traction), the battery discharge calculation for
the complete system is carried out by the traction inverter; the information
about the pump inverter consumption is sent on the can-bus line from the
pump inverter to the traction inverter. So the correct programming for the
"Battery check" option is:
- traction inverter: ON
- pump inverter: OFF.
4) SET MOT TEMPERATURE

- ANALOG: an analogue motor thermal sensor is connected between A22
and A23 inputs (the curve can be customized on a customer request).
- DIGITAL: a digital (ON/OFF) motor thermal sensor is connected between
A22 and A23 inputs.
- NONE: no motor thermal sensor switch is connected.
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.
3) THROTTLE 0 ZONE
It establishes a dead band in the lift potentiometer input curve (see also
curve below).

4) THROTTLE X POINT
This parameter, together with the THROTTLE Y POINT, changes the
characteristic of the lift potentiometer input curve : when the potentiometer is
depressed to X point per cent, the corresponding pump speed is Y point per
cent of the Maximum pump speed. The relationship between the lift
potentiometer position and the pump speed is linear between the THROTTLE
0 ZONE and the X point and also between the X point and the maximum
potentiometer position but with two different slopes.
5) THROTTLE Y POINT
This parameter, together with the THROTTLE X POINT, changes the
characteristic of the lift potentiometer input curve (see also paragraph 13.5):
when the potentiometer is de-pressed to X point per cent, the corresponding
pump speed is Y point per cent of the Maximum pump speed. The relationship
between the potentiometer position and the pump speed is linear between the
THROTTLE 0 ZONE and the X point and also between the X point and the
maximum accelerator position but with two different slope.
VACC MIN and VACC MAX are values programmable by the "Program Vacc"
function.
6) BATT. MIN. ADJ.

It adjusts the lower level of the battery discharge table. It is used to calibrate
the discharge algorithm with the battery of the application. See chapter 9.5
for more information.
7) BATT. MAX. ADJ.

It adjusts the upper level of the battery discharge table. It is used to calibrate
the discharge algorithm with the battery of the application. See chapter 9.5 for
more information.
8) ADJUSTMENT #03
This parameter adjusts the updating of battery charge after Key-On.
Decreasing this parameter the minimum difference between the battery
voltage measured after Key-On and the last stored value, necessary to
update the charge with the new value measured, decrease. It is used to

calibrate the discharge algorithm with the battery of the application. See
chapter 9.5 for more information.
9) LOAD HM FROM MDI

When set On, the HourMeter of the Controller is transferred and recorded on
the HourMeter of the Standard MDI (connected on the Serial Link).
10) CHECK UP DONE

Turn it On when the required Maintenance service has been executed to
cancel the CHECK UP NEEDED warning.
11) CHECK UP TYPE

It specifies the handling of the CHECK UP NEEDED warning:
- NONE: No CHECK UP NEENED warning
- OPTION#1: CHECK UP NEENED warning shown on the hand set and
MDI after 300 hours
- OPTION#2: Equal to OPTION#1 but Speed reduction after 340 hours
- OPTION#3: Equal to OPTION#2 but the truck definitively stops after 380
hours
12) MAIN CONT VOLT

It specifies the percentage of battery voltage supplied to MC coil to close the
contactor.
13) AUX OUT VOLT

It specifies the percentage of battery voltage supplied to AUX coil to close the
AUXILIARY electro valve.
14) MAIN CONT. V RID

It specifies the percentage of battery voltage supplied to MC coil to keep the
contactor closed. This percentage is lower than the MAIN CONT VOLT value.
15) AUX OUTPUT V RID

It specifies the percentage of battery voltage supplied to AUX coil to keep the
AUXILIARY electro valve closed. This percentage is lower than the AUX
OUT VOLT value.

Flow chart showing how to make changes to OPTION Menu.
AE2T2B ZP0.12
1) Opening Zapi Menu.
2) Press Top Left & Right Buttons to enter SET % ' %

Menu. ' ' '
CONFIG MENU
3) The Display will show: SET MODEL.
4) Press ROLL UP or ROLL DOWN button until % ' '

SET MODEL Menu appears. ' ' '
CONFIG MENU
5) SET OPTIONS appears on the display.
' % '
6) Press ENTER to go into the SET MODEL Menu.
HOUR COUNTER
7) The display will shows the first OPTION.

desired OPTION appears. % ' '
BATTERY CHECK
9) Desired OPTION appears.
10) Press SET UP or SET DOWN button in order to ' ' %

modify the changes. ' ' %
BATTERY CHECK
11) New OPTION appears.
' ' '

12) Press OUT to exit the Menu.
ARE YOU SURE?

13) Confirmation request appears.
14) Press ENTER to accept the changes, or press ' % ' ' '
OUT if you do not accept the changes. ' ' % '
' ' '
CONFIG MENU
15) SET OPTIONS Menu appears.
16) Press OUT again. Display now show the ' ' '
Opening Zapi Menu. ' % '

Flow chart showing how to make changes to ADJUSTMENTS Menu.
AE2T2B ZP0.12
2) Press Top Left & Right Buttons to enter CONFIG % ' %

Menu. ' ' '
CONFIG MENU
3) The display will show: SET MODEL.

ADJUSTMENTS Menu appears. ' ' '
CONFIG MENU
5) ADJUSTMENTS appears on the display.
6) Press ENTER to go into the ADJUSTMENTS ' % '

Menu. ' ' '
BATTERY TYPE
7) The display will shows SET BATTERY TYPE.
8) Press ROLL UP or ROLL DOWN button until the % ' '

desired parameter is reached. % ' '
TROTTLE 0 ZONE
9) The desired parameter appears.
10) Press SET UP or SET DOWN button to modify ' ' %

the adjustment. ' ' %
TROTTLE 0 ZONE
7%
' ' '

11) Press OUT.
' % '
12) Press ENTER to confirm.
13) Repeat the same from 5 to 12 points for the
other adjustments.

Flow chart showing how to use the SET BATTERY TYPE adjustment.
AE2T2B ZP0.12

Menu. ' ' '
CONFIG MENU
4) Press ROLL UP button until % ' '

ADJUSTMENTS Menu appears. ' ' '
CONFIG MENU
5) ADJUSTMENTS appears on the display.

Menu. ' ' '
SET BATTERY TYPE

7) The display will show: SET BATTERY TYPE.
8) Press SET UP to choose nominal value of the ' ' %

battery. ' ' '
SET BATTERY TYPE

9) New battery value appears.
' ' '

10) Press OUT.
ARE YOU SURE?

11) Confirmation request appears.
' ' '
13) Press OUT. Display now shows the Opening ' ' '
Zapi Menu. ' % '

Flow chart showing how to carry out ADJUSTMENT BATTERY operation by
console.
AE2T2B ZP0.12

Menu. ' ' '
CONFIG MENU
4) Press ROLL UP button until ADJUSTMENTS % ' '

Menu appears. ' ' '
CONFIG MENU
5) ADJUSTMENTS appears on the display. ADJUSTMENTS

Menu. ' ' '
SET BATTERY TYPE

7) The display will show the first OPTION. 48V

desired OPTION appears. % ' '
ADJUSTMENT BATTERY
9) ADJUST BATTERY appears. 50.2V
10) Press SET UP or SET DOWN button in order to

' ' %
increase or decrease respectively. Set the value ' ' %
read by an external meter.
ADJUSTMENT BATTERY
11) Battery value appears on the display. 50.6V
' ' '

12) Press OUT to exit the Menu. ' %
ARE YOU SURE?

13) Confirmation request appears. YES=ENTER NO=OUT
' ' '
CONFIG MENU
15) ADJUSTMENTS Menu appears. ADJUSTMENT
16) Press OUT. Display now show the Opening ' ' '
Zapi Menu. ' % '

8.5 Parameter regulation
In addition to the input configuration, parameter modification is made directly by
ZAPI on customer specifications, or by the customer, making the adjustments
using the programming console.
8.5.1 Traction
The following parameters can be modified:
1) ACCELERATION 0
It specifies the motor acceleration at 0 Hz. At level 0 the acceleration is
maximum. Increasing the parameter’s level the acceleration decreases.
2) INV. ACCEL 0
It specifies the motor acceleration at 0 Hz after an inversion of direction. At
level 0 the acceleration is maximum. Increasing the parameter’s level the
acceleration decreases.
3) ACCELERATION 1
It specifies the motor acceleration at ACC PROF. FREQ 1 [Hz]. At level 0 the
acceleration is maximum. Increasing the parameter’s level the acceleration
decreases.
4) ACCELERATION 2
decreases.
5) ACCELERATION 3
decreases.
6) ACC PROF. FREQ 1

In correspondence to this frequency in [Hz] the acceleration is defined by the
ACCELERATION 1 parameter.
7) ACC PROF. FREQ 2

8) ACC PROF. FREQ 3


9) RELEASE BRAKING
Seconds. It controls the deceleration ramp when the travel request is
released. The parameter sets the time needed to decelerate the traction
motor from 100Hz to 0Hz.
10) INVERSION BRAKING

Seconds. It controls the deceleration ramp when the direction switch is
inverted during travel. The parameter sets the time needed to decelerate the
traction motor from 100Hz to 0Hz.
11) INVERSION BRAKING

Seconds. It controls the deceleration ramp when the direction switch is
inverted during travel. The parameter sets the time needed to decelerate the
traction motor from 100Hz to 0Hz.
12) DECELERATION BRAKING

Seconds. It controls the deceleration ramp when the accelerator has turned
down but not completely released. The parameter sets the time needed to
decelerate the traction motor from 100Hz to 0Hz.
13) PEDAL BRAKING

Seconds. It controls the deceleration ramp when the pedal position is changed
but not completely released. The parameter sets the time needed to
decelerate the traction motor from 100Hz to 0Hz.
14) SPEED LIMIT BRAKING

Seconds. It controls the deceleration ramp when a speed reduction has been
activated. The parameter sets the time needed to decelerate the traction motor
from 100Hz to 0Hz.
15) MAX SPEED FORW

It determines the maximum speed in forward direction.
16) MAX SPEED BACK

It determines the maximum speed in backward direction.
17) CUTBACK SPEED 1

Speed reduction when the cutback input is active.
18) FREQUENCY CREEP

Minimum speed when the forward or reverse switch is closed, but the
accelerator is on a minimum position.
19) MAXIMUM CURRENT

This parameter changes the maximum current of the inverter.
20) BRK SMOOTH

It gives a parabolic form to the deceleration ramp.
21) STOP BRK SMOOTH

Hz. It sets the level of frequency where the smooth effect of the deceleration
parabolic form ends.
22) AUXILIARY TIME

Time units value (seconds). For the encoder version, it determines the time
duration the truck is hold on the ramp if the STOP ON RAMP option is ON.
The following table shows the minimum / maximum programmable value for
each parameter. In the table is also present the parameters resolution.
PARAMETER UNIT MIN VALUE MAX VALUE RESOLUTION

ACCELERATION 0 (*) Sec. 0,3 10 0,1
INV. ACCEL 0 (*) Sec. 0,3 10 0,1
ACC PROF. FREQ 1 Hz 0 200 1
RELEASE BRAKING (**) Sec. 0,3 10 0,1
INVERS BRAKING (**) Sec. 0,3 10 0,1
DECELERATION BRAKING (**) Sec. 0,3 10 0,1
PEDAL BRAKING (**) Sec. 0,3 10 0,1
SPEED LIMIT BRAKING (**) Sec. 0,3 10 0,1
MAX SPEED FW Hz 5 200 1
MAX SPEED BW Hz 5 200 1
CUTBACK SPEED 1 %Max Sp 10 100 1
FREQUENCY CREEP Hz 0,6 4 0,1
MAXIMUM CURRENT % IMAX 0 100 1
BRK SMOOTH Num 1 5 0,1
STOP BRK SMOOTH Hz. 3 20 1
AUXILIARY TIME Sec. 0 10 0,1

4 (*) The acceleration time shown is the time from 0 Hz to 100 Hz. This is the ideal
ramp calculated by the software; the real ramp could change as a function of
motor control parameter setting and, obviously, as a function of the load.
4 (**) The braking feature is based upon deceleration ramps. The value shown in the
table is the time to decrease the speed from 100 Hz to 0 Hz. This is the ideal
ramps calculated by the software; the real ramp could change as a function of
motor control parameter setting and, obviously, as a function of the load.
After changing a parameter, press ENTER to confirm data when requested by

the message on the console. Parameters modified and optimized on one unit can
be stored by the console (SAVE) and then released (RESTORE) on another
inverter, thus allowing fast and standardized settings (see console manual for
details).
8.5.2
Pump The following parameters can be modified:
1) ACCELERATION 0
It specifies the motor acceleration at 0 Hz. At level 0 the acceleration is
maximum. Increasing the parameter’s level the acceleration decreases.
2) ACCELERATION 1
decreases.
3) ACCELERATION 2
decreases.
4) ACCELERATION 3
decreases.
5) ACC PROF. FREQ 1

6) ACC PROF. FREQ 2

7) ACC PROF. FREQ 3


8) RELEASE BRAKING
Seconds. It controls the deceleration ramp when the pump request is
released. The parameter sets the time needed to decelerate the traction
motor from 100Hz to 0Hz.
9) MAX SPEED LIFT

It determines the pump maximum speed when LIFT ENABLE switch is
closed .
10) 1ST SPEED COARSE

It determines the pump maximum speed when SPEED1 switch is closed .
11) 2ND SPEED COARSE

It determines the pump maximum speed when SPEED2 switch is closed .
12) 3RD SPEED COARSE

It determines the pump maximum speed when SPEED3 switch is closed.
13) HYD SPEED FINE

It determines the pump maximum speed when an hydraulic steering function
request is received via CAN BUS.
14) CUTBACK SPEED 1

Speed reduction when the cutback input is active.
15) FREQUENCY CREEP

Minimum speed when the LIFT ENABLE switch is closed, but the accelerator
is on a minimum position.
16) MAXIMUM CURRENT

This parameter changes the maximum current of the inverter.
17) AUXILIARY TIME

Time units value (seconds). For the encoder version, is the delay when an
hydraulic steering function request is switched off.

The following table shows the minimum / maximum programmable value for
each parameter. In the table is also present the parameters resolution.
MIN MAX
PARAMETER UNIT RESOLUTION
VALUE VALUE
RELEASE BRAKING (**) Sec. 0,3 10 0,1
MAX SPEED LIFT Hz 5 200 1
ST
1 SPEED COARSE Hz 5 200 1
ND
RD
HYD SPEED FINE Hz 5 200 1
CUTBACK SPEED 1 %Max Sp 10 100 1
FREQUENCY CREEP Hz 0,3 2 0,1
MAXIMUM CURRENT % IMAX 0 100 1
AUXILIARY TIME Sec. 0 10 1

Flow Chart showing how to make Programme changes using Digital Console
fitted with Eprom CK ULTRA.
AE2T2B ZP0.12
1) Opening Zapi Display. 24V 400A 00000
' % '
2) Press ENTER to go into the General Menu. ' ' '
MAIN MENU
4) Press ENTER to go into the Parameter Change ' % '

facility. ' ' '
ACCELERATION 0
5) The Display will show the first parameter. 2
6) Press either ROLL UP and ROLL DOWN to % ' '

display the next parameter. % ' '
7) The names of the Parameters appear on the INV. ACCEL

Display. 0
1
8) When the desired Parameter appears, the

Display will show the parameter value. Press either ' ' %
SET UP (Top Right) or SET DOWN (Bottom Right) ' ' %
buttons to increase/decrease the value.
INV. ACCEL 0
9) The Display will show the New Level. 2
10) When you are satisfied with the results of the ' ' '
changes you have made, Press OUT. ' % '
ARE YOU SURE?

11) The Display asks “ ARE YOU SURE?”. YES=ENTER NO=OUT
12) Press ENTER to accept the changes, or press

OUT if you do not wish to accept the changes and ' % ' ' '
wish to make further modifications to the ' ' % '
parameters. ' ' '
MAIN MENU

8.6 Programming console functions
- Functional configuration (see 8.1, 8.2, 8.3, 8.4).
- Parameter programming (see 8.5.1, 8.5.2).
- Tester: the user can verify the state of the following parameters:
TRACTION PUMP
battery voltage (V) battery voltage (V)
motor voltage (%) motor voltage (%)
voltage booster (%) voltage booster (%)
frequency (Hz) frequency (Hz)
encoder (Hz) encoder (Hz)
slip value (Hz) slip value (Hz)
current rms (A) current rms (A)
motor power (W) motor power (W)
battery charge (%) battery charge (%)
temperature (°C) temperature (°C)
motor temperat. (°C) motor temperature (°C)
accelerator (V) handle/seat switch (ON/OFF)
handle/seat switch (ON/OFF) lifting control (V)
forward switch (ON/OFF) lifting enable (ON/OFF)
backward switch (ON/OFF) 1st speed switch (ON/OFF)
cutback switch (ON/OFF) 2nd speed switch (ON/OFF)
hand brake (ON/OFF) 3rd speed switch (ON/OFF)
Brakepedal pot. (%) hydro speed req. (ON/OFF)
2ND hourmeters 2nd hourmeters
- Save function (for storing data).

- Restore function (for loading parameters on another inverter).
- Display of the last 5 alarms including hour-meter value and temperature at
the moment of the alarm.
- Accelerator range programming: records the minimum and maximum useful
accelerator stroke values for both direction of running.
- See the console manual for a detailed description of function and
parameters.

8.7 Sequence for Ac Inverter Traction setting
When the "Key Switch" is closed, if no alarms or errors are present, the Console
Display will be showing the Standard Zapi Opening Display.
If the controller is not configured to your requirements, follow the sequence
detailed on Chapter 9.2. Remember to re-cycle the Key Switch if you make any
changes to the controller’s configuration. Otherwise follow the sequence detailed
below:
1) Select the Options required. See Chapter 8.4.1.

2) Select and set the Battery Voltage. See Chapter 8.4.1.
3) Confirm correct installation of all wires. Use the Console’s TESTER function
to assist.
4) Perform the accelerator signal acquisition procedure using the Console
“PROGRAM VACC”. Procedure is detailed on Chapter 9.4.
5) Set the "MAXIMUM CURRENT” Current, using the table on Chapter 8.5.1.
6) Set the Acceleration Delay requirements for the machine. Test the
parameters in both directions.
7) Set the FREQUENCY CREEP level starting from level 0.3 Hz. The machine
should just move when the accelerator microswitch is closed. Increase the
Level accordingly.
8) Set the Speed Reductions as required. Make adjustments to “CUTBACK
SPEED” Check the performance with the accelerator pedal totally depressed.
If the machine is a forklift, check the performance with and without load.
9) RELEASE BRAKING. Operate the machine at full speed. Release the
accelerator pedal. Adjust the level to your requirements. If the machine is a
forklift, check the performance with and without load.
10) INVERSION BRAKING. Operate the machine at 25% full speed. Whilst
travelling INVERT the Direction Switch. Set a soft Level of Inversion Braking.
When satisfactory, operate the machine at Full Speed and repeat. If the
machine is a Forklift, repeat the tests and make adjustments with and without
load. The unloaded full speed condition should be the most representative
condition.
11) DECELERATION BRAKING. Operate the machine at full speed. Release the
accelerator pedal until 50% of its range is reached. Adjust the level to your
requirements. If the machine is a forklift, check the performance with and
without load.
12) PEDAL BRAKING (If used). Operate the machine at full Speed. Release the
accelerator pedal and press the Pedal Brake. Set braking level to your
requirements. If the machine is a forklift, check the performance with and
without load.
13) SPEED LIMIT BRAKING (If used). Operate the machine at full Speed. Close
the speed reduction switch. Set braking level to your requirements. If the
machine is a forklift, check the performance with and without load.
14) Set “MAX SPEED FORW”.
15) Set “MAX SPEED BACK” (Reverse).
16) Make the choice for the truck behaviour on a slope (see chapter 8.4). If the
"Stop on ramp" option is ON, set the desired value of "auxiliary time"
parameter.
17) Set “SET TEMPERATURE”, setting the motor thermal sensor type used.

8.8 Sequence for Ac Inverter Pump setting
When the "Key Switch" is closed, if no alarms or errors are present, the Console
Display will be showing the Standard Zapi Opening Display.
If the controller is not configured to your requirements, follow the sequence
detailed on Chapter 9.2. Remember to re-cycle the Key Switch if you make any
changes to the controller’s configuration. Otherwise follow the sequence detailed
below:
1) Select the Options required. See Chapter 8.4.2.

2) Select and set the Battery Voltage. See Chapter 8.4.2.
3) Confirm correct installation of all wires. Use the Console’s TESTER function
to assist.
4) Perform the lift signal acquisition procedure using the Console “PROGRAM
VACC”. Procedure is detailed on Chapter 9.4.
5) Set the "MAXIMUM CURRENT” Current, using the table on Chapter 8.5.2.
6) Set the Acceleration and Deceleration Delay requirements for the pump.
7) Set the “FREQUENCY CREEP” level starting from 0 Hz. The pump should
just turn when the request microswitch is closed. Increase the level
accordingly.
8) Set the Speed Reductions as required. Make adjustments to “CUTBACK
SPEED 1”. Check the performance with the full request. Check the
performance with and without load.
9) Set “MAX SPEED LIFT” , max speed of pump motor when Lift enable switch
is closed.
10) Set “1ST SPEED COARSE”, speed of pump motor when SPEED1 switch is
closed.
11) Set “2ND SPEED COARSE”, speed of pump motor when SPEED2 switch is
closed.
12) Set “3RD SPEED COARSE”, speed of pump motor when SPEED3 switch is
closed.
13) Set “HYD SPEED FINE” to adjust the hydraulic steering speed (pump motor
speed when HYDRO function is requested).
14) Set “AUXILIARY TIME” (time delay before pump stops when an hydraulic
steering function request is switched off).
15) Set “SET TEMPERATURE”, setting the motor thermal sensor type used.

8.9 Tester: description of the function
The most important input or output signals can be measured in real time using
the TESTER function of the console. The Console acts as a multimeter able to
read voltage, current and temperature. The following definition listing shows the
relative measurements.
8.9.1 Traction
1) BATTERY VOLTAGE
Level of battery voltage measured at the input to the key switch.
2) MOTOR VOLTAGE
This is the RMS voltage supplied to the motor by the inverter; it is expressed
as a percentage of the full voltage (which depends of the battery voltage).
3) 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.
4) FREQUENCY
This is the frequency of the voltage and current supplied to the motor.
5) ENCODER
This is the speed of the motor, expressed in the same unit of the frequency;
this information comes from the speed sensor.
6) 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.
7) CURRENT RMS
Root Mean Square value of the motor current.
8) MOTOR POWER
It is the power provided to the motor.
9) BATTERY CHARGE
The percentage Charge level of the battery.
10) TEMPERATURE
The temperature measured on the aluminium heat sink holding the MOSFET
devices.
11) MOTOR TEMPERAT.
This is the temperature of the motor; if the option is programmed "None" (see
chapter 8.4.1) it shows 0°.
12) ACCELERATOR
The voltage of the accelerator potentiometer's wiper (CPOT). The voltage
level is shown on the Left Hand Side of the Console Display and the value in
percentage is shown on the Right Hand Side.
13) HANDLE/SEAT switch
The level of the Handle/Seat digital entry
- ON / GND = active entry of closed switch.
- OFF / GND = non active entry of open switch.
14) FORWARD SWITCH
The level of the Forward direction digital entry FW.
- ON / +VB = active entry of closed switch.
15) BACKWARD SWITCH
The level of the Reverse direction digital entry BW.
16) CUTBACK SWITCH

The level of the Speed Reduction Microswitch.
- ON / GND = active entry of speed reduction microswitch.
- OFF / +VB = non active entry of microswitch.
17) HAND BRAKE
The level of the Hand Brake Microswitch.
- ON / GND = active entry of Brake pedal Microswitch.
18) BRAKEPEDAL POT.
The percentage of the pressure on the brake pedal (100% if the pedal is
totally pressed, 0% if the pedal is released).
19) 2ND HOURMETERS
This parameter displays the working hour of traction controller.
8.9.2
Pump 1) BATTERY VOLTAGE
Level of battery voltage measured at the input to the key switch.
2) 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).
3) 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.
4) FREQUENCY
This is the frequency of the voltage and current supplied to the motor.
5) ENCODER
This is the speed of the motor, expressed in the same unit of the frequency;
this information comes from the speed sensor.
6) 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.
7) CURRENT RMS
Root Mean Square value of the motor current.
8) MOTOR POWER
It is the power provided to the motor.
9) BATTERY CHARGE
The percentage Charge level of the battery.
10) TEMPERATURE
The temperature measured on the aluminium heat sink holding the MOSFET
devices.
11) MOTOR TEMPERATURE
This is the temperature of the motor; if the option is programmed "None" (see
chapter 8.4.2) it shows 0°.
12) HANDLE/SEAT switch
The level of the Handle/Seat digital entry
- OFF / +VB = non active entry of open switch.
13) LIFTING CONTROL
The voltage of the lift potentiometer's wiper (CPOT). The voltage level is
shown on the Left Hand Side of the Console Display and the value in
percentage is shown on the Right Hand Side.
14) LIFT ENABLE
Status of the lifting switch.
15) 1ST SPEED SWITCH
Status of the first speed switch of the pump.

16) 2ND SPEED SWITCH
Status of the second speed switch of the pump.
17) 3RD SPEED SWITCH
Status of the third speed switch of the pump.
- OFF / +VB = non active entry of open switch.
18) HYDRO SPEED REQ.
Status of the hydro speed request of the pump.
- ON = an hydro speed request is received via Can Bus.
- OFF = no hydro speed request active.
19) CUTBACK SWITCH
The level of the Speed Reduction Microswitch.
- ON / GND = active entry of speed reduction microswitch.
20) 2ND HOURMETERS
This parameter displays the working hour of pump controller.

Flow Chart showing how to use the TESTER function of the Digital Console.
AE2T2B ZP0.12
' % '
2) Press ENTER to go into the General menu. ' ' '
MAIN MENU

TESTER MENU appear on the display. % ' '
MAIN MENU
5) The Display shows: TESTER
' % '
6) Press ENTER to go into the TESTER function. ' ' '
7) The first variable to be tested is shown on the BATTERY

Display. VOLTAGE
%
8) Press either ROLL UP or ROLL DOWN buttons

% ' '
until your desired variable for measurement % ' '
appears on the Display.
' ' '

9) When you have finished, Press OUT. ' %
FREQUENCY
10) The Display shows: Hz
11) Press OUT again and return to Opening Zapi ' ' '
Display. ' % '
MAIN
MENU
TESTER
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.
21) Other functions

8.10 Description of the Console “SAVE” function
The SAVE function allows the operator to transmit the Parameter values and
Configuration data of the inverter into the Console memory. It is possible to load
64 different programmes.
The information saved in the Console memory can then be reloaded into another
inverter using the RESTORE function.
The data that is available via the SAVE function is as follows:
- All Parameter Values (PARAMETER CHANGE).
- Options (SET. OPTIONS).
- The Level of the Battery (ADJUST BATTERY).
Flow Chart showing how to use the SAVE function of the Digital Console.
AE2T2B ZP0.12
' % '
MAIN MENU

SAVE PARAM. appears on the display. % ' '
MAIN MENU
5) The Display will show: SAVE
' % '
6) Press ENTER to go into the SAVE function. ' ' '
7) If this facility has been used before the type of

SELECT: MOD. 00
inverter data stored appears on the top Main with a FREE
2 digit reference.
8) Keep pressing either ROLL UP or ROLL DOWN

% ' '
keys until the second Main indicates a FREE % ' '
storage facility.
SELECT: MOD. 01
FREE
' % '
9) Press ENTER to commence SAVE routine. ' ' '
10) You can see the items that are being stored READING …
whilst the SAVE routine is happening. ACCEL. DELAY
(ECC.)
MAIN MENU
11) When finished, the Console shows: SAVE
12) Press OUT to return to the Opening Zapi ' ' '
Display. ' % '

8.11 Description of Console “RESTORE” function
The RESTORE PARAM function allows transfer of the Console’s stored data into
the memory of the inverter. 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).
- The level of the Battery (ADJUST BATTERY).
U ATTENTION: When the RESTORE operation is made, all data in the inverter
memory will be written over and replace with data being restored.
Flow Chart showing how to use the RESTORE function of the Digital Console.
AE2T2B ZP0.12
' % '
MAIN MENU

RESTORE PARAM. appears on the Display. % ' '
MAIN MENU
5) The Display will show: RESTORE PARAM.
6) Press ENTER to go into the RESTORE PARAM. ' % '

Function. ' ' '
7) The Display shows the type of Model stored, SELECT : MOD. 00

with a Code Number. AE2T ZAPI
V1
8) Keep pressing either ROLL UP and ROLL

% ' '
DOWN buttons until the desired model appears on % ' '
the Display.
SELECT : MOD. 01
AE2T ZAPI V1
9) Press ENTER to commence the Restore ' % '

operation. ' ' '
10) The Display will ask “ARE YOU SURE?”. ARE YOU SURE?
YES=ENTER NO=OUT
' % ' ' '

11) Press ENTER for YES, or OUT for No. ' ' ' ' % '
'

12) You can see the items that are being stored in
STORING
the inverter memory whilst the RESTORE routine is ACCELER.
happening. DELAY
MAIN MENU
13) When finished the Console displays: RESTORE PARAM.
Display. ' % '
8.12 Description of Console “PROGRAM VACC” function

This enables adjustment of the minimum and maximum useful signal level, in
either direction. This function is unique when it is necessary to compensate for
asymmetry with the mechanical elements associated with the potentiometer,
especially relating to the minimum level.
The two graphs show the output voltage from a non-calibrated potentiometer with
respect to the mechanical “zero” of the control lever. MI and MA indicate the point
where the direction switches close. 0 represents the mechanical zero of the
rotation.
The Left Hand graph shows the relationship of the motor voltage without signal
acquisition being made. The Right Hand Graph shows the same relationship after
signal acquisition of the potentiometer.
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.
AC2 ZAPI V0.0

' % '
2) Press ENTER to go into the General Menu. ' ' '
MAIN MENU

PROGRAM VACC appears on the display. % ' '
MAIN MENU
5) The Display will show: PROGRAM
6) Press ENTER to go into the PROGRAM VACC ' % '

routine. ' ' '
7) The Display will show the minimum and

VACC
maximum values of potentiometer wiper output. SETTING
Both directions can be shown. 4.8 4.8
8) Press ENTER to clear these values. ' % '

Display will show 0.0. ' ' '
9) Select Forward Direction, close any interlock MIN VACC MAX

switches that may be in the system. 0.0 - 0.0
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 Item MIN VACC MAX
10. 0.6 ↑ 4.4
' ' '

12) When finished, press OUT. ' %
ARE YOU SURE

13) The Display will ask: “ARE YOU SURE?”. YES=ENTER NO=OUT
' % '
14) Press ENTER for yes, or OUT for NO. ' %
MAIN MENU
15) When finished, the Console shows: PROGRAM
16) Press OUT again to return to the Opening Zapi ' ' '
Menu. ' % '

8.13 Description of the battery charge detection setting
The Battery Charge detection uses two setting that specify the Full Charge
Voltage Level (100%) and the Discharge Voltage Level (10%). These two
settings are the Bat.Max.Adj and the Bat.Min.Adj. It is possible to adapt the
Battery Charge Detection to your specific battery, by changing the above two
settings (e.g. if the Battery Discharged Detection occurs when the battery is not
totally discharged, it is necessary to reduce the Bat.Min.Adj setting as indicated
in the figure below).
48V NOMINAL BATTERY VOLTAGE
24V NOMINAL BATTERY VOLTAGE

8.14 Description of “ALARMS” menu
The ALARMS logbook in the MAIN MENU’ records the alarms of the controller. It
has a FIFO (First Input First Output) structure that means the oldest alarm is lost
when the database is full and a new alarm occurs. The logbook is composed of
five locations getting possible to stack five different type of alarms with the
following information:
1) The alarm code

2) The times that each alarm occurs consecutively
3) The Hour Meter value when the first event of every alarm occurred
4) And the inverter temperature when the first event of every alarm occurred.
This function permits a deeper diagnosis of problems as the recent history can be
revised.
4 NOTE: if the same alarm is continuously happening, the controller does not use
new memory of the logbook, but only updates the last memory cell increasing the
related counter (point 2) of previous list). Nevertheless, the hourmeter indicated
in this memory refers to the first time the alarm occurred. In this way, comparing
this hourmeter with the controller hourmeter, it is possible to determine:
- When this alarm occurred the first time.
- How many hours are elapsed from the first occurrence to now.
- How many times it has occurred in said period.

Flow Chart showing how to use the ALARMS function via the Digital Console.
AE2T2B ZP0.12
' % '
MAIN MENU

PARAMETER CHANGE appears on the display. % ' '
MAIN MENU
5) The Display will show: ALARMS
' % '
6) Press ENTER to go into the ALARMS function. ' ' '
CODE
7) The Display will show the most recent Alarm. 00005 #02 20°C
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 CODE

show: ALARM NULL. 00007 #03 18°C
10) When you have finished looking at the Alarms, ' ' '
press OUT to exit the ALARMS menu. ' % '
CLEAR LOGBOOK?
11) The Display will ask “CLEAR LOGBOOK?”. YES=ENTER NO=OUT
' % ' ' '

12) Press ENTER for yes, or OUT for NO. ' ' ' ' % '
'
Display. ' % '
8.15 Faults diagnostic system

The fault diagnostic system of ACE-2 controller is divided into 2 main groups of
faults:
ALARMS: these are the faults which open the power section, which means the
power bridge is opened and, when possible, the LC is opened and EB is applied.
These are faults related to:
- failures in the motor/controller that the power system is not anymore able to
drive the truck
- safety related failures
WARNINGS: these are faults which do not stop the truck or stop it by a controlled
regenerative braking. In other words, the controller is working well, but it has
detected conditions to reduce the performances or to stop the truck without
opening the power devices. These warnings are related to:
- wrong operator sequences
- conditions which require performance reduction (like high temperatures, ….)
8.16 Microcontroller alarms overview
Error Description Effect Machine status Restart

Code When the test is procedure
done
Flash checksum The program verify MC is not closed, Start-up Key re-cycle
is EB is applied,
not OK traction/pump
stopped
Analog The analogue MC is opened, Start-up, running Traction/Pump
channel EB is applied, request
Reading is not traction/pump
updated stopped
Wrong set battery The absolute MC is not closed, Start-up Traction/Pump
difference between EB is applied, Request
the Key voltage and traction/pump
the nominal battery stopped
voltage is greater
than 20% of Vbatt
nom.
Capacitor charge Power capacitors MC is not closed, Start-up Traction/Pump
voltage does EB is applied, request
not increase Traction/Pump
stopped
Coil shorted hw ko The harware to MC is not closed, Start-up Traction/Pump
check a MC or EB is applied, Request
EB/AUX coil Traction/Pump
shorted is damaged stopped
Driver shorted The MC driver is MC is opened (the Start-up, stand-by, Traction/Pump
shorted so it is not command is running Request
able to open the released), EB is
contactor applied,
Traction/Pump
stopped
Aux driver shorted The EB/AUX driver MC is opened (the Start-up, stand-by, Traction/Pump
is shorted so it is command is running Request
not able to open the released), EB is
contactor applied,
Traction/Pump
stopped
Safety in The safety input is MC is opened, Start-up, stand-by, Key re-cycle
open (it is not EB is applied, running
connected to –Batt) Traction/Pump
stopped

Safety out The Safety-out MC is not closed, Start-up Traction/Pump
driver is damaged EB is applied, request
(shorted or open) Traction/Pump
stopped
Watchdog#1 The watchdog MC is opened, Start-up, stand-by, Key re-cycle
signal #1 is not in EB is applied, running
the correct status Traction/Pump
stopped
Watchdog#2 The watchdog MC is opened, Start-up, stand-by, Key re-cycle
signal #2 is not in EB is applied, running
the correct status Traction/Pump
stopped
Keyoff shorted At Start-up the Key- MC is not closed, Start-up Key re-cycle
off EB is applied,
logic signal is low Traction/Pump
stopped
Logic Failure#1 An undervoltage / MC is not closed, Start-up, stand-by, Traction/Pump
overvoltage EB is applied, running request
condition has been Traction/Pump
detected stopped
Logic failure #3 High current HW MC is not closed, Start-up Traction/Pump
protection circuit is EB is applied, request
damaged Traction/Pump
stopped
Power mos shorted Short circuit on the MC is not closed, Start-up Traction/Pump
power Mosfets EB is applied, request
Traction/Pump
stopped
Vmn high Motor output MC is not closed, Start-up, Traction/Pump
voltage higher than EB is applied, Stand-by request
expected Traction/Pump
stopped
Vmn low Motor output MC is opened, Start-up, running Traction/Pump
voltage lower than EB is applied, request
expected Traction/Pump
stopped
Stby I high In stby condition MC is not closed, Start-up Traction/Pump
(no current applied EB is applied, request
to the motor) the Traction/Pump
current feedbacks stopped
are out of permitted
stby range
Wrong 0 voltage The motor phases MC is not closed, Start-up Traction/Pump
voltage feedback EB is applied, Request
are out of permitted Traction/Pump
range stopped
Contactor closed LC contact is stuck MC is not closed Start-up Traction/Pump
(command is not Request
activated),
EB is applied,
Traction/Pump
stopped

Hardware fault 20 The Mosfets driver MC is not closed , Start-up Key re-cycle
are not switched off EB is applied,
with Watch-dog Traction/Pump
signal in alarm stopped
status
Hardware fault 21 The EB/AUX driver MC is not closed , Start-up Key re-cycle
is not switched off EB is applied,
status
Hardware fault A1 The MC driver is MC is not closed , Start-up Key re-cycle
not switched off EB is applied,
status
Coil shorted MC Shortcircuit on MC MC is opened, Start-up Traction/Pump
coil EB is applied, (immediately after Request
Traction/Pump MC closing),
stopped stand-by, running
Coil shorted EF Shortcircuit on MC is opened, Start-up Traction/Pump
EB/AUX coil EB is applied, (immediately after Request
Traction/Pump MC closing), stand-
stopped by, running
Contactor open The MC coil has MC is opened , Start-up Traction/Pump
been driven but MC EB is applied, (immediately after Request
does not close Traction/Pump MC closing),
stopped Stand-by,
running
Logic failure #2 Motor phases MC is opened , Start-up Traction/Pump
voltage feedback EB is applied, (immediately after Request
circuits are Traction/Pump MC closing)
damaged stopped
Contactor driver Driver of MC coil is MC is opened (the Stand-by, running Traction/Pump

damaged (not able command is Request
to close) released), EB is
applied,
Traction/Pump
stopped
Aux Driver Open Driver of EB/AUX MC is opened, EB Stand-by, running Traction/Pump
coil is damaged is applied, Request
(not able to apply Traction/Pump
the brake) stopped
Encoder Problem on the MC is opened, EB is Running Traction/Pump

Error encoder reading applied, Request
Traction/Pump
stopped
Wrong Ram The program checks MC is opened, EB is Continuous Key re-cycle

Memory the contents of main applied,
RAM registers and Traction/Pump
find a “dirty value” stopped

8.17 Analysis and troubleshooting of alarms displayed on console
1) FLASH CHECKSUM
Cause:
After Key-on the software verifies the integrity of program stored in the flash
memory, if the verify has a negative result this alarm is generated.
Troubleshooting:
The problem is in the microcontroller flash memory, which could be
damaged, or in the program stored inside, which could be corrupted.
Try to program the logic again, if the alarms is still signalled the problem is in
the microcontroller. Replace the ACE logic board.
2) ANALOG
Cause:
This alarm occurs when the A/D conversion of the analog inputs gives frozen
value, on all of the converted signals, for more than 400msec. The goal of
this diagnosis is to detect a failure of the A/D converter or a problem in the
code flow that omits the refreshing of the analog signal conversion.
Troubleshooting:
If the problem occurs permanently it is necessary to substitute ACE logic
board.
3) WRONG SET BATTERY

Cause:
At start-up, the controller checks the battery voltage and verify it is within a
window around the nominal value.
Troubleshooting:
A) Check that the controller SET BATTERY parameter value matches
the battery nominal voltage.
B) Check that TESTER MENU / BATTERY VOLTAGE parameter shows
same value as the battery voltage measured with a voltmeter. If it does
not match, then do an “ADJUST BATTERY” function.
C) Replace the battery.
4) CAPACITOR CHARGE
Follows the charging capacitor system:

Cause:
When the key is switched ON, the inverter tries to charge the power
capacitors through a series of a PTC and a power resistance, and check if the
capacitor are charged within a timeout. If the capacitor voltage measured is
less than 20% of the nominal battery voltage, an alarm is signalled; the main
contactor is not closed.
Troubleshooting:
A) There is an external load in parallel to capacitor bank, which sinks
current from the controller capacitors pre-charging circuit, thus
preventing the caps from charging. Check if a lamp or a dc/dc converter
or an auxiliary load is placed in parallel to capacitor bank.
B) The charging resistance or PTC is opened; insert a power resistance
across line contactor power terminals; if the alarm disappears, it means
the controller internal charging resistance is damaged.
C) The charging circuit has a failure, inside the controller.
D) There is a problem in the controller power section.
5) COIL SHORT HW KO
Cause:
The hardware circuits which manages short circuits protection of LC and
EB/AUX coils has a problem.
Troubleshooting:
This type of fault is not related to external components; replace the ACE logic
board.
6) DRIVER SHORTED
Cause:
The driver of the main contactor coil is shorted.
Troubleshooting:
A) Check if there is a short or a low impedance pull-down between NMC
(CNA#16) and –BATT.
B) The driver circuit is damaged in the logic board, which has to be
replaced.
7) AUX DRIVER SHORTED

Cause:
The driver of the electro mechanic brake/ auxiliary electro valve coil is
shorted.
Troubleshooting:
A) Check if there is a short or a low impedance pull-down between
NEB/NAUX (CNA#18) and –BATT.
replaced.
8) SAFETY IN
Cause:
The safety input is opened and accordingly the MC is opened an EB/AUX
OUT coil is driven.
Troubleshooting:
Check the CAN#11 input, if it is connected to –Batt and the alarm is
generated then there is a fault in the SAFETY IN hardware circuit. Replace
the logic board.
9) SAFETY OUT
Cause:
The safety out driver is shorted.

Troubleshooting:
A) Check if there is a short or a low impedance pull-down between SAFETY
OUT (CAN#19) and –BATT.
replaced.
10) WATCHDOG#1
Cause:
generated it. At stby or running condition the watch dog signal is not active
(in alarm status).
Troubleshooting:
11) WATCHDOG#2
Cause:
generated it. At stby or running condition the watch dog signal is not active
(in alarm status).
Troubleshooting:
12) KEYOFF SHORTED

Cause:
This fault is displayed when the controller detects a low logic level of Key-Off
signal during Start-Up diagnosis.
Troubleshooting:
It is very likely the fault is due to an under voltage, so it is suggested to
check:
A) Key input signal down-going pulses (below under voltage threshold)
due to external loads, like DC/DC converters starting-up, relays or
contactor switching, solenoids energizing / de-energizing.
B) Check the connection of power cables to the battery terminal, positive
and negative, to MC and to controller +Batt and –Batt, which must be
screwed with a torque comprised in the range 13Nm÷15Nm.
C) If no voltage transient is detected on the supply line and the alarm is
present every time the key is switched ON, the failure is probably in the
controller hardware, so it is necessary to replace the logic board.
13) LOGIC FAILURE#1

Cause:
This fault is displayed when the controller detects an over voltage or under
voltage condition. Over voltage threshold is 45V, under voltage threshold is
9V in the 24V controller. In 48V controller over voltage threshold is 65V,
under voltage threshold is 11V.
Troubleshooting:
Troubleshooting of fault displayed at start-up or in standby; in these cases it is
very likely the fault is due to an under voltage, so it is suggested to check: A)
Key input signal down-going pulses (below under voltage threshold) due
to external loads, like DC/DC converters starting-up, relays or contactor
switching, solenoids energizing / de-energizing.
B) Check the connection of power cables to the battery terminal, positive
and negative, to MC and to controller +Batt and –Batt, which must be
screwed with a torque comprised in the range 13Nm÷15Nm.

C) If no voltage transient is detected on the supply line and the alarm is
present every time the key is switched ON, the failure is probably in the
controller hardware, so it is necessary to replace the logic board.
Troubleshooting of fault displayed during motor driving; in this case it can
be an under voltage or an over voltage condition.
D) If the alarm happens during traction acceleration or driving hydraulic
functions, it is very likely it is an under voltage condition; check battery
charge condition, power cable connection.
E) If the alarm happens during release braking, it is very likely it is due to
over voltage condition; check line contactor contact, battery power cable
connection.
14) LOGIC FAILURE #3

Cause:
Hardware problem in the logic card circuit for high current (overload)
protection.
Troubleshooting:
This type of fault is not related to external components, so, when it is present it
is necessary to replace the ACE logic board.
15) POWER MOS SHORTED

Cause:
Before switching the MC on, the software checks the power bridge: it turns
on alternatingly the Low side and High side Power Mosfets and expects the
phases voltage to decrease down to –BATT (increase up to +Batt). If the
phases voltage do not follow the commands, this alarm occurs.
Troubleshooting:
This type of fault is not related to external components; replace the controller.
16) VMN HIGH

Cause 1:
Before switching the LC on, the software checks the power bridge: it turns on
alternatingly the Low side Power Mosfets and expects the phases voltage to
decrease down to -BATT. If the phases voltage is higher than 10% of
nominal battery voltage, this alarm occurs.
Cause 2:
This alarm may occur also when the start up diagnosis is overcome, and so
the LC is closed. In this condition, the phases’ voltages are expected to be
lower than 1/2 Vbatt. If it is higher than that value, fault status is entered.
Troubleshooting:
A) If the problem occurs at start up (the LC does not close at all), check:
- Motor internal connections (ohmic continuity)
- Motor power cables connections
- If the motor connection are OK, the problem is inside the controller,
replace it.
B) If the problem occurs after closing the LC (the LC closed and then opens
back again), check:
- Motor connections
- If motor phases windings/cables have leakages towards truck frame
- If no problem are found on the motors, the problem is inside the
controller, replace it.
17) VMN LOW

Cause 1:
Start-up test. Before switching the LC on, the software checks the power
bridge: it turns on alternatingly the High side Power Mosfets and expects the

phases voltage to increase toward the rail capacitor value. If the phases
voltage is less than 66% of the rail capacitor voltage, this alarm occurs.
Cause 2:
Motor running test. When the motor is running, power bridge is ON, the motor
voltage feedback is tested; if it is lower than commanded value (a window of
values are considered) fault status is entered.
Troubleshooting:
A) If the problem occurs at start up (the LC does not close at all), check:
- Motor leakage to truck frame
- If the motor connections are OK, the problem is inside the controller,
replace it.
B) If the alarm occurs during motor running, check:
- Motor connections
- If motor phases windings/cables have leakages towards truck frame
- That the LC power contact closer properly, with a good contact
- If no problem are found on the motors, the problem is inside the
18) STBY I HIGH

Cause:
The current transducer or the current feedback circuit is damaged in the
controller.
Troubleshooting:
This type of fault is not related to external components so, when it is present, it
is necessary to replace the controller.
19) WRONG 0 VOLTAGE

Cause:
At start-up the high resolution VMN feedback is not comprised in a permitted
window of values centred around 2,5V. The circuit is damaged in the
controller.
Troubleshooting:
It is suggested to check:
- Motor leakage to truck frame
- If the motor connections are OK, the problem is inside the controller,
replace the logic board
20) CONTACTOR CLOSED

Cause:
Before driving the MC coil, the controller checks if the contactor is stuck. The
controller drives the bridge for some tens milliseconds, trying to discharge the
capacitors bank. If the capacitor voltage does decrease by 20% of the key
voltage the alarm is generated.
Troubleshooting:
It is suggested to verify the power contacts of LC; to replace the LC is
necessary.
21) HARDWARE FAULT 20

Cause:
Before driving the MC coil, the controller checks if the Mosfets drivers are
turned of by a not active (alarm status) Watch-dog signal. If they are not
turned of then the alarm is generated.

Troubleshooting:
The problem is inside the controller, no external component are involved,
replace the logic board.
22) HARDWARE FAULT 21

Cause:
Before driving the MC coil, the controller checks if the EB/AUX driver is
turned of by a not active (alarm status) Watch-dog signal. If it is not turned of
then the alarm is generated.
Troubleshooting:
23) HARDWARE FAULT A1

Cause:
Before driving the MC coil, the controller checks if the MC/AUX driver is turned
of by a not active (alarm status) Watch-dog signal. If it is not turned of then the
alarm is generated.
Troubleshooting:
24) COIL SHORTED MC

Cause:
This alarm occurs when there is a short circuit of the MC coils connected to
CNA#16 output. After the overload condition has been removed, the alarm
exits automatically by releasing and then enabling a travel demand.
Troubleshooting:
A) The typical root cause for this error code to be displayed is in the
harness or in the load coil. So the very first check to carry out concerns
connections between controller outputs and loads.
B) In case no failures/problems have been found externally, the problem is
in the controller, which has to be replaced.
25) COIL SHORTED EF

Cause:
This alarm occurs when there is a short circuit of the EB/AUX coils connected
to CNA#18 output. After the overload condition has been removed, the alarm
exits automatically by releasing and then enabling a travel demand.
Troubleshooting:
A) The typical root cause for this error code to be displayed is in the
harness or in the load coil. So the very first check to carry out concerns
connections between controller outputs and loads.
B) In case no failures/problems have been found externally, the problem is
in the controller, which has to be replaced.
26) CONTACTOR OPEN

Cause:
The main contactor coil has been driven by the controller, but the contactor
does not close.
Troubleshooting:
A) It could be a problem of the contacts in the MC that are not working
(does not pull-in), try replacing the MC.
B) If the contactors of MC are working correctly than the problem is in the

27) LOGIC FAILURE #2
Cause:
Fault is in the hardware section of the logic board which manages the
phase’s voltage feedback.
Troubleshooting:
This type of fault is not related to external components, so when it happens it
is necessary to replace the ACE2 logic board.
28) CONTACTOR DRIVER

Cause:
The MC coil driver is not able to drive the load. The device itself or its driving
circuit is damaged.
Troubleshooting:
This type of fault is not related to external components; replace the ACE2
logic board.
29) AUX DRIVER OPEN

Cause:
The EB/AUX coil driver is not able to drive the load. The device itself or its
driving circuit is damaged.
Troubleshooting:
This type of fault is not related to external components; replace the ACE2
logic board.
30) ENCODER ERROR

Cause:
This fault is signalled in following conditions: the frequency supplied to the
motor is higher than 40 Hz and the signal feedback from the encoder has a
jump higher than 40 Hz in few tens mSec. This condition is related to a
malfunctioning of the encoder.
Troubleshooting:
A) Check both the electric and the mechanical encoder functionality,
the wires crimping.
B) Check the encoder mechanical installation, if the encoder slips inside its
compartment raising this alarm condition.
C) Also the electromagnetic noise on the sensor bearing can be a cause for
the alarm. In these cases try to replace the encoder.
D) If the problem is still present after replacing the encoder, the failure is in
the controller.
31) WRONG RAM MEMORY

Cause:
The algorithm implemented to check the main RAM registers finds a wrong
contents: the register is “dirty”. This alarm inhibit the machine operations.
Troubleshooting:
Try to switch the key off and then on, if the alarm is still present replace the
ACE2 logic board.

8.18 Microcontroller warning overview
Error code Description Effect Machine status Restart
when the test is procedure
done
Vacc not OK The accelerator/ lift Traction/ Pump motor Start-up, stand- Traction/Pump
potentiometer value is higher is stopped by, running request
than the minimum value
recorded, and the
direction/enable switches are
opened.
Incorrect start Incorrect starting sequences Traction/ Pump motor Start-up, stand- Traction/Pump
is stopped by request
Vacc out of The accelerator input is out Traction/ Pump motor Start-up, stand- Traction/Pump
range of the range Vacc_min ÷ is stopped by, running request
Vacc_max, which has been
acquired with “PROGRAMM
VACC” function.
Temperature The controller has reached Traction controller Continuous
the thermal cutback reduces the maximum
temperature of 85°C when current linearly from
the current is IMAX Imax (85°C) down to
0A (105°C)
Motor Motor temperature sensor is The maximum current Continuous
temperature opened (if digital) or has is reduced to half and
overtaken the threshold of speed is reduced
150°C (if analogue)
Brake run out The Brake potentiometer No effect, the warning Continuous Traction/Pump
input is at the maximum is only displayed request
value without the HB request through the console
Handbrake A traction request is done Traction motor is Stand-by, Traction/ Pump
with the Handbrake input stopped running request
active
Current Gain The Maximum current gain Controller works, but Start-up, stand-
parameters are the default with low maximum by
values, which means the current
maximum current adjustment
procedure has not been
carried out yet
Sens mot The output of the motor The maximum current Continuous
temp Ko thermal sensor is out of is reduced to half and
range. speed is reduced
Thermic sens The output of the controller The maximum current Continuous
Ko thermal sensor is out of is reduced to half and
range. speed is reduced
Slip profile Error on the parameters of Traction/Pump motor Start-up, stand- Traction/ Pump
the slip profile setting. is stopped by, running request
EEPROM KO Error is detected in Eeprom Controller works continuous
or in Eeprom management using default
parameters
Forward + The travel demands are Traction is stopped Start-up, stand- Traction
Backward active in both directions at by, running request
the same time

8.19 Analysis and troubleshooting of warnings displayed on
console
1) VACC NOT OK
Cause:
The test is made at key-on and immediately after that both the travel
demands have been turned off. This alarm occurs if the ACCELERATOR
reading in the TESTER menu’ is 1,0V higher than PROGRAM VACC min
acquisition when the accelerator is released.
Troubleshooting:
Acquire the maximum and minimum potentiometer value through the
PROGRAM VACC function. If the alarm is still present, check the mechanical
calibration and the functionality of the potentiometer. If the alarm is not
disappeared the failure is in the ACE logic board, replace it.
2) INCORRECT START
Cause:
This is a warning for an incorrect starting sequence.
Troubleshooting:
The possible reasons for this alarm are (use the readings in the TESTER to
facilitate the troubleshooting):
A) A travel demand active at key on
B) Presence man sensor active at key on
Check the wirings. Check the micro switches. It could be also an error
sequence made by the operator. A failure in the logic is possible too; so
when all of the above conditions were checked and nothing was found,
replace the ACE logic board.
3) VACC OUT OF RANGE

Cause:
The CPOT input red by the microcontroller is not comprised in the range
Vacc_min ÷ Vacc_max, programmed through the “PROGRAMM VACC”
function.
Troubleshooting:
Acquire the maximum and minimum potentiometer value through the
PROGRAM VACC function. If the alarm is still present, check the mechanical
calibration and the functionality of the potentiometer. If the alarm is not
disappeared the failure is in the ACE logic board, replace it.
4) TEMPERATURE
Cause:
This alarm occurs when the temperature of the base plate is higher than 85°.
Then the maximum current decreases proportionally with the temperature
increases from 85° up to 105°. At 105° the Current is limited to 0 Amps.
Troubleshooting:
It is necessary to improve the controller cooling. For realise an adequately
cooling in case of finned heat sink are important factor the flux [m3/h] and
temperature [°C] of cooling air. In case of thermal dissipation realised with the
controller base plate installed on truck frame it is important the thickness of
frame and the planarity and roughness of its surface. If the alarm is signalled
when the controller is cold, the possible reasons are a thermal sensor failure
or a failure in the logic card. In this case, it is necessary to replace the
controller.

5) MOTOR TEMPERATURE
Cause:
This warning occurs when the temperature sensor is opened (if digital) or has
overtaken the threshold of 150° (if analogue).
Troubleshooting:
Check the thermal sensor inside the motor (use the MOTOR
TEMPERATURE reading in the TESTER menu); check the sensor ohmic
value and the sensor wiring. If the sensor is OK, improve the cooling of the
motor. If the warning is present when the motor is cool, then the problem is
inside the controller.
6) BRAKE RUN OUT

Cause:
The CPOTBRAKE input red by the microcontroller is at the maximum value
without the hand brake request.
Troubleshooting:
Check the mechanical calibration and the functionality of the brake
potentiometer. If the alarm is not disappeared the failure is in the ACE logic
board, replace it.
7) HAND BRAKE
Cause:
The hand brake input is active when a traction request is done.
Troubleshooting:
The possible reasons for this alarm are (use the readings in the TESTER to
facilitate the troubleshooting):
A) The HB switch is damaged so it does not close the input CNA#13 to –
Batt. Replace it.
B) The HB switch work correctly but in the tester menu the HB input is
always ON. In this case the failure is in the logic board, replace it.
8) CURRENT GAIN
Cause:
The Maximum current gain parameters are at the default values, which
means the maximum current adjustment procedure has not been carried out
yet.
Troubleshooting:
Ask the assistance of a Zapi technician to do the correct adjustment
procedure of the current gain parameters
9) SENS MOT TEMP KO

Cause:
The output of the motor thermal sensor is out of range.
Troubleshooting:
Check the sensor ohmic value and the sensor wiring. If the sensor is OK,
then the problem is inside the ACE logic board, replace it.
10) THERMIC SENS KO

Cause:
The output of the controller thermal sensor is out of range.
Troubleshooting:
This type of fault is not related to external components; replace the controller.

11) SLIP PROFILE
Cause:
There is an error on the choice of the parameters of the slip profile.
Troubleshooting:
Check in the hardware setting menu the value of those parameter
12) EEPROM KO
Cause:
It’s due to a HW or SW defect of the non-volatile embedded memory
supporting the controller parameters. This alarm does not inhibit the machine
operations, but the truck will work with the default values.
Troubleshooting:
Try to execute a CLEAR EEPROM operation (refer to Console manual).
Switch the key off and on to check the result. If the alarm occurs
permanently, it is necessary to replace the controller. If the alarm disappears,
the previously stored parameters will have been replaced by the default
parameters.
13) FORW+BACK
Cause:
This alarm occurs when both the travel demands (Fwd and Bwd) are active
at the same time.
Troubleshooting:
Check the wiring of the Fwd and Rev travel demand inputs (use the readings
in the TESTER to facilitate the troubleshooting). Check the microswitches for
failures.
A failure in the logic is possible too. So, when you have verified the travel
demand switches are fine working and the wiring is right, it is necessary to
replace the ACE-2 logic board.

9 RECOMMENDED SPARE PARTS FOR
INVERTER
Part number Description ACE Version
C16588 Protected 350 A strip UL Fuse. 24V/400 &

36-48V/450
C16588 Protected 350 A strip UL Fuse. 24V/500
C16586 Protected 250 A strip UL Fuse. 36-48V/350
C16520 10 A 20 mm Control Circuit Fuse All
C29522 SW 180 48 V All

Single Pole Contactor
C29508 SW 180 24 V All

Single Pole Contactor
C12531 Connector Ampseal 23 pins Female All
C12372 Connector Molex 8 pins Female All

10 PERIODIC MAINTENANCE TO
BE REPEATED AT TIMES
INDICATED
Check the wear and condition of the Contactors’ moving and fixed
contacts. Electrical Contacts should be checked every 3 months.
Check the Foot pedal or Tiller microswitch. Using a suitable test meter,
confirm that there is no electrical resistance between the contacts by
measuring the volt drop between the terminals. Switches should operate
with a firm click sound. Microswitches should be checked every 3 months.
Check the Battery cables, cables to the inverter, and cables to the motor.
Ensure the insulation is sound and the connections are tight.
Cables should be checked every 3 months.
Check the mechanical operation of the pedal or tiller. Are the return springs
ok ? Do the potentiometers wind up to their full or programmed level ?
Check every 3 months.
Check the mechanical operation of the Contactor(s). Moving contacts

should be free to move without restriction.
Check every 3 months.
Checks should be carried out by qualified personnel and any replacement

parts used should be original. Beware of NON ORIGINAL PARTS.
The installation of this electronic controller should be made according to the
diagrams included in this Manual. Any variations or special requirements
should be made after consulting a Zapi Agent. The supplier is not
responsible for any problem that arises from wiring methods that differ from
information included in this Manual.
During periodic checks, if a technician finds any situation that could cause
damage or compromise safety, the matter should be bought to the attention
of a Zapi Agent immediately. The Agent will then take the decision
regarding operational safety of the machine.
Remember that Battery Powered Machines feel no pain.
NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER.
1
2
3

DEC068-06 Tailift FBT15-18 Service Manual

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DEC068-06 Tailift FBT15-18 Service Manual

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Service Manual for

Tailift tricycle Forklift.

TAILIFT ELECTRIC FORKLFT TRUKS

TAILIFT ELECTRIC FORKLIFT TRUCKS

Please have this manual available on the truck for reference

FACTORY：NO.5, ZIHLI 1ST RD., NANKANG,

Chapter 2 Steering system.

Chapter 3 The hydraulic system, mast and forks.

Chapter 4 Electric control monitor.

Chapter 5 The controller.

Chapter 6 The routine check, maintenance and lubrication.

Chapter 8 ZAPI SYSTEM 186

The sequence to disassemble the transmission is as follows:

Front wheel Battery Rear wheel

The sequence to disassemble the transmission is as follows:

The following resins are recommended: RHODORSIL CAF 1-LOCTITE

1. Motor, O-ring 6. Bolts 11. A hexagonal bolt

※ The judging method unit: mm

◎ The way to measure:

◎ The way to adjust the gap.

(d) Cone-shaped roller bearing.

※ Any rubber products must be replaced after being deteriorated.

◎ The tips to disassemble.

◎ The tips to disassemble.

Adjust the chain tension by turning the nut

◎ The tips to disassemble.

2-4 Electrical steering system-GE&DANAHER A

◎ The universal joint (Fig. 2)

◎ The universal joint. (Fig.2)

1.Seal, dual ring. 6.Spring, centering. 11.Gerotor.

2. The steering power.

※ Disassemble tilt cylinder:

(2) Measure the gap between the The mast.

1.Marked connector plate.

While examining the chain tension, be

2. Steering hydraulic motor.

3. The hydraulic motor of the forks.

1 motor body 15 bearing 31 bolts and wirings

(2) Insulation test.

(3) The armature axle.

2. The carbon brush, the brush seat and the spring.

◎ The way to fix.

(2) The insulation test.

◎ The way to measure.

2. The assembly of the carbon brush.

3. The assembly of the terminals.

4. To check the motor.

◎ The way to test.

(2) The insulation test on the motor.

※ During measuring. Keep hands off from the wiring terminal.

Chapter 5 The Controller.

Then discharge the battery fully.

5-2 The components of the controller-GE

5-3 The procedure to

(2) Remove the capacitor.

◎ The way to check.

b) Check the diode. Check the diode

(2) The capacitor.

5-5 Assembly and key points-GE

(4) Confirmation after assembly

5-6 Assembly, adjustment and confirmation-GE

Adjustment of reversing phase to function as brake (PLUG)…Adjust the

AC/TIME… it is adjusted to determine the acceleration speed.

a) Place the ammeter onto the device.