Sm Eu110 Psx16 Service Manual Psx 2018 05

Service Manual
PSX16
Electric
Stacker
with foldable
Driver Platform
LOT 83010
SM-EU110 05/18
Release Date Version No. Changes (Serial number)
2018-05-30 SM-EU110 New Version
* If there are any changes, revised version will be published once every 12 months;
if there is no change, please follow the most recent version.
* Please refer to the corresponding version of the service manual against the purchase time
of your vehicle.
* If you need the latest versions of the manual, please contact our service department or
dealer to obtain.
This manual applies to:
Model Specifications LOT

PSX16 1,600 kg Capacity 83010
Some sections of the manual only involve certain model, please refer to the manual
according to the actual configuration of the vehicle.
SM-EU110 05/18
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FOREWORD
This Service Manual can help readers learn more about the truck system components,
maintenance and troubleshooting, and other related information. The operation and
maintenance personnel must read this Manual carefully before using the product. And when
vehicle is in use, be sure to follow the complete operation and maintenance information in
this Manual for vehicle maintenance.
Before using, please check if the pages of the Manual are clear and complete, so as not
to affect your normal use because of incomplete information. If the contents of the Manual
have been illegible or damaged, which may affect reading, please contact Clark Europe or
your dealer for replacement.
With the constant update and improvement of our products, the equipment you are using
may be slightly different from what has been described in this Manual, therefore, we must
reserve the right to modify the appearance, configuration and technical specifications. If you
have any questions, please contact our sales department or dealer.
Safety signs and instructions:
Please strictly adhere to these safety instructions to avoid personal injury.
Please pay attention to the important safety instructions.
i Instructions.
Copyright
Copyright of Service Manual belongs to Clark Europe GmbH
Clark Europe GmbH
Dr.-Alfred-Herrhausen-Allee 33
D - 47228 Duisburg
Germany
www.clarkmheu.com
info-europe@clarkmheu.com
REV. SM-EU110 05/18
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TABLE OF CONTENTS
SECTION PAGE
1.INFORMATION & SPECIFICATIONS .............................11
1.1 Introduction .................................................................12
1.2 Common Tools............................................................13
1.3 General Tightening Torques .......................................14
2. MAINTENANCE .............................................................16
2.1 Overview.................................................................... 17
2.2 Maintenance ............................................................... 18
2.2.1 Cleaning ........................................................................18
2.2.2 Inspection ......................................................................18
2.2.3 Lubrication .....................................................................22
3. STRUCTURE & FUNCTIONS ........................................ 25

3.1 Structure & Functions ................................................. 26
3.1.1 Travel Switch .................................................................26
3.1.2 Lifting/Lowering Switch ..................................................26
3.1.3 Horn Switch ...................................................................26
3.1.4 Emergency Reverse Switch ..........................................26
3.1.5 Emergency Stop Switch ................................................27
3.1.6 Key Switch .....................................................................27
3.1.7 Battery Discharge Indicator............................................27
3.1.8 Horn ...............................................................................27
3.1.9 Power Fuse 1.................................................................28
3.1.10 Power Fuse 2...............................................................28
3.1.11 Power Fuse 3...............................................................28
3.1.12 Control Fuse 1.............................................................28
3.1.13 Control Fuse 2.............................................................28
3.1.14 AC0 Controller (Traction Controller).............................28
3.1.15 EPS-DC0 Controller ...................................................29
3.1.16 Lifting Limit Switch .......................................................29
3.1.17 Interlock Switch ...........................................................29
3.1.18 Pump Motor .................................................................29
3.1.19 Gear Pump ..................................................................30
3.1.20 Solenoid Valve .............................................................30
3.1.21 Main Contactor ............................................................30
3.1.22 Potentiometer ..............................................................30
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TABLE OF CONTENTS
SECTION PAGE
4. CHASSIS SYSTEM........................................................ 31
4.1 Load Wheel ................................................................ 32
4.1.1 Removal and Installation ...............................................32
4.1.2 Faults and Causes.........................................................32
4.2 Cover .......................................................................... 33
4.3 Caster ......................................................................... 33
4.4 Safety Gate................................................................. 34
5. DRIVE SYSTEM ............................................................. 35

5.1 Drive Wheel ................................................................ 37
5.2 Electromagnetic Brakes.............................................. 38
5.2.3 Checking and Testing ....................................................39
5.2.4 Control Circuit Troubleshooting .....................................40
5.3 Drive Motor ................................................................. 41
5.4 Gearbox ...................................................................... 44
5.5 Proximity Switch ......................................................... 45
5.6 Steering Motor ............................................................ 48
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TABLE OF CONTENTS
SECTION PAGE
5.7 Speed Encoder ........................................................... 50
6. OPERATING SYSTEM................................................... 51
6.1 Control Head.............................................................. 52
6.2 Button Switch.............................................................. 52
6.2.3 Checking and Testing.....................................................55
6.3 Travel Switch .............................................................. 58
6.4 Potentiometer ............................................................. 60
6.5 Sidegate Switch.......................................................... 62
6.5.2 Connection Mode ..........................................................62
7. HYDRAULIC SYSTEM................................................... 64
7.1 Overview..................................................................... 65
7.1.1 Hydraulic Schematic Diagram .......................................66
7.2 Pump and Motor Assembly......................................... 67
7.2.1 Removal and Installation................................................67
7.2.2 Component.....................................................................67
7.3 Pump Motor................................................................. 68
7.3.1 Removal and Installation................................................68
7.3.3 Checking and Testing.....................................................69
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TABLE OF CONTENTS
SECTION PAGE
7.4 Solenoid Valve ........................................................... 70

7.5 Lift Cylinder ................................................................ 72
7.5.1 Cylinder Removal Precautions ......................................72
7.5.2 Cylinder Installation Precautions ...................................73
7.6 Hydraulic Troubleshooting .......................................... 74
7.7 Hydraulic Symbol......................................................... 75
8. ELECTRICAL SYSTEM ................................................. 76

8.1 Controller .................................................................... 77
8.1.2 Controller Interface Function .........................................78
8.2 Fuse............................................................................ 82
8.2.1 Location of Fuses ..........................................................82
8.3 Main Contactor ........................................................... 84
8.4 Lifting Limit Switch ...................................................... 86
8.4.1 Connection Mode ..........................................................86
8.5 Key Switch .................................................................. 88
8.6 Battery Discharge Indicator (BDI)................................. 89
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TABLE OF CONTENTS
SECTION PAGE
8.7 Interlock Switch .......................................................... 90

8.8 Deadman Switch......................................................... 91
8.8.2 Connection Mode ..........................................................91
8.9 Proximity Switch .......................................................... 92
8.10 CAN Console.............................................................. 94
8.10.1 Connection..................................................................94
8.10.2 CAN Console Selection Menu ....................................94
8.10.3 TESTER Menu Traction..............................................96
8.10.4 TESTER Menu Steering..............................................97
8.10.5 Menu Alarm / Logbook / Tester...................................98
8.10.6 Settings and Adjustments............................................99
8.10.6.1 Set Options.............................................................99
8.10.6.2 Adjustments..........................................................102
8.10.6.3 Parameter Change...............................................104
8.11 Controller Error Message........................................ 106
8.11.1 Traction Controller ..................................................... 106
8.11.2 Steering Controller (EPS-DC0) .................................. 111
8.12 Cable Wiring Diagrams........................................... 120
8.13 Wiring Harness and Connectors............................. 121
8.14 Electrical Schematic Diagrams ............................... 122
9. TROUBLESHOOTING ................................................. 124

9.1 Preparation Before Troubleshooting ......................... 125
9.1.1 Check the Voltage of Battery .......................................125
9.2 Troubleshooting Solutions of Common Faults �� 126
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TABLE OF CONTENTS
SECTION PAGE
10. SERVICE MANUAL - MAST ........................................ 129
10.1 Two-stage Mast ........................................................... 130

10.1.1 Lifting Chains .......................................................... 130
10.1.1.1 Chain Adjustment ................................................ 130
10.1.1.2 Chain Replacement..................................................130
10.1.2 Lift Cylinder ...................................................................132
10.1.2.1 Cylinder Removal ....................................................132
10.1.2.2 Cylinder Maintenance .............................................134
10.1.2.3 Cylinder Installation ............................................ 134
10.2 Two-stage Full Free Mast ...............................................135
10.2.1 Lifting Chains .......................................................... 135
10.2.1.2 Chain Replacement..................................................136
10.2.2 Lift Cylinder ...................................................................137
10.2.2.1 Cylinder Removal ....................................................137
10.2.2.2 Cylinder Maintenance .............................................139
10.2.2.3 Cylinder Installation ............................................ 140
10.3 Three-stage Mast ............................................................141
10.3.1 Lifting Chains .......................................................... 141
10.3.1.2 Chain Replacement.................................................142
10.3.1.2.1 Mast Chain..........................................................142
10.3.1.2.2 Fork carriage Chain ............................................142
10.3.2 Lift Cylinder ..................................................................143
10.3.2.1 Cylinder Removal .............................................. 143
10.3.2.2 Cylinder Maintenance ....................................... 145
10.3.2.3 Cylinder Installation .......................................... 146
11. SCHEDULE ................................................................ 147
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SAFETY WARNING
For your own safety and that of others, please observe the following safety instructions:
Thorough and normative maintenance is one of the most important prerequisites to ensure
stable and reliable operation of truck. Neglecting regular maintenance could easily lead
to the truck malfunction and failure, and potential threats to staff and operational safety.
Therefore, there must be adequate maintenance equipment, professional maintenance
personnel and a comprehensive maintenance plan in place.
Please perform the maintenance and inspections according to the following provisions:
1. To strictly enforce the truck maintenance, lubrication and inspection plans.
2. Truck maintenance, lubrication and inspection personnel must be approved by accredited
certification or evaluation agency.
3. The following operations shall be performed before you leave the truck:
- No parking on slopes.
- Fully lower the forks.
- Cut off the power supply.
- Turn the switch lock to “STOP” and remove the key.
4. Prior to truck maintenance:
- Raise the drive wheel off the ground, or cut off the power supply connection.
- Use wooden wedges or other effective fixtures.
- When performing maintenance underneath the vehicle, make sure that the lifting device
or jack leg is secure.
- Park your vehicle in a safe and secure area.
5. Never use an open flame to check level of electrolyte, other oils or fluids for leaks.
6. Keep the parking lot clean, well-ventilated and dry.
7. Regular checks and maintenance should be conducted to braking, steering, control, warning
and safety devices to keep them in good condition.
8. All nameplates and safety signs on the truck should be cleaned regularly to make them
clearly visible.
9. Regular checks and maintenance should be conducted to all the devices of lifting system to
ensure them to be safe for use.
10. The hydraulic system should be checked regularly based on usage. Hydraulic cylinders,
hydraulic valves and other hydraulic components should be ensured to be without leakage.
11. Regular checks and maintenance should be conducted to batteries, motors, controllers,
limit switches, protective devices, wires and connectors, and so on. Please pay particular
attention to the electrical insulation.
12. Park the truck in a clean environment to minimize the risk of fire.
13. Without the permission of the manufacturer, users are not allowed to change or increase
the capacity of the truck. After having been changed under permission, the nameplates and
safety signs on the truck should also be changed accordingly.
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1. INFORMATION & SPECIFICATIONS
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INFORMATION & SPECIFICATIONS
1.1 Introduction
WARNING
This series are electric stacker. Its important - Please refer to the nameplate for rated load
structure is as shown in Figure 30001. capacity of the vehicle.
- The vehicle can only be used on the level gro-
und indoors, never use it on mezzanine or
balcony area.
No. Name No. Name

1 Folding operator pedal 7 Emergency stop swich
2 Safety Gate 8 Fork
3 Drive wheel 9 Chassis
4 Battery discharge indicator 10 Caster wheel
5 Control Handle
6 Mast
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The truck is driven forward or backward by AC

motor.
The Electric Power Steering has greatly met the
demand for high mobility of the truck.
The truck is equipped with interlock switch at

handle joint, only by pressing the switch can the
truck be operated, which has greatly reduced
the possibility of misuse by the operator.
WARNING
Truck can only be operated by single operator;
other personnel is forbidden from riding.
1.2 Common Tools
No. Name Remark

1 Hex Wrench 2#~14# One Set
2 Hex Head Socket Wrench 10#~27# One Set
3 Phillips Screwdriver 2# One Piece
4 Slotted Screwdriver 2# One Piece
5 Circlip Pliers One for holes and one for shaft
6 Hammer One Piece
7 Spreader, Crane One Pair
8 Cylinder Wrenches For removal and installation of cylinders
9 Diagonal Pliers One Piece
10 Cylinder Pliers One Piece
11 Grease Gun One Piece
12 Tiger Tooth Wrench 22#/27# One of Each
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1.3 General Tightening Torques

Screws or bolts used on the truck are of 8.8
grade or higher performance level.
When you are conducting truck maintenance,
you can refer to Table 1.4.1 and Table 1.4.2 to
select the suitable screws or bolts for replace-
ment.
Screws/Bolts Performance Levels

Performance Level Material Specification (mm)
5.8 5.8 grade Low carbon steel M6 ~ M48
Quenched and tempered medium

8.8 8.8 grade M6 ~ M48
carbon steel

10.9 10.9 grade M6 ~ M48
carbon alloy steel

12.9 12.9 grade M6 ~ M48
carbon alloy steel
CAUTION
- The performance levels of screws or bolts are
marked on the heads of the screws or bolts.
- If you find the screws or bolts used on certain
position are not marked with performance
level, please select spare parts with perform-
ance level of at least 8.8 grade or higher level
forreplacement.
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Table 1.3.2 Metric Screws/Bolts Tightening Torque Table (n•m)

Performance Level
Nominal Diameter 5.8 8.8 10.9 12.9

(mm) Proof Stress (MPa)
380 600 830 970
M6 7~8 10~12 14~17 17~20
M8 16~18 25~30 34~41 41~48
M8×1 17~20 27~32 37~43 43~52
M10 31~36 49~59 68~81 81~96
M10×1 35~41 55~66 76~90 90~106
M12 55~64 86~103 119~141 141~167
M12×1.5 57~67 90~108 124~147 147~174
M14 87~103 137~164 189~224 224~265
M14×1.5 144~170 149~179 206~243 243~289
M16 136~160 214~256 295~350 350~414
M16×1.5 144~170 228~273 314~372 372~441
M18 186~219 294~353 406~481 481~570
M18×1.5 210~247 331~397 457~541 541~641
M20 264~312 417~500 576~683 683~808
M20×1.5 294~345 463~555 640~758 758~897
M22 360~431 568~680 786~941 918~1099
M22×1.5 395~473 624~747 803~1034 1009~1208
M24 457~547 722~864 998~1195 1167~1397
M24×2 497~595 785~940 1086~1300 1269~1520
M27 669~801 1056~1264 1461~1749 1707~2044
M27×2 723~865 1141~1366 1578~1890 1845~2208
M30 908~1087 1437~1717 1984~2375 2318~2775
M30×2 1005~1203 1587~1900 2196~2629 2566~3072
M36 1587~1900 2506~3000 3466~4150 4051~4850
M36×3 1680~2011 2653~3176 3670~4394 4289~5135
M42 2538~3039 4088~4798 5544~6637 6479~7757
M42×3 2731~3269 4312~5162 5965~7141 6921~8345
M48 3813~4564 6020~7207 8327~9969 9732~11651
M48×3 4152~4970 6556~7848 9069~10857 10598~12688
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2. MAINTENANCE
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MAINTENANCE
2.1 Overview
i NOTE
Only by performing regular vehicle maintenance - Under harsh working conditions: such as, the
and repair, can ensure the continuous and external temperature is too high or too low,
reliable use of the truck. dusty, or implementing multiple shifts per day,
Only specially trained and qualified personnel the maintenance and care interval should be
are capable of maintenance and repair opera- shortened.
tions of the equipment. If you want to perform - Prior to lubrications, replacement of filters or
the maintenance and repair on your own, it is operating the hydraulic system, please clean
recommended that on-site training should be the external parts carefully and use a clean
conducted to your maintenance personnel by container.
the service representative of the vendor.
- Only compliant lubricants can be used See
Table 2.2 Lubricants.
Working conditions:
- Truck must be parked on the level ground
reserved for maintenance (such area needs
to be clean and with less dust), block the
wheels with wooden wedges, disconnect
the key switch and disconnect the battery
connections.
- When lifting the truck, the lifting tools can
only be installed on the fixed positions as
specified.
- When jacking up the truck, appropriate tools,
such as wedge blocks, wooden blocks, and
so on, must be used to secure the truck to pr-
event the occurrence of accidental rolling or
tipping over.
WARNING
When lifting load components or during the
operations under the cabin, sufficiently strong
chains or safety device must be used to secure
the vehicle.
CAUTION
Without the supplier's consent, it is strictly
forbidden to make modifications to truck, espe-
cially to the safety devices. It is strictly forbidden
to change the various working speeds of the
truck.
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MAINTENANCE
2.2 Maintenance Regular inspection and maintenance under

harsh conditions of use:
2.2.1 Cleaning Under harsh working conditions, especially:
- Dusty environment
- Do not use flammable liquids to clean the - Corrosive environment
truck. - Cold storage environment
- Before starting to clean, all necessary The maintenance intervals should be shortened
security measures must be taken to prevent by half.
sparking (short circuit) during operation. If the
truck is powered by battery, battery plug must
be pulled out.
- When cleaning electrical and electronic com-
ponents, you should use low-intensity suction
gas or compressed dry air. Meanwhile, clean
the dust on the surface of components with
non-conductive and antistatic brush.
- Do not use vapor steam to clean the equipm-
ent.
2.2.2 Inspection
Regular inspection and maintenance under
normal conditions of use:
Operating
Requirements
Hours (h)
50 At least once per 7 days
1000 At least once every 6 months
2000 At least once per year
CAUTION
When the truck is at running-in phase (after
approximately 100 hours of operation), the
equipment user must check the fastening of
wheel nuts and bolts and re-tighten them if
necessary.
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MAINTENANCE
Service to be done in accordance of list
Type of a) Weekly by
b) 250 h c) 500 h d) 2000 h
Lubricant driver
1) Lifting device
Forks thickness at heel x
Forks permanent deformation, left and right forks

uniformity x
Forks cracks at heel and mountings x
Cylinder leakage, deformation, mounting looseness,

uneven movement and damage x
2) Drive unit and brakes
Service brake, braking performance x
Parking brake, braking performance x
Brake system: check for damage and cable looseness x
Brake system: check for functionality, distance and wear x
Check wheel condition (Damage, screws and nuts,

abnormal noise) x
Replace drive unit oil x
Check drive unit oil level (First : 50 hours) x
Check drive unit mounting and fasteners x
3) Operator controls
Control lever linkage looseness and functionality x
4) Electrical equipment
Battery condition, restraint and data x
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MAINTENANCE
b) 250 h c) 500 h d) 2000 h
Lubricant driver
Emergency shut off x
Electrical wiring and fuses x
Horn functionality x
Instrumentation functionality x
5) Hydraulic system
Lift system creep test x
Oil leakage and damage, unusual noise x
Replace hydraulic oil x
6) Vehicle frame and safety equipment
Mounting points x
Frame, safety equipment check deformation, damage and

welded portion cracking x
7) Tiller handle
Functions of the switches x
Operability of the directional lever x
Movement of the tiller handle x
8) Miscellaneous
Check safety marking and decals x
Operating instructions x
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MAINTENANCE
b) 250 h c) 500 h d) 2000 h
Lubricant driver
Check Attachments x
NOTES:
a) Weekly by driver
b) 250 hours or every 6 month
c) 500 hours or every year
d) 2000 hours or every year
* In heavy conditions the service intervals must be reduce accordingly
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MAINTENANCE
2.2.3 Lubrication Please see Table 2.2 for the lubricants used in
this truck.
Lubricant
CAUTION
- Improper operations may constitute hazards
to the operator's health and life, as well as to The use and disposal of lubricants must be
the surrounding environment. carried out in strict accordance with the manufa-
- When storing or adding lubricant, use clean cturer's regulations.
containers. It is strictly forbidden to mix
different types and specifications of lubricants
with each other (except for those can be
mixed under clear statement).
Sliding surface
Hydraulic oil injection nozzle
Gear oil injection nozzle
Gear oil discharge nozzle
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MAINTENANCE
Table 2.2 Lubricants
Code Type Specification Amount Position
Anti-wear hydraulic oil L-HM46

Hydraulic
A Low temperature anti-wear See Table 2.3
L-HV32 System
hydraulic oil (cold storage)
Sliding surface
B Multi-purpose grease Polylub GA352P Appropriate amount
(See Table 2.4)
C Heavy duty gear oil 80W-90 GL-5 1.38L Gearbox
Table 2.3 Application Amount of Table 2.3 Application Amount of

Hydraulic Oil - 1 Hydraulic Oil - 2
Lifting height Amount Lifting height Amount
Mast Series Mast Series
(mm) (L) (mm) (L)
2700 5.5 4000 8.8
3000 6.0 3-stage Mast 4500 9.8
3300 6.8 4800 10.5
2-stage Mast
3600 7.5
3900 8.0
4190 8.5
2700 10.8
2-stage Full
3000 12.0
Free Mast
3300 13.2
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MAINTENANCE
Table 2.4 Sliding Surface

Lubrication Table
Code Position
L1 Rollers
L2 Steel channel and rollers
L3 Load Wheel
L4 Caster
L5 Steering gear
L6 Steering bearing
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3. STRUCTURE & FUNCTIONS
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STRUCTURE & FUNCTIONS
3.1 Structure & Functions

3.1.1 Travel Switch
Location: control lever;
Function: to output travel speed signal to the
drive controller;
Description: when the vehicle is powered on,
the travel switch is at Middle position;
Note: Unserviceable.
3.1.2 Lifting/Lowering Switch

Location: control lever; Travel Switch
Function: to lift / lower the fork;

Description: the lifting/lowering switch is nor-
mally-open. When pressing, the switch is on;
after release, the switch will automatically reset;
3.1.3 Horn Switch

Function: to press the horn;
Description: the horn switch is normally- Lifting/Lowering Switch Horn Switch

open. When pressing, the horn switch is on;
after re-lease, the switch will automatically
reset;
Emergency Reverse Switch
3.1.4 Emergency Reverse Switch
Function: press the switch, the vehicle will

travel in reverse direction;
Description: reverse switch is normally-open.

When pressing, the reverse switch is on; after
release, the switch will automatically reset;
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3.1.5 Emergency Stop Switch

Location: upper plate of chassis;
Function: to disconnect the circuit and switch
off all electrical functions, achieving emergency
braking;
Description: under normal circumstances,
switch cover is at high position, and the circuit is
connected, when pressing this switch, the circuit
is disconnected; Emergency Stop Switch
3.1.6 Key Switch

Location: upper cover;
Function: for operator to switch on or off the
truck;
Description: remove the key to prevent opera-
tions to the truck by unauthorized operator;
Key Switch
3.1.7 Battery Discharge Indicator (BDI)

Location: upper cover;
Function: display battery power, working hours
(this function is available on the component with
timer function);
Description: 24V operating voltage;
Battery Discharge Indicator
3.1.8 Horn
Location: left the traction controller;
Function: can provide sound alarm through the
operation to horn switch operation;
Horn
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3.1.9 Power Fuse 1
Location: electrical mounting plate;
Function: overcurrent protection;
Description: fusing current is 200A;
Note: Unserviceable. Power

3.1.10 Power Fuse 2 Fuse 3
Function: overcurrent protection; Power

Fuse 1
3.1.11 Power Fuse 3 (since SEQ 0058)
Function: overcurrent protection;

Power
Note: Unserviceable. Fuse 2
3.1.12 Control Fuse 1

Function: overcurrent protection complete

control circuit;

Control
Note: Unserviceable. Fuse 1
3.1.13 Control Fuse 2
Function: overcurrent protection controller and

valves; Control
Fuse 2
3.1.14 Combi ACX Controller

(Traction & Hydraulic Controller)
Function: to control the speed of drive & Combi ACX

pump motor through the signal input by the
accelerator Controller
Description: 24V operating voltage, to control
the drive motor circuit;
Note: Unserviceable
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3.1.15 EPS-DC0 Controller

Function: to control the rotating direction of
steering motor through signal input by potentio-
meter;
Description: 24V operating voltage, to control
the steering motor; EPS-DC0 Controller
Note: Unservicable.
3.1.16 Lifting Limit Switch

Location:mounting plate of Outside mast;
Function: limit the lifting height of the fork;
Description: lifting limit switch is normally
closed. When the fork is lifted in higher
position (that is to trigger the limit switch to
open), lifting will be limited;
Lifting Limit Switch
3.1.17 Interlock Switch

Location: at handle joint;
Function: the truck cannot be operated if the
interlock switch is not closed;
Description: to prevent misuse of truck;
Interlock Switch
3.1.18 Pump Motor

Location: right side of drive assembly;
Function: to provide power for gear pump for
lifting the loading rack;
Pump
Description: upon receiving the signal input by Motor
control switch, traction controller to control the
power transmission of pump motor;
Note: Unservicable.
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3.1.19 Gear Pump

Location: below the valve body; inside of the
reservoir
Function: to provide pressure for hydraulic

system of the entire vehicle;
Description: N/A;
Gear
Pump
3.1.20 Solenoid Valve

Location: on valve body at pump and motor as-
sembly;
Function: to realize the lowering of fork,
controller gets signal from the lowering
switch to control the absorption of
Solenoid
solenoid valve, forming a hydraulic circuit; Valve
3.1.21 Main Contactor

Function: to connect and disconnect circuit and
to control the power transmission of drive motor;
Description: to provide power loads through
controller under the circumstances that the
controller is failure-free;
Main Contactor
3.1.22 Potentiometer
Location: below the handle joint;
Function: to provide steering input signals to
the steering controller;
Potentiometer
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4. CHASSIS SYSTEM
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CHASSIS SYSTEM
4.1 Load Wheel Single Wheel (see Figure 30102)

- Remove the elastic cylindrical pin (20) within
4.1.1 Removal and Installation the wheel bracket（19） with an ejector pin;
Removal - Knock out the wheel pin shaft (21) from side
and remove load wheel and bearing assem-
- Lift the vehicle carefully with lifting equipment bly;
through the lifting holes at back;
- Remove the bearing (2) of load wheel (4) with
hammer and jacking equipment.
WARNING
Make sure the lifting equipment is solid and
secure, and the load capacity should be greater Installation and Commissioning
than the total weight of the vehicle. - Install according to the reverse order of rem-
oval;
- Run the truck to see if the load wheel is fun-
ctioning properly. If there is blocking or noise,
please install again.
CAUTION
When installing, please apply appropriate
amount of grease on the axle first.
(See Section 2.2.3 for specifications)
Quality of tyres directly affects the stability and
driving performance of the device.
- Place a wooden wedge under the chassis
near load wheel, make the load wheel off the If you need to replace the factory-fitted tyres,
ground; please use original spare parts provided by the
equipment manufacturer to reach the original
WARNING design performance of the truck.
When replacing wheels, be sure that the truck

won't tilt. 4.1.2 Faults and Causes
Fault Bearing noise or jammed

1
Cause Bearing fatigue damage or foreign
Abnormal tyre wear, cracking or
Fault
2 degumming
Cause Improper use
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CHASSIS SYSTEM
4.2 Cover 4.3 Caster

4.2.1 Removal and Installation 4.3.1 Removal and Installation
Removal Removal
- Unscrew the two screws (3) and remove the - Remove the lower cover;(See Section 4.2.1)
lower cover (4) ;
- Unscrew four screws (1), then remove the
- Unscrew the two screws (7) and remove the
upper cover (8); Caster Cover(4),caster (3) and adjustment
shim (2).
- Unscrew the two screws (5) with a wrench
and remove the rotate cover (6) ;
WARNING
- Unscrew the two screws (1) and remove the Make sure the lifting equipment is solid and
middle cover (2) ; secure, and the load capacity should be greater
than the total weight of the vehicle.Lifting height
of not more than 300mm, to prevent the hazards
to the maintenance personnel working under
the vehicle for caster removal and installation.
- Lift the vehicle carefully with lifting equipment

through the lifting holes at at front and back;
CAUTION
Installation
When the outer cover is drawn, the force is
uniform, be sure not to concentrate the force - Install according to the reverse order of rem-
on one spot to prevent the covers from being oval.
damaged.
Adjustment
Installation
- Park the truck with replacement completed
- Install according to the reverse order of rem- on level ground to see if the casters and drive
oval. wheel can both be in contact with the ground;
- When the truck is running, check if the three
wheels are functioning properly.
SM-EU110 05/18
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CHASSIS SYSTEM
4.4 Safety Gate

CAUTION
After long time of use, the drive wheel will wear 4.4.1 Removal and Installation
and tear to certain level, at this time, adjust
the height of drive wheel through adjusting the
Removal
adjusting nut to make the two casters and drive - Remove the cover ;(See Section 4.2.1)
wheel to be in close contact with the ground. - Disconnect the connection between speed
mode switch (14) and main wiring harness;
CAUTION
- Unscrew the two screws (3) with a wrench
Tyre wear can affect the stability of the truck, and remove the mounting plate (4) from the
adjust the caster with minor wear on a regular bracket (8);
basis, or replace the caster with heavy wear.
driving performance of the device. If you need
to replace the factory-fitted tyres, please use
original spare parts provided by the equipment
manufacturer to reach the original design
performance of the truck.
Upon maintenance or replacement for parts

of the caster, please refer to Figure 30106 for
removal and installation.
- Unscrew the screws (20) and nuts (21) ,

remove the right sheath (18) or the left sheath
(19) ;
- Unscrew the four screws (11) with a wrench
and remove the safety gate from the chassis.
Installation
- Install according to the reverse order of rem-
oval.
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5. DRIVE SYSTEM
SM-EU110 05/18
35
DRIVE SYSTEM
Drive System
No. Name No. Name

1 Drive Wheel 7 Steering Motor
2 Electromagnetic Brakes 8 Motor Gear
3 Drive Motor 9 Pinion Gear
4 Large Steering Bearing 10 Proximity Switch
5 Large Ring Gear 11 Speed Encoder
6 Gearbox
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DRIVE SYSTEM
5.1 Drive Wheel

5.1.1 Removal and Installation
Removal
- Lift the vehicle carefully with lifting equipment
through the lifting holes at at front and back;
WARNING
Make sure the lifting equipment is solid and
secure, and the load capacity should be greater
than the total weight of the vehicle.Lifting height
of not more than 300mm, to prevent the hazards
to the maintenance personnel working under
the vehicle for caster removal and installation. CAUTION
Tyre wear can affect the stability of the truck,
adjust the caster with minor wear on a regular
basis, or replace the caster with heavy wear.
driving performance of the device. If you need
to replace the factory-fitted tyres, please use
original spare parts provided by the equipment
manufacturer to reach the original design
performance of the truck.
5.1.2 Faults and Causes
- Rotate the drive assembly to the right. Fault Drive wheel slipping or jumping
1
- Loosen the five flange nuts (1) with wrench or Cause Wear
socket wrench, and then unscrew the flange Drive wheel cracking or degumm-
nuts and spherical washer by order. Fault
2 ing
- Remove the drive wheel (2) from the gearbox
Cause Improper use
(3).
Fault Vehicle sways while running
3
Installation Cause Drive wheel lock nut loosening

oval.
CAUTION
- Screw the five nuts as shown in Figure
30203.
- Tighten the nuts by order and mark with the
torque: 140 N • m.
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DRIVE SYSTEM
5.2 Electromagnetic Brakes 5.2.1 Removal and Installation

Removal
The truck is braked through electromagnetic
brake. When the truck is powered off, the The brake is installed on the drive motor. See
electromagnetic coil (6) doesn't absorb the Figure 30205
pressure plate (8), the friction force generated
between brake pads (2), pressure plate and
friction plates (5) will prevent the drive motor
from rotating, thus to brake the vehicle.
- Switch off the truck power connections and

No. Name pull out the brake connectors;
1 Mounting screw - Remove the lower cover;(see Section 4.2)
2 Brake pads - Remove the three mounting screws (1) with
3 Brake gear wrench. Remove the electromagnetic coil (2)
and dust cover (3);
4 Dust cover
- Remove the brake pads (4) and friction plates
5 Friction plate (5) by order;
6 Electromagnetic coil - Remove the circlip (6) on the shaft with circlip
7 Spring pliers and remove the brake gear (7).
8 Pressure plate
Installation
9 Adjusting screw
oval.
SM-EU110 05/18
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DRIVE SYSTEM
CAUTION After the coil is powered off, the

Fault
2 pressure plate won't release
When installing the brake gear (7), make sure
the flat key is installed on the shaft of drive Cause Foreign body blocking
motor . Fault Abnormal noise after absorption
Adjustment 3 a. Fully absorbed, but plate not

Cause flat.
- Switch off the truck power connection; b. Mechanical resistance
- Remove the lower cover;(see Section 4.2)
Fault Brake temperature is too high
- Loosen the mounting screws (9);
- Adjust the three adjusting screws (1) with 4 Pressure plate does not fully
wrench to make the air gap between electro- Cause absorb, overcurrent of the coil, or
magnetic coils and pressure plate be 0.2mm energized too frequently
~ 0.3 mm
- Turn on the power and press the handle.
5.2.3 Checking and Testing
Slowly turn the accelerator button:
If the brake is absorbed (with the sound of Electromagnetic Coil Checks
absorption), it is working properly;
If the brake does not absorb, it needs to be - Switch off the truck power connections and
re-adjusted. pull out the brake connectors;
Air gap Standard value Maximum value - Check the resistance of the coil with a multi-
meter: measurement method is as shown in
s 0.2 mm 0.4 mm Figure 30207;
CAUTION
When the air gap s exceeds 0.4mm, replace the - Identify if the electromagnetic coil is normal
brake pads (2, Figure 30204) according to the readings of resistance on the
multimeter.
5.2.2 Faults and Causes As shown in the following table:
Resistance
Judgment
After the coil is energized, the Measurement
Fault
pressure plate does not absorb Approx. 30 Ω Normal
a. Mechanical part failure; Coil shorting
1 b. Foreign body blocking; 0Ω
(replace the brake)
Cause c. Coil failure;
Coil breaking
d. Coil supply voltage less than ∞Ω
24V (replace the brake)
SM-EU110 05/18
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DRIVE SYSTEM
Air Gap Checks Check if there is foreign body in the air gap that
may affect the absorption or bouncing off of the
- Switch off the truck power connections and pressure plates.
pull out the brake connectors;
- Check the air gap between electromagnetic
coil and pressure plate with feeler gauge: Spring Checks
measurement method is as shown in Figure Deformation or foreign bodies stuck in the
30206; spring may affect the normal absorption of
- Determine if the air gap is normal according pressure plates.
to the gauge measurements. Check if the distribution of the springs on the
As shown in the following table: electromagnetic coil is correct, and check if
there is foreign body in the spring hole.
Air gap distance Judgment
0.2~0.4mm Normal i NOTE
The air gap is too large After a period of time of use, the springs may
> 0.4mm
(replace brake pads) be deformed due to the effect of radial force,
such case may result in abnormal air gap of the
brake, and the spring must be replaced.
i NOTE
After a period of use, brake pads of the electr-
omagnetic brake will wear. After being worn 5.2.4 Control Circuit Troubleshooting
too much, the air gap between electromagnetic
coil and pressure plate may exceed the Brake Control Circuit (Figure 30209)
predetermined maximum value, which may Check if the circuit is broken by using a multi-
cause electromagnetic absorption failure. meter:
- Set the multimeter to ON-OFF;
Foreign Body Checks - Check if #23 circuit (circuit between brake
Foreign bodies stuck in the brake may affect the and controller) is conducted;
normal absorption of pressure plates. - Check if #14 circuit (circuit between brake
and controller) is conducted;
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DRIVE SYSTEM
5.3 Drive Motor Speed Encoder

This truck obtains drive force through AC motor. Removal
Temperature
Sensor
Speed
Encoder
- Switch off the truck power connections;

- Unplug the AMP connector on the speed
5.3.1 Removal and Installation encoder(2, Figure 30211) ;
Drive Motor - Unscrew the screw (1) from the drive motor
and remove the speed encoder (2).
Removal
Drive motor (3, Figure 30201) is mounted on Installation
the large steering bearing (4).
- Switch off the truck power connections and oval.
remove the brake;
- Unplug the AMP connector on the drive
motor, and remove the U, V and W cables co- 5.3.2 Faults and Causes
nnected between drive motor and controller;
- Unscrew the six screws from the drive motor Fault Motor does not rotate
and remove the drive motor.
a. Cable U, V, or W is broken;
b. Loosening connections to cable
Installation 1 U, V or W ;
Cause c. Stator coil open circuit;
- Install according to the reverse order of rem- d. Motor bearing damage;
oval. e. Speed encoder or its circuit
failure.
CAUTION
Motor is rotating in slow speed and
- When installing the motor gear of gearbox Fault
2 reverse
onto the shaft of the motor, make sure that
Cause Cable connection error
the woodruff key on the motor shaft is fully
seated on the motor gear; Motor with abnormal noise or
Fault
- Motor gear should fully engage with the gear vibration
within the gearbox, rotate the gearbox without a. Uneven clearance between
blocking, and then fix it with six screws; 3 stator and rotor;
- Requirements on tightening torque of fixing Cause b. Bearing failures;
screws: 40 N • m. c. Loosening fixing screws on
motor housing.
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DRIVE SYSTEM
Motor temperature too high, - Identify if there is leakage current through

Fault measuring the resistance between U, V, W
controller failure
and motor housing respectively.
a. Stator winding short circuit; as shown in the following table:
b. Motor U, V and W terminals with
Resistance
5 surface ; Judgment
c. Bearing failure, resulting in Measurement
Cause Leakage current
severe heating; 0Ω
d. Motor cooling duct blockage (replace the motor)
with foreign body; ∞Ω Normal *
e. Overload.
* For normal motor, U, V and W terminals are
On load, motor speed is turning insulated from motor housing.
Fault
slow
a. Insufficient voltage of battery; Temperature Sensor
6 b. Overload;
c. U, V, W terminals with abnormal Temperature sensor is used to monitor motor
Cause temperature.
voltage input;
d. Speed encoder or its circuit
failure.

U, V, W Terminals
- Identify if the motor windings are normal
through measuring the resistance of U-V, V-W,
and U-W respectively, if there is short circuit
or breakage;
as shown in the following table:
Measure the resistance between pin connector
CAUTION (20#) and (24#) with a multimeter to identify if
Due to the small size of windings, when measu- the temperature sensor is normal.
ring with a multimeter, put it on a low resistance As shown in the following table:
range. Resistance
Judgment
Resistance Measurement
Judgment
Measurement With readings Normal
With readings,
Normal * Sensor short circuit
but very low 0Ω
(replace the motor)
Winding internal short circuit
0Ω Sensor open circuit
(replace the motor) ∞Ω
(replace the motor)
Winding internal open circuit
∞Ω
(replace the motor)
Speed Encoder
* The difference between the resistance values
measured at U-V, V-W and U-W shall not be Speed encoder is used to detect the speed
greater than 2%. of the motor and covert the speed into fixed
signals.
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DRIVE SYSTEM
Checking
- Check if the motor encoder and the appear- - The vehicle is powered on, measure the
ance of cables are in good condition, and if voltage between pin connector (15#) and
the plug connection is secure. (19#) with a multimeter, normally should be
- Remove the speed encoder and check its 12V;
sensing surface for wear. - Check if the connection between 16# and 17#
is reversed. (If the two circuits are connected
Testing reversely, the controller won't report for
failure, but the travel speed of the vehicle
may slow down)
- Check the “ENCODER” readings on TESTER
Menu. Operate the truck, if the display is
always “0”: (see Section 8.10)
speed encoder failure;
motor encoder disc failure;
5.3.4 Control Circuit Troubleshooting

Motor Control Circuit (Figure 30215)
Check if the circuit is broken by using a multi-
meter:
- Check if #15/#16/#17/#19 circuit (circuit
between motor encoder and controller) is
conducted;
- Check if #20/#24 circuit (circuit between
motor temperature sensor and controller) is
conducted.
SM-EU110 05/18
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DRIVE SYSTEM
5.4 Gearbox Seals Replacement

5.4.1 Removal and Installation - Loosen the oil drain plug (2), drain the gear
oil within the gearbox;
Removal - Unscrew the four screws (6) and remove the
The gearbox is installed under the drive mount- upper cover (20) and the O-ring (19) from box
ing base. - (1);
- Remove the drive motor (see Section 5.3.1) Unscrew the eight screws (6) and remove the
side cover (4) and the O-ring (3) from box (1);
- Unscrew the six bolts (1) on the drive mount-
ing base and remove the gearbox; Unscrew the three bolts (13) and remove the
- Unscrew the eight bolts on the steering bear- locking tab (12) and washer (11) from gear
shaft (24);
ing, remove the large steering bearing, large
ring gear and gearbox . Knock out the gear shaft (24) from box(1)
and remove the oil seal (23);
Replace the new seals : O-ring (3), O-ring (19)
and oil seal (23);
Install according to the reverse order of rem-
oval.
Installation
oval.
CAUTION
- Before installing the new gearbox, please add
gear oil (see Section 2.2.3 for specification
and filling amount);
- Before installing gearbox, remove the proxi-
mity switch first; after the installation is
completed, then adjust the proximity switch.
(see Section 5.5)
CAUTION
- Carry out the maintenance work in a clean Check the gear oil level
environment to prevent impurities from enter-
ing into gearbox, causing gearbox damage. - Loosen the oiling port plug and observe the
oil level;
- During the installation, hydraulic oil of
the same specifications must be used for - If oil level is aligning with lower level of oiling
cleaning or lubrication. port, it indicates that the oil level is normal;
- If the oil level is below the lower level of oiling
port, it is necessary to add gear oil.
SM-EU110 05/18
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DRIVE SYSTEM
Add / Replace Gear Oil 5.5 Proximity Switch

- Loosen the oil drain plug, drain the gear oil
within the tank;
- Remount the oil drain plug, and add the gear Removal
oil of same specification with tubing through Proximity switch is installed on the drive mount-
oiling port: ing base.
gear oil specification: 80W-90 GL-5
Gear oil filling amount: 1.38 L - Pull out the AMP connector on proximity swit-
ch;
- Loosen Nut (1) and unscrew the proximity
5.4.2 Faults and Causes switch.
Fault Gearbox Abnormal Noise
1 a. Supporting bearing wear;

Cause b. Gear wear, the gap is too big;
c. Foreign objects in gear oil.
Fault Gearbox Oil Leaks
2
Cause Oil seal wear or aged
Fault Gearbox Stuck
a. Gear fastening screws or nuts
3 loosening;
Cause
b. Support bearing damage
c. Foreign objects in gear oil.
Installation and Commissioning
- Adjust the position of big ring gear to align
the mounting holes of proximity switch to the
convex of the big ring gear;
- Screw the proximity switch into the mounting
hole on driver's seat. Make sure that Lock
Washer (2,Figure 30216) has been mounted;
SM-EU110 05/18
45
DRIVE SYSTEM
- Adjust the height of Proximity Switch (3,Figure 5.5.3 Checking and Testing
30217) to make the spacing between proxi-
mity switch end face and upper surface of big
ring gear to be between 1~2 mm; Brown
- Turn the key switch on and pull the emergen- Blue Black
cy stop switch, the system will carry out self-
test (positioning) to the position of drive
wheel;
- The truck starts properly, instrument displays
are normal, and the proximity switch is
installed properly, tighten Nut (1).
i NOTE
Installation Failure:
Steering positioning failed, drive wheel keeps
rotating with system error. - The truck adopts NO (normally open) proxi-
mity switches: When no signal is triggered,
Carry out the debugging again until the system the output wire (44# Black Wire) is dangling,
can start normally . that is, 44# line is not connected with positive
power supply input wire (1# Brown Wire).
- LED Indicator (1): when energized and the
5.5.2 Faults and Causes inductive surface is facing convex of big ring
gear, proximity switch will trigger signal, and
Drive wheel fails to position and 44# wire will be connected with 1# wire, LED
keeps rotating; will be lit.
(the controller reports for error, - Inductive Surface (2): induction of iron or
Fault
and fault information is displayed
steel objects (upper surface of big ring gear
on the handheld unit: EPS NOT
for the truck) with inductive distance of 1~2
ALIGNED)
mm.
a. Between the proximity switch
1 and the ring gear convex, there Checking
are impurities attached, such as
- Check if the proximity switch and the appear-
iron scrap;
ance of wiring harness are in good condition,
Cause b. Proximity switch with too large
and if the plug connection is secure;
inductive clearance;
c. Proximity switch failure; - Check if the inductive distance is normal, if
d. Proximity switch control circuit exceeding inductive range, please re-adjust
malfunction. (see 5.5.2).
Testing
- Start the vehicle;
- Align the inductive surface of proximity switch
(2, Figure 30216) to concave of big ring gear,
so that it does not sense. Measure if there is
24V voltage between Pin (45#) and Pin (1#)
with multimeter. If there is no voltage, check
if the circuit is connected; if there is voltage,
move on to the next step.
SM-EU110 05/18
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DRIVE SYSTEM
- Measure the voltage between Pin (44#) and

Pin (1#). If there is 24V voltage (or the switch
is energized under non-induction state, LED
is lit), the switch has been damaged, please
replace; if there is no voltage, move on to the
next step.
- Touch the inductive surface with an iron sheet
to make it trigger signals. If there is still no
voltage between Pin (44#) and Pin (1#), the
switch has been damaged, please replace.

Control Circuit (Figure 30219)
meter:
- Check if #1/#44/#45 circuit (circuit between
proximity switch and controller) is conducted.
Key Switch
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DRIVE SYSTEM
5.6 Steering Motor - Switch off the truck power connections;

- Remove the lower cover; (see Section 4.2)
This truck is driven by DC steering motor to the
large ring gear, thus achieving the function of - Unplug the AMP connector on the steering
steering. motor, and remove the cables connected
between steering motor and controller;
- Unscrew the screw (1) with a wrench and
remove the pinion gear (2) from the steering
motor (5);
- Unscrew the three mounting screws (3) with
hex wrench and remove the speed encoder
(4) from the steering motor (5);
- Unscrew one copper screw (9) with a wrench
and remove the magnet (10) and copper
stopper (11);
- Unscrew the four screws (6) with a wrench
and remove the steering motor (5) from the
drive mounting base .
Steering Motor Carbon Brush
- Unscrew the four screws (7) and remove the
Removal motor end cover;
Steering motor (5, Figure 30221) is mounted on - Then the carbon brush (8) can be replaced.
the drive mounting base .
Installation
oval.
CAUTION
- During installation, fasten the bottom surface
of steering motor into the groove of motor
mounting base, and then tighten the four
mounting screws.
WARNING
Due to magnetic force, the rotor and the stator
may pull each other, therefore, when disman-
tling motor rotor, do not hold your hand between
the rotor and the stator to avoid pinch hazard!
SM-EU110 05/18
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DRIVE SYSTEM
Adjustment Motor with abnormal noise or

Fault
- After replacing the steering motor or carbon vibration
brush, conduction test must be carried out to
a. Uneven clearance between
the motor (see Section 5.6.3). 4 stator and rotor;
- After replacing carbon brush, running opera- Cause b. Bearing failures;
tion must be carried out to the carbon brush: c. Loosening fixing screws on
By running the motor with repeated steering, motor housing.
letting the carbon brush to be fully running,
making its surface smooth to fit the rotor. Fault Motor smoking or burning smell
5 Stator winding short circuit, motor
Cause
burnt
Fault Excessive temperature rise
Fault Motor does not rotate a. Stator winding short circuit;
a. Negative electrode cable b. Motor positive and negative
broken; 6 electrodes with surface
b. Motor positive and negative Cause oxidation, resistance increases
electrode with loose terminals; and results in heating;
1 c. Armature winding with broken c. Bearing failure, resulting in
Cause severe heating.
circuits;
d. Motor bearing damaged and
blocked; 5.6.3 Checking and Testing
e. Serious wearing of carbon
brush. Checking
- Check if the motor and appearance of
Fault Motor speed is turning slow cables are in good condition, and if the plug
a. Insufficient voltage of battery; connection is secure;
b. Carbon brush worn or carbon - Check if the circuit is connected.
brush spring pressure
Testing
2 decreases;
Cause c. Bearing wear or lack of - Carry out ON/OFF test to motor positive and
lubricating oil; negative electrodes with a multimeter:
d. Armature winding has short If connected, the motor is normal;
circuit elements; If not connected:
e. Carbon brush winding grounded. 1) Broken circuits in rotor coils (replace the
motor);
Motor sometimes can start, 2) Carbon brush wearing, move on to the
Fault
sometimes cannot next step.
a. Motor positive and negative - Replace the carbon brush (See Section
electrode with loose terminals 5.6.1).
3
and poor connection;
Cause CAUTION
b. Carbon brush wear and tear;
c. Armature winding has circuit When replacing the carbon brush, replace the
broken unit. complete set of carbon brushes.

See Section 5.7.4 .
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DRIVE SYSTEM
5.7 Speed Encoder

Speed encoder is used to detect the speed
of the motor and covert the speed into fixed
signals.
Speed Encoder
Copper Screw
Magnet
Copper Stopper Testing
- The vehicle is powered on, measure the volt-
age between pin connector (40#) and (43#)
5.7.1 Removal and Installation with a multimeter, normally should be 5V;
- Check if the connection between 41# and 42#
See Section 5.6.1 .
is reversed. (If the two circuits are connected
reversely, the controller will report for failure,
5.7.2 Faults and Causes and the handheld unit will display fault code:
83 BAD ENCODER SIGN)
Fault Motor does not rotate
1 - Check “ENC SPEED” readings on TESTER
Cause Speed encoder or its circuit failure Menu (EPS-DC0).(see Section 8.10)
On load, motor speed is turning Operate the forklift, if the display is always “0”:
Fault Speed encoder failure, replace the encoder.
2 slow
Cause Speed encoder or its circuit failure
5.7.3 Checking and Testing Control Circuit (Figure 30224)
Checking Check if the circuit is broken by using a multi-

meter:
- Check if the speed encoder and the appear-
ance of cables are in good condition, and if - Set the multimeter to ON-OFF;
the plug connection is secure; - Check if #40/#41/#42/#43 circuit (circuit
between speed encoder and controller) is
- Remove the speed encoder and check if conducted.
its sensing surface is parallel to the round
section of magnet.
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6. OPERATING SYSTEM
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51
OPERATING SYSTEM
6.1 CONTROL HEAD In the electrical control circuits of this truck, the
push button switch is used for manual emitting
Control lever is used to control the travel, lifting, of control signals to control the vehicle lifting,
lowering, horn and emergency reverse of the lowering, horn and emergency reverse.
vehicle.
By function:
6.1.1 Cap Assembly Removal - Proportional Lifting & Lowering Button Switch
Removal - Tilt Button Switch
- Forward & Backward Switch Button Switch
1.Engage the emergency stop switch(see Se- - Horn Button Switch
ction 4.1.1) and turn off key switch. - Emergency Reverse Switch
2.Remove four screws (19&20, Figure 30302),
lift up cap(2) and disconnect harness from main 6.2.1 Removal and Installation
harness(15,Figure30301).
Proportional Lifting & Lowering Switch
1.Remove the cover; (see Section 6.1.1)
Installing 2.Disconnect switch harness（8，Figure30302）
- Install according to the reverse order of rem- from harness (15, Figure30301);
oval; 3.Remove proportional Lifting & Lowering swit-
ch.
6.1.2. Control Head Removal
Removal oval;
1. Engage the emergency stop switch(see Se-

ction 4.1.1) and turn off key switch. Emergency Reverse Switch
2. Remove four screws (13, Figure 90301), remove
control head(1,Figure 30301) and disconnect 1.Remove the cover; (see Section 6.1.1)
harness form harness(15,Figure30301). 2.Remove Spring(16, Figure30302)and button rev-
erser Cover(6);
Installing - Install according to the reverse order of rem-

oval;
oval;
Horn Button
(See Figure 30302)
CAUTION 2.Disconnect switch harness（9，Figure30302）
from harness (15, Figure30301);
When removing or installing, please pay attent- 3.Unscrew the two screws (22) ,remove swi-
ion to protect the cables from being damaged. tch harness(9) on the bracket (23);
4.Unscrew the two screws (15) ,remove mount-
6.2 Button Switch ing(14)and horn button(5);
Push button switch is the switch that makes

the dynamic and static contacts ON or OFF to - Install according to the reverse order of rem-
achieve the switching of circuits through push- oval;
button drive mechanism.
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OPERATING SYSTEM
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OPERATING SYSTEM
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OPERATING SYSTEM
Operate the push button switch,

Fault but the vehicle responds with no
action
1
a. Push button switch failure;
Cause b. Push button switch circuit not
conducted.
Push button switch not operated,
Fault but the vehicle responds with
2 action
Cause Pushbutton switch failure

Checking
- Check if the pushbutton switch and the
appearance of cables are in good condition,
and if the plug connection is secure.
Testing
- Check if the push button switch circuit is
connected;
- Carry out ON/OFF test to the push button
switch with a multimeter:

(See Figure 30303)
- Carry out ON/OFF test to the circuit between
#1 and #2 with a multimeter:
push button switch at original position, broken
circuit;
press the button , the circuit is conducted.
Horn Button
(See Figure 30305)
circuit;
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OPERATING SYSTEM
Emergency Reverse Switch

(See Figure 30306）
circuit;

Control Circuit

meter:
- Check if #1 circuit (circuit between switch and
key switch) is conducted.
- Check if #2 circuit (circuit between Lifting &
Lowering switch and controller) is conducted.
proportional switch and controller) is conduc-
ted.
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OPERATING SYSTEM
Horn Button Control Circuit Horn Checks

Check if the circuit is broken by using a multi- Energize the horn with a voltage of 24V:
meter: Horn sounds, it is working properly;
- Set the multimeter to ON-OFF; Horn does not sound, it failure, needs to be
replaced.
- Check if #1 circuit (circuit between horn swit-
ch and key switch) is conducted.
- Check if #4 circuit (circuit between horn swit-
ch and horn) is conducted.
Horn
Key Switch
Emergency Reverse Switch Circuit

meter:
- Check if #1 circuit (circuit between Emerg-
ency Reverse switch and key switch) is con-
ducted.
- Check if #6 circuit (circuit between Emerg-
ency Reverse switch and controller) is
conducted.
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OPERATING SYSTEM
6.3 Travel Switch Testing

Travel switch provides forward or backward in- Enter TESTER Menu to check the status of
put signals for the vehicle. the switch:
"FORWARD SWITCH" / "BACKWARD SWIT-
CH", toggle the switch forward / back-ward, if
6.3.1 Removal and Installation the display does not change, then it indicates
the travel switch or its circuit failure;
Removal
2.Disconnect travel accelerator harness（13，Fig
ure30302）from harness (15, Figure30301);
3.Unscrew the screws (17) and(18),remove
Travell-ing Knob(L)and Travelling Knob(R);
Installation
oval.
CAUTION
- Turn off the vehicle to check the travel swit-
When removing or installing, please pay attent- ch and its wiring harness. (See Figure 90312)
ion to protect the cables from being damaged.
- Energize the travel switch with a voltage of
24V and check the voltage of each port with
6.3.2 Faults and Causes a multimeter;
Operate travel switch, the vehicle - Place the travel switch at Middle position.
Fault Respectively, measure the voltage of pin (11),
cannot go forward or backward
1 pin (12) and pin (10) of the travel switch:
a. Travel switch failure;
if the voltage is not 0, it indicates the travel
Cause b. Travel switch circuit not
switch failure, needs to be replaced;
conducted.
if the voltage is 0, indicating the switch is
Travel switch not operated, the normal, move to the next step.
Fault vehicle goes forward or backward - Toggle the travel switch forward, measure the
2 automatically voltage of pin (11), pin (12) and pin (22) of
Cause Travel switch failure; the travel switch:
Pin(12) : 24V . Normal
6.3.3 Checking and Testing Pin(11) : 0V . Normal
Pin(10) : 0V~5V, the maximum value is
Checking 4V~5V. Normal
- Check if the appearance of travel switch and
its wiring harness are in good condition, and - Toggle the travel switch backward, measure
if the connectors are connected securely. the voltage of pin (11), pin (12) and pin (22)
of the travel switch:
Pin(12 : 0V . Normal
Pin(11) : 24V . Normal
Pin(10) : 0V~5V, the maximum value is
4V~5V. Normal
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OPERATING SYSTEM

Travel Switch Control Circuit
(Figure 30313)
meter:
- Check if #1/#10/#11/#12/#18 circuit (circuit
between travel switch and controller) is con-
ducted.
Key Switch
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OPERATING SYSTEM
6.4 Potentiometer Adjustment

Potentiometer provides the vehicle with steering STER 1:
input signals.
Connect the handheld unit with EPS controller.
6.4.1 Removal and Installation STER 2:
Go into "Adjustment" menu.

Removal
(See Figure 20308) STER 3:
Find "ZERO SP POT" and enter
STER 4:
Turn the handle you will find the value of
"ZERO SP POT" is changing.and put the
handle in straight way,then save the value
(usually around 2.1-2.5)
STER 5:
restart the truck,and check if the wheel is

straight when the handle is straight (zero
position).
Straight,please go to SETP 9;
Not straight,please go to SETP 6. (usually it
should be straight, SETP 6-SETP 8 is just for
special case)
STER 6:
Go into "Adjustment" menu
STER 7:
Find "SET STEER 0-POS." and enter

- Disconnect the connection between potentio-
meter and main wiring harness; STER 8:
- Unscrew the two screws (1) with a wrench,
Increase or decrease the value to make the
and remove the mounting plate (3) from the
zero position go right or left.Then try turn
joint holder (2);
around the handle and make it straight again
- Unscrew the two screws (5), and remove the
to make sure the wheel is correct,then save.
potentiometer (6) and the rocker (4) from the
mounting plate (3). STER 9:
Installation Turn the handle to the max position (both

side),and check if the wheel can reach the 90
- Install according to the reverse order of rem- deg in both side
oval.
CAUTION
When removing or installing, please pay attent-
ion to protect the cables from being damaged.
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OPERATING SYSTEM
STER 10: Testing

- Enter TESTER Menu (EPSDC0) to check the
If the wheel can not match the handle max stepper motor voltage:
position,please go into "Parameter Change"
menu.
Green White
STER 11:
Red Black
Find the "1ST ANGLE COARSE","1ST
ANGLE FINE","2ND ANGLE COARSE","2ND
ANGLE FINE",1ST is for the left max position:
Increase 1 level of "1ST ANGLE COARSE"
can increase 10deg;
Increase 1 level of "1ST ANGLE FINE" can
increase 1deg (same for 2ND,right side).
Each time change the level,please turn back
the handle then turn to the max position,check
the wheel position again.
“SET POINT POT”, turn the handle, if the
STER 12: voltage display is always "0", it indicates that
the potentiometer has no signal output (see
Save the parameter and key off. Section 8.10):
- mechanical loosening between potentiome-
ter and rocker;
6.4.2 Faults and Causes - potentiometer failure or its circuit not cond-
ucted.
Operate the handle, the vehicle - Check if the circuit from controller to potentio-
does not respond to the steering meter is conducted.
Fault signal;
the handheld unit displays fault If the circuits are conducted, but the fault still
1 code: S.P.Outoff Range exists, then replace the potentiometer .
a. Potentiometer failure;
Cause b. Potentiometer circuit not
conducted.
Potentiometer Control Circuit
(Figure 20310)
6.4.3 Checking and Testing Check if the circuit is broken by using a multi-
meter:
Checking
- Check if the appearance of the potentiometer
- Check if #28/#29/#30/#31 circuit (circuit
and its wiring harness are in good condition,
and if the connectors are connected securely; between potentiometer and controller) is con-
ducted.
- Check if the mechanical connection between
potentiometer and rocker is secure and if
there is loosening.
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OPERATING SYSTEM
6.5 Sidegate Switch
Normally-closed (NC):
Terminal (1) and Terminal (3) for connection of
wiring harness connector to switch base
6.5.1 Removal and Installation When put down the safety gate,
Fault
but travel speed is not reduced
See Section 4.4.1 .
1 a. Sidegate switch failure;
6.5.2 Connection Mode Cause b. Sidegate switch with broken
Sidegate switch has 3 terminals. circuit.
The switch can be switched between open and When open the safety gate, the
Fault
close by toggling the roller lever to achieve the speed is reduced
control of connection and disconnection of the 2 a. Sidegate switch failure;
circuit.
Cause b. Sidegate switch shorted
(short circuit).
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OPERATING SYSTEM

Checking
- Check the switch for damage and check the
roller for deformation;
- Check if the handwheel is working smoothly
and if there is foreign body blockage.
Testing
- Enter TESTER Menu to check the status of
the switch; (see Section 8.10)
- Turn the key switch to "OFF", remove key.
And switch off the power supply.
- Check the ON/OFF normally-opened (NO)
terminal with a multimeter: with handwheel
at natural position, Terminal (2) and (3) not
conducted; toggle the handwheel, Terminal (2)
and (3) conducted.
- Check the ON/OFF normally closed (NC)
terminal with a multimeter: with handwheel
at natural position, Terminal (1) and (3) con-
ducted; toggle the handwheel, Terminal (1)
and (3) not conducted.

Speed Mode Switch Control Circuit
(Figure 20313)
meter:
- Check if #1/#21 circuit (circuit between switch
and controller) is conducted.
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7. HYDRAULIC SYSTEM
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HYDRAULIC SYSTEM
The system pressure of the entire hydraulic Hydraulic Oil

system pressure is provided by hydraulic power
unit system, which is used for lifting. While the Hydraulic oil for truck:
hydraulic power unit is equipped with a relief Specifications: Anti-wear Hydraulic Oil L-HM46.
valve to ensure that the entire system pressure * For cold storage: Low Temperature Anti-wear
is always within the safety limits that can lift the Hydraulic Oil L-HV32.
maximum load capacity.
Solenoid valve on the valve body is used for the
control of lowering. Throttle valve is used for the Hydraulic Seals
control of lowering speed. Inlet is equipped with The seals installed within the cylinder are made
a filter to prevent the impurities in the hydraulic of rigid polyurethane. The deformation during
oil from entering into the pump. assembly due to compression will not cause a
Hydraulic Schematic Diagram is as shown in permanent deformation.
Figure 30401; When assembling, pay attention to prevent the
See Section 7.8 for hydraulic symbol descripti- seals from being broken, rolled and undercut.
ons.
Assembly Instructions
7.1 Overview The tools used to install the seals must be made
of soft metal or suitable plastic, without burrs
- Lower the fork to the bottom, remove the air and sharp edges on surfaces. It is prohibited
filter on cylinder, observe the oil level with the to use the tools that can easily damage the
oil dipstick. When adding hydraulic oil, please surface of seals, such as, screwdriver or other
use hydraulic oil of the same specifications. similar tools with hard front edges.
- When the fork occasionally jitters, that may Where the hydraulic seals to be installed should
be leaks in the cylinder, or there could be be free of burrs, sharp edges and cracks. If the
leaks on the valve body. Dismantle and clean installation of seals needs to cross sharp edges,
(to clean with hydraulic oil of the same spe- grooves or cuts, protective devices must be
cifications) the valve on the valve body, disch- used for protection. Before installing, lubrication
arge the foreign bodies within the valve body should be performed to the seals and the
through repeatedly lifting and lowering of the mounting positions first.
fork.
- If hydraulic oil is becoming less, please tho- CAUTION
roughly check the hydraulic system for leaks. The lubricant used during assembly must be of
- Disassembly of cylinder needs to be perfor- the same specifications with the hydraulic oil
med in a clean environment. Before removing used in the vehicle.
the cylinder, the stains on the cylinder must
be removed first. Carefully remove the piston
rod to prevent the cylinder wall from being
scratched by its end surface or damaged
part. Every time when replacing the cylinder,
also replace the cylinder seals.
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HYDRAULIC SYSTEM
7.1.1 Hydraulic Schematic Diagram
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HYDRAULIC SYSTEM
7.2 Pump and Motor Assembly 7.2.2 Component

Removal
- Remove the lower cover; (see Section 4.2)

- Remove the positive and negative electrode
cables (1) from the pump contactor and the
wires from the solenoid valve (4) (see Figure
20402);
- Unscrew the screw(5) between valve and
pump and motor assembly with a wrench, No. Name
and remove the tubing and Accumulator;
1 Pump Motor
- Unscrew the two screws (3) and screw (2) on
mounting plate with a wrench, and remove 2 Carbon Brush
the pump and motor assembly. 3 Hoop
4 Solenoid Valve
Installation
5 Valve Body
- Install according to the reverse order of rem- 6 Gear Pump
oval.
7 Filter
CAUTION
When removing the tubing and pump and
motor assembly, the system will lose some
hydraulic oil, please refer to Section 2.2.3 for
supplementary adding of hydraulic oil.
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HYDRAULIC SYSTEM
7.3 Pump Motor Adjustment

7.3.1 Removal and Installation - After replacing the steering motor or carbon
brush, conduction test must be carried out to
Removal the motor (see Section 7.3.3).
- After replacing carbon brush, running opera-
tion must be carried out to the carbon brush:
By running the motor with repeated lifting,
letting the carbon brush to be fully running,
making its surface smooth to fit the rotor.
Fault Motor does not rotate

a. Negative electrode cable
broken;
b. Motor positive and negative
electrode with loose terminals;
- Remove the pump and motor assembly; 1 c. Armature winding with broken
Cause
- Remove the 2 long screws (1) and 4 screws circuits;
(5) on the motor end cover, remove the hoop d. Motor bearing damaged and
and remove the pump motor (2) from the blocked;
valve block (3); e. Serious wearing of carbon
- If you need to replace carbon brush (4). Re- brush.
move motor end cover, replace the carbon Fault Motor speed is turning slow
brush on the holder.
a. Insufficient voltage of battery;
CAUTION b. Carbon brush worn or carbon
brush spring pressure
When replacing the carbon brush, replace the decreases;
2
complete set of carbon brushes. Cause c. Bearing wear or lack of
Installation lubricating oil;
d. Armature winding has short
circuit elements;
oval.
e. Carbon brush winding grounded.
CAUTION Motor sometimes can start,
Fault
When installing the pump motor, make sure the sometimes cannot
shaft and the coupling on motor rotor are mated a. Motor positive and negative
in place. (Rotate the motor around to make the electrode with loose terminals
3
end surface of motor be in full contact with valve and poor connection;
block). Cause
b. Carbon brush wear and tear;
c. Armature winding has circuit
WARNING broken unit.
Due to magnetic force, the rotor and the stator
may pull each other, therefore, when disman-
tling motor rotor, do not hold your hand between
the rotor and the stator to avoid pinch hazard!
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HYDRAULIC SYSTEM
Motor with abnormal noise or

Fault CAUTION
vibration
When replacing the carbon brush, replace the
a. Uneven clearance between
4 complete set of carbon brushes.
stator and rotor;
Cause b. Bearing failures;
c. Loosening fixing screws on
motor housing.
Fault Motor smoking or burning smell
5 Stator winding short circuit, motor
Cause
burnt
Fault Excessive temperature rise
a. Stator winding short circuit;

b. Motor positive and negative
electrodes with surface
oxidation, resistance increases
and results in heating;
c. Bearing failure, resulting in
6
Cause severe heating.
d.The mast is locked or the pipe
loss of the hydraulic pipeline
becomes larger, which leads
to the pressure of the hydr-
aulic station and even the ov-
erflow condition.

Checking
- Check if the pump motor and appearance of
cables are in good condition, and if the plug
connection is secure;
- Check if the circuit is connected.
Testing
- Remove the cables on the pump motor;
- Carry out ON/OFF test to motor positive and
negative electrodes with a multimeter:
If connected, the motor is normal;
If not connected:
1) Broken circuits in rotor coils (replace the
motor);
2) Carbon brush wearing, move on to the
next step.
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HYDRAULIC SYSTEM
7.4 Solenoid Valve Fault Internal leakage

When solenoid valve coil is energized (there 3 Damaged seals or spring
Cause
is voltage between coil end A and B), the deformations
electromagnetic coil generates electromagnetic
Fault External leakage
force, and the spool will move, the valve will
open, and the vehicle will be lowered. 4 Loose connections or damaged
Cause
When the contactor coil is de-energized, the seals
closing part will be released under the effect Fault Noisy when energized
of the released spring, the hydraulic oil cannot
form a loop, thus the lifting mechanism cannot a. Unstable supply voltage;
5 b. Impurities on absorption surface
be lowered. Cause
or uneven surface of core,
needs cleaning.
Spool
Checking
Electromagnetic Coil - Check the solenoid valve connector for loos-
ening or poor connection of leads.
7.4.1 Faults and Causes Testing

- Switch off the power supply of the vehicle;
Solenoid valve does not work after
Fault - Measure the resistance between solenoid
energized
valve coil end point A and B to identify if the
a. Different power supply circuits; coil is normal;
b. Insufficient power supply as shown in the following table:
voltage;
Resistance
c. Short circuit; Judgment
Measurement
1 d. Unsoldering coil (coil short
circuit); Approx. 32 Ω Normal
Cause
e. Main spool and moving core Coil shorting
of the solenoid valve blocked by 0Ω
(replace the solenoid valve)
impurities;
Coil breaking
f. High viscosity of hydraulic oil; ∞Ω
g. High frequency of use, service (replace the solenoid valve)
life has expired already. If the coil is normal, move on to the next step.
Fault Solenoid valve cannot be closed - Check the solenoid valve for blocking:
a. Main spool or core seals broken the fitting clearance between slide valve
or aged; sleeve and spool is very small, when there
b. Main spool and moving core is impurity entering or too less lubricant, it is
of the solenoid valve blocked by easily blocked.
2 impurities; Handling method:
Cause
c. Spring deformation;
- Insert a steel wire from the small hole at va-
d. Balancing hole blocked by
lve end to make the spool rebound;
impurities;
e. High frequency of use, service
life has expired already.
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HYDRAULIC SYSTEM
- Remove the solenoid valve, take out the

spool and spool sleeve, clean with CCI4 to
enhance the flexibility of the moving of spool
within the spool sleeve. During disassembly,
pay attention to the sequence of assembly
and position of external wiring for correct re-
assembly and wiring, also check the oil mist
spray orifice for blockage and if the lubricant
is sufficient.
CAUTION
If the solenoid valve is found with the above
mechanical failures, it is recommended to re-
place the solenoid valve directly.

Solenoid Valve Control Circuit
(Figure 30407)
meter:
- Check if #9/#22 circuit (circuit between
solenoid valve) is conducted.
solenoid valve
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HYDRAULIC SYSTEM
7.5 Lift Cylinder - Upon removal, the damage to cylinder

threads, oil port threads, cylinder cap threads,
7.5.1 Cylinder Removal Precautions piston rod surface and inner cylinder wall
should be prevented.
- Before removing the cylinder, be sure to reli-
eve the hydraulic circuit first, which is to lower In order to prevent piston rod from bending or
the lifting mast to the bottom. Otherwise, deformation, support it wooden block when
when removing the tubing connected with the placing.
cylinder, the pressured hydraulic oil within When removing seals, the use of sharp
the circuit may be sprayed out at high speed tools should be avoided, so as not to stab
along with the tubing, and there is risk of the seals. For the seals that are difficult to
causing personal injury. remove, soak them with boiled water, remove
Turn off the power source, so that the entire them when getting softened.
hydraulic system will stop functioning, then - Before removing, try to create conditions
the connecting tubing can be loosened; in
to prevent the cylinder parts from being
order to avoid the residual pressure within the
contaminated by the surrounding dust and
circuit, the tubing joint should be loosened
impurities. For example, try to disassemble
slowly, loosen the joint by half and shake the
the equipment in a clean environment; after
tubing to see if there is overflow of pressured
the disassembly, all parts should be covered
oil, and then go on with the removal;
with plastic, do not cover with cotton cloth or
- Cylinder is the powered actuator in hydraulic other cloth used during operation;
system. Therefore, before removing the - For the cylinder which is found with internal
cylinder from the equipment, the connection or external leakage during use, if the piston
part must be supported with appropriate rod or cylinder tube is not scratched, such
supporting to avoid personal injury or damage case may be due to wear or aged seals.
to the equipment;
- Cylinder is the powered actuator in hydraulic CAUTION
system. Therefore, before removing the
cylinder from the equipment, the connection When the seals need to be replaced, replace
part must be supported with appropriate with the complete set of seals in the cylinder
supporting to avoid personal injury or damage repair kit.
to the equipment;
- Pay special attention to the cylinder tube,
- Upon disassembly of the cylinder, you should piston rod and other moving parts for bumps
know the main structure of the cylinder to and scratches. If only minor damage, sand
avoid sightless removal. Due to the different the edge point around the damaged part with
size, structure, purpose of use of the fine stone and then polish the part smooth
cylinders, the sequences and methods used with metallographic sandpaper.
for removal are also different;
- When removing each part, do not hammer
forcefully, it such case cannot be avoided,
please lay a copper rod to avoid damage
to the parts; special tools must be used for
the parts having such requirements, do not
hammer forcefully or pry. Fine pitch threaded
cylinder cap, after being shaken loose,
loosen it with cylinder wrench with even force,
copper rod can be used to hammer the part
that cannot easily deform, do avoid violent
shocks.
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HYDRAULIC SYSTEM
CAUTION
Cylinder Cap
- O-ring is quite flexible and easy to install,
but it must not be pulled up to the extent of
permanent deformation, nor scroll it while
installing;
Cylinder Wrenches - Y-ring or X-ring needs to be identified if it is
for shaft or hole to avoid misplacement;
- The removed O-rings and dust rings should
be replaced with new ones.
Piston Rod
- Cylinder parts must not be arbitrarily repla-
ced, the original products provided by the
manufacturer should be used;
- After maintenance and assembly of the cylin-
Cylinder Tube der is completed, pressure leak testing must
be carried out before it can be put operation
once again.
Before the testing, discharge the air within
the cylinder, run the cylinder in a small range
of movement for several times, and pay
attention if it is moving without blocking and if
there is uneven resistance during the moving.
Upon the pressure testing, raise the pressure
7.5.2 Cylinder Installation Precautions slowly and observe carefully for leaks.
- All parts should be cleaned up before asse-
mbly, then to be assembled after being
dried;(during assembly, apply appropriate
amount of hydraulic oil for lubrication)
- The tools used to install the seals must
be made of soft metal or suitable plastic,
without burrs and sharp edges on surfaces.
It is prohibited to use the tools that can
easily damage the surface of seals, such as,
screwdriver or other similar tools with hard
front edges.
Where the hydraulic seals to be installed
should be free of burrs, sharp edges and
cracks. If the installation of seals needs to
cross sharp edges, grooves or cuts, protective
devices must be used for protection. Before
installing, lubrication should be performed to
the seals and the mounting positions first with
hydraulic oil.
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HYDRAULIC SYSTEM
7.6 Hydraulic Troubleshooting
Fault Symptom Failure Causes Troubleshooting Measures
a. Insufficient oil; 1. Check the hydraulic oil level.

b. High viscosity of oil; 2. Replace the hydraulic oil.
c. Oil suction pipe air leak; 3. Check the oil suction pipe.
1 Noisy pump
d. Filters clogged by impurities; 4. Clean the oil inlet piping,
replace the filter, if necessary.
e. Hydraulic oil with foam; 5. See Fault 2.
1. Check the amount of oil;

2. Check if the viscosity of
a. Pump cavitation; hydraulic oil is normal;
2 Hydraulic oil with foam b. There is water in the oil. 3. Check the oil inlet piping for air
leaks;
4. Discharge and clean, and
replace with new hydraulic oil.
1. Discharge and clean, and add

a. Oil is too thin; new hydraulic oil;
Pump or oil
3 b. Pump cavitation; 2. Check the oil inlet piping for air
temperature is too high c. Valve body internal relief. leaks;
3. Replace the valve body.
a. Insufficient oil; 1. Check the hydraulic oil level;

4 Low System Pressure b. Relief valve failure. 2. See Fault 6;
c. Pump wear, internal leakage. 3. Replace the gear pump.
1. Check and clean the solenoid

5 On load, declined a. Solenoid valve failure.
valve spool.
a. Pressure adjustment screw too 1. Adjust to proper pressure

loose; through hydraulic pressure
Relief valve pressure b. Relief valve spring breakage or gauge.
6
unstable or too low deformation; 2. Replace the relief valve.
c. Relief valve spool wear or 3. Clean or replace the relief
blocked. valve.
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HYDRAULIC SYSTEM
7.7 Hydraulic Symbol
Symbol Description Symbol Description
Tank
Pipe end below liquid Explosion-proof valve
level
Tank
Pipe end above liquid
Check valve
level
Cylinder
Filter Single-acting direction
Service line
(Supply line or return Relief valveRelief
line) valve
Control line
(Drain line)
Throttle valve
With pressure
compensation device
Connecting pipe Solenoid Valve

Two-way two-pass
Port
(Test port)
Motor
Hydraulic pump
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8. ELECTRICAL SYSTEM
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ELECTRICAL SYSTEM
8.1 Controller 8.1.1 Removal and Installation
Controller Functions Removal

Electrical control of this truck is mainly driven by - Remove the cover; (see Section 4.2)
traction controller and steering controller. - Remove the wiring harness, cables and copp-
- Controller: er strips on the controller;
traction controller: mainly used for the control - Unscrew the four screws (2) with a wrench
of drive motor and remove the traction controller (1);
Steering controller: mainly used for the control - Unscrew the four screws (4) with a wrench
of steering motor and remove the steering controller (3).
- Other:
Button switches, drive speed sensor, steering
speed sensor, interlock switch, limit switch,
potentiometer, speed mode switch, etc.
Steering
Controller
Power
Fuse 1
Main
Contactor
Traction
Controller
Power
Fuse 2
Installation
- Apply appropriate amount of thermal grease
on the back of controller;
- Place the controller onto the electrical mount-
ing plate, tighten the four screws with a
wrench;
- Plug the wiring harness and cables into cor-
responding ports.
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ELECTRICAL SYSTEM
8.1.2 Controller Interface Function

Traction Controller (COMBIACX-ACEX)
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ELECTRICAL SYSTEM
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ELECTRICAL SYSTEM
Steering Controller (EPS-DC0)
A Interface
Pin No. Signal Name Description
A#1 DRIVE SWITCH Traction Travel Demand Input.
A#2 SW1 1st Toggle Switch.
A#3 SW2 2st Toggle Switch.
A#4 NK1 Safety Switch Lower Voltage Point.
A#5 K1 Safety Switch Higher Voltage Point.
Can Bus Low.
A#6 CANL
Connected to traction controller.
A#7 KEY Key Switch Signal Input Port.
A#8 CPOC2 / QL Stepper Motor Q line.
A#9 CPOC1 / DL Stepper Motor D line.
A#10 NPOC Twin SP POT Negative Supply (GND).
A#11 GND GND. Encoder Negative Supply
A#12 GND GND. SW1 & SW2 Negative.
A#13 GND GND. Motor Thermal Sensor Negative.
Can Bus High.
A#14 CANH
Connected to traction controller.
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ELECTRICAL SYSTEM
B Interface
B#1 NPOT FB POT Negative Supply.
B#2 PPOT FB POT Positive Supply.
B#3 THMOT Motor Thermal Sensor (KTY84-130) Input.
B#4 +5VDC Encoder Positive Supply.
B#5 CPOT Twin SP POT Positive Supply (5 Vdc).
B#6 CPOT FB POT Wiper.
B#7 CHB phase B of encoder.
B#8 CHA phase A of encoder.
C Interface (handheld unit communication interface)

C#1 PCLRXD Positive serial reception.
C#2 NCLRXD Negative serial reception.
C#3 PCLTXD Positive serial transmission.
C#4 NCLTXD Negative serial transmission.
C#5 GND Negative console power supply.
C#6 +12V Positive console power supply.
It must be connected to C8 for the Flash memory
C#7 FLASH
programming.
It must be connected to C7 for the Flash memory
C#8 FLASH
programming.
Terminal stud
- -B Negative of the battery.
- +B Positive of the battery.
Connection bars of the three motor phases; follow this
- FU, FV, FW
sequence and the indication on the motor.
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8.2 Fuse
The entire vehicle is installed with five fuses
altogether. When there is fuse failure, the truck
may not be able to run properly due to that.
8.2.1 Location of Fuses × : Failure

Ο : Normal
Power Fuse 1-3: installed on electrical mounting plate
Control Fuse 1-2: installed on main harness
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Checking
- Check the fuses for damage, check the
connectors at terminal lugs for loosening or
poor connection of leads.
Testing
- Turn the key switch to "OFF", remove key;
pull out the battery plug and disconnect the
power supply.
- Set the multimeter to resistance measure-
ment: with black probe (-) connected to one
end of the fuse; red probe (+) connected to
another end of the fuse.
- Identify if the fuse is normal according to the
readings of resistance on the multimeter.
As shown in the following table:
Resistance
Judgment
Measurement
0Ω Normal
Failure
∞Ω
(replace the fuse)
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8.3 Main Contactor
This truck is using main contactor with norm-

ally-opened contacts. And the ON/OFF of the
contactors is controlled through controller, thus
to achieve the control of ON/OFF of the vehicle.
When the contactor coil is energized, the coil
current will create a magnetic field, making the - After the replacement, re-install in reverse
static stator core produce a steady magnetic order and tighten the two fastening screws
force to absorb the core and drive the contactor (4);
actions: normally-opened contact connected, so
- Following the reverse order of step 1, fast-
the circuit is disconnected.
en the main contactor onto the electrical
When the contactor coil is powered off, the mounting plate, and re-connect it according
magnetic force disappears, the pressure plate to the original connection methods.
is released along with the release of spring, and
the contact recovers: normally-opened contact
disconnected, so the circuit is disconnected.
8.3.1 Removal and Installation Fault Contact adhesion or slow release

Main contactor is installed on the electrical
a. Contact fusion welding;
mounting plate.
1 b. Contact spring pressure is too
- Remove the cables and wiring harness on low;
the main contactor, and remove the main Cause
c. Mechanical moving parts
contactor from the electrical mounting plate; blocked, shaft rusted or crooked;
- Unscrew the two fastening screws (4) with a d. Anti-force spring damaged.
Phillips screwdriver and remove the top cover Contact not absorbed or not fully
of contactor (3); Fault
absorbed
- Remove the auxiliary contact assembly
(2), replace the assembly or coil (6); (when a. Insufficient voltage of battery;
2 b. Main contactor coil open circuit;
replacing the contacts, replace in pairs)
Cause c. Mechanical moving parts
blocked, shaft rusted or crooked;
d. Control contact poor contact.
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Visual Inspection
- Check the surface and appearance of contac-
tor;
- Visually check the surface of contactor for
scratches, damages and stains;
- If any of the above case is found, please
replace with new contactor.
Coil Checks
- Disconnect the cables on the contactor;
- Check the resistance of the coil with a multi-
meter: measurement method is as shown in Contact Checks
Figure 30508; - Check if the surface of contact surface is
- Identify if the contactor is normal according to smooth and symmetrical;
the readings of resistance on the multimeter. - Separately provide the contact with a voltage
As shown in the following table: of 24V to observe if the contact can absorb;
Resistance - If the surface is uneven or the contact does
Judgment
Measurement not absorb, replace the main contactor.
Approx. 30 Ω Normal
Coil shorting
0Ω
(replace the contactor) 8.3.4 Control Circuit Troubleshooting
Coil breaking Main Contactor Control Circuit
∞Ω
(replace the contactor)
(Figure 30509)
meter:
- Check if #13/#26 circuit (circuit between main
contactor and controller) is conducted.
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8.4 Lifting Limit Switch 8.4.2 Removal and Installation
- Unscrew three fixing screws (1), then the

limit switch cover (3) can be removed from
- the limit switch seat (2),remove the switch
harness;
Put the wiring harness through the wire
protective ring (4) and install the connector to
- terminals on switch seat (2);
- Re-install the switch cover (3) onto the switch

seat (2) and tighten the fixing screws (1).
See Section 3.1 for mounting position of lifting

limit switch.
8.4.1 Connection Mode

Limit switch has 4 terminals, one pair is
normally-opened (NO) and the other pair
is normally-closed (NC), the switch can be
switched between open and close by toggling
the roller lever to achieve the control of
connection and disconnection of the circuit.
CAUTION
When installing waterproof rubber ring, make
sure it is fully seated in the mounting slot of the
switch seat.
Adjustment
- The direction of roller lever seat (5) can be
adjusted through adjusting the adjustment
screw (8);
Lifting Limit Switch - The sensing distance of roller lever (6) can
be adjusted through adjusting the adjustment
Normally-Closed (NC): screw (7).
Terminal (1) and Terminal (2) for connection of
wiring harness connector to switch base
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- Enter TESTER Menu to check if each limit
Lifting Speed Reduction Switch switch is working properly; (see Section 8.10)
- Turn the key switch to "OFF", remove key;
When speed reduction switch is pull out the battery plug and switch off the
Fault
activated, the speed is not reduced power supply.
1
Cause
Speed reduction switch is not reset - Check the ON/OFF normally-open (NO)
and always in a closed state. terminal with a multimeter: with handwheel
at natural position, Terminal (3) and (4) not
8.4.4 Checking and Testing and (4) conducted.
Checking - Check the ON/OFF normally closed (NC)
- Check the limit switch for damage and check terminal with a multimeter: with handwheel
the roller for deformation; at natural position, Terminal (1) and (2)
- Check if the handwheel is working smoothly
and (2) not conducted.
and if there is foreign body blockage.

Lifting Speed Reduction Switch
meter:
- Check if #5/#25 circuit (circuit between limit
switch and controller) is conducted.
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8.5 Key Switch 8.5.2 Faults and Causes

Key switch is used to START / STOP the truck. Turn the key switch to “ON”, the
Fault
vehicle won’t start
1
8.5.1 Removal and Installation Cause
a. Key switch failure;
b. Key switch circuit not conducted.
Removal
Turn the key switch to “OFF”, the
- Remove the front cover Fault
vehicle won’t stop
2
a. Key switch failure;
Cause
b. Key switch shorted (short circuit)

Checking
- Check if the appearance of key switch its
wiring harness are in good condition, and if
the connectors are connected securely.
Testing
- Check if the key switch circuit is conducted;
- Carry out ON/OFF test to the key switch with
a multimeter:
- Disconnect the key switch connector from key switch at “OFF” position, open circuit;
main wiring harness; place the key switch at “ON” position, the
circuit is conducted.
- Unscrew the nut and remove the key switch
from the mounting plate.
Installation Key Switch Control Circuit

(Figure 30515)
oval. Check if the circuit is broken by using a multi-
meter:
- Check if #0/#1 circuit is conducted.
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8.6 Battery Discharge Indicator (BDI) 8.6.3 Checking and Testing

The BDI is used to display remaining Checking
battery power of forklift, working hours
- Check if the appearance of the BDI its wiring
(this function is available on the
harness are in good condition, and if the
component with timer function).
connectors are connected securely.
- Check if the BDI gear is in the correct
8.6.1 Removal and Installation position.
Removal
- Remove the cover ;(See Sention 4.2)
BDI with timer
Needle
M: for lead-acid battery

- Disconnect the BDI connector from main Q: for maintenance-free battery
wiring harness;
- Unscrew the nut and remove the charge gau-
ge from the mounting plate.
Installation 8.6.4 Control Circuit Troubleshooting
- Install according to the reverse order of rem- BDI Control Circuit

oval. (See Electrical Schematic Diagrams )
meter:
8.6.2 Faults and Causes - Set the multimeter to ON-OFF;
- Check if #1/#8/#18 circuit is conducted.
Fault No display on the BDI
1 a. BDI failure;
Cause b. BDI circuit not conducted.
Power capacity display not

Fault
accurate
2
a. BDI wrong gear;
Cause
b. BDI failure.
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8.7 Interlock Switch Interlock switch pressed, the

Fault
8.7.1 Removal and Installation vehicle cannot travel
2 a. Interlock switch failure;
Removal
Cause b. Interlock switch with broken
circuit.

Checking
- Check if the appearance of interlock switch
and its wiring harness are in good condition,
and if the connectors are connected securely;
- Repeatedly press the interlock switch to che-
ck if it can reset properly.
- Normally-opened (NO):
Terminal (1) and Terminal (4) for connection
of wiring harness connector.
- Loosen the rotation cover; (see Section 4.2) (see Figure 30518)
- Disconnect the connection between interlock Testing
switch and main wiring harness; - Enter TESTER Menu to check the status of
- Unscrew the two screws (1) and nuts (2) with the switch; (see Section 8.10)
a wrench, and remove the mounting plate (3) - Check if the interlock switch circuit is condu-
from the joint holder (4); cted;
- Remove the interlock switch (5) from the
- Carry out ON/OFF test to interlock switch
mounting plate (3). with a multimeter:
Reset the interlock switch (original position),
Installation the circuit is disconnected;
Press the interlock switch, the circuit is con-
ducted.
oval.
8.7.2 Faults and Causes Interlock Switch Control Circuit
(Figure 30518)
Interlock switch not pressed, the
Fault
vehicle can still travel Check if the circuit is broken by using a multi-
1 meter:
a. Interlock switch failure;
Cause b. Interlock switch shorted - Set the multimeter to ON-OFF;
(short circuit). - Check if #25/#8 circuit (circuit between inter-
lock switch and controller) is conducted.
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8.8 Deadman Switch

8.8.1 Removal and Installation Checking
- Check if the appearance of deadman switch
- Disconnect the switch harness（3） and and its wiring harness are in good condition,
main harness; and if the connectors are connected securely;
- Unscrew the two screws（4）on the moun- - Repeatedly press the deadman switch to
ting plate,remove the deadman switch ; check if it can reset properly.

Deadman Switch
When deadman switch is

Fault activated, the truck can not walk
1 and operate.
deadman switch is not reset and in

Cause
OFF state.
Testing
- Enter the TESTER Menu to check the status
of switches;(see Section 8.10)
- Turn the key switch to "OFF", remove key.
Pull out the battery plug and disconnect the
power supply;
- Check the ON/OFF normally-open (NO)
terminal with a multimeter:
with handwheel at natural position, Terminal
(2) and (3) not conducted;
Press the handwheel, Terminal (2) and (3)
8.8.2 Connection Mode
conducted.
Deadman switch has 3 terminals.
The switch can be switched between open and
close by toggling the roller lever to achieve the
control of connection and disconnection of the
circuit.
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8.8.5 Control Circuit Troubleshooting a. Between the proximity switch

Deadman Switch Control Circuit and the pedal, there
(Figure 30523) are impurities attached, such as
iron scrap;
Check if the circuit is broken by using a multi- 1 Cause b. Proximity switch with too large
meter: inductive clearance;
- Set the multimeter to ON-OFF; c. Proximity switch failure;
d. Proximity switch control circuit
- Check if #1/#3circuit (circuit between malfunction.
deadman switch and controller) is conducted.

- The truck adopts NO (normally open) proxi-
mity switches: When no signal is triggered,
the output wire (7# ) is dangling, that is, 7#
line is not connected with positive power
supply input wire (1# ).
Checking
- Check if the proximity switch and the appear-
ance of wiring harness are in good condition,
and if the plug connection is secure;
8.9 Proximity Switch
Removal
Proximity switch is installed on the pedal.
- Pull out the AMP connector on proximity swit-

ch;
- Loosen Nut and unscrew the proximity
switch.

- Start the vehicle;
- Align the inductive surface of proximity switch
The truck can walk after the pedal (2, Figure 30524) to concave of pedal, so that
1 Fault is closed it does not sense. Measure if there is 24V
voltage between Pin (18#) and Pin (1#) with
multimeter. If there is no voltage, check if the
circuit is connected; if there is voltage, move
on to the next step.
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- Measure the voltage between Pin (7#) and

Pin (1#). If there is 24V voltage (or the switch
is energized under non-induction state, LED
is lit), the switch has been damaged, please
replace; if there is no voltage, move on to the
next step.
- Touch the inductive surface with an iron sheet
to make it trigger signals. If there is still no
voltage between Pin (7#) and Pin (1#), the
switch has been damaged, please replace.

meter:
proximity switch and controller) is conducted.
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8.10 CAN Console 8.10.2 CAN Console Selection Menu

CAN Console must be used together with con-
troller. 启动
Start
* CONS AFG ZP100 *

RS232 CONSOLE
CAN CONSOLE
Display AUTOSCAN CAN
CONSOLE UTILITIES
MENU CONSOLE
Power button 09：10
Navigation Parameter
keys OK
adjustment
button
CANCONSOLE
ESC / EXIT Enter/OK
SELECT NODE 2
SELECT SUB NODE 0
SELECT BAUDRATE 125Kb
PRESS OK TO START
( PRESS F3 FOR AUTOSCAN )
Figure 80513
8.10.1 Connection SELECT NODE :

2 = Traction Controller
- Remove front cover; 6 = Steering Controller
- Plug the handheld unit communication OK
cable into the handheld unit SELECT BAUDRATE : 125Kb
communication interface of the truck. (Transmission speed must be
set to 125Kb)
- Turn on the key switch, pull out
emergency stop switch,
if the connection is successful: the
handheld unit display will be illuminated;
if failed: the display will have no display ADXT2SS EP0.16
(check if the circuit connection is normal).
** V ** A ** h
SMARTDRIVER KO
OK
Next Page
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ELECTRICAL SYSTEM
Previous Page
OK
* MAIN MENU *
PARAMETER CHANGE
TESTER
ALARMS
PROGRAM VACC
SAVE PARAMETERS
RESTORE PARAMETERS
SET MODEL
- With Navigator keys (Figure 80513), you can

carry out menu switching;
- “OK”, select ENTER the menu.
PARAMETER CHANGE : parameter change

TESTER : vehicle running test
ALARMS : error alrms
PROGRAM VACC : accelerator match
SAVE PARAMETERS : read parameter
RESTORE PARAMETERS : write parameter
SET MODEL : set node
SET OPTIONS : set options
ADJUSTMENTS : parameter match
SPECIAL ADJUSTMENTS: special parameter
match
HARDWARE SETTING : hardware setting
* See “Handheld Unit Operation Manual” for

detailed operations
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8.10.3 TESTER MENU

The parameters in TESTER Menu are real-
time presentation of the running status of the
equipment.
Traction Controller (Combi ACX)
Parameters Description Remark

BATTERY VOLTAGE Check the voltage of storage battery Display the current voltage ( V )
LIFT STOP - -
STEER ANGLE Check the drive wheel angle Display the current angle ( ° )
Check the status of emergency reverse If the function is triggered properly,
QUICK INVERSION
switch the value will change
Check the status of 2-stage speed reduction If the function is triggered properly,
CUTBACK SWITCH 2
Check the status of 1-stage speed reduction If the function is triggered properly,
CUTBACK SWITCH
If the function is triggered properly,
HANDLE/SEAT SW. Check the status of interlock switch
the value will change
BACKWARD SWITCH Check the backward status of travel switch
FORWARD SWITCH Check the forward status of travel switch
DESCENT SWITCH Check the status of lowering switch
LIFTING SWITCH Check the status of lifting switch
ACCELERATOR Check the output voltage of travel switch Display the current voltage ( V )
MOTOR TEMPERAT Check motor temperature Display the current temperature ( ℃ )
TEMPERAT URE Check the temperature of controller Display the current temperature ( ℃ )
BATTERY CHARGE Check the remaining capacity of battery Display the current capacity ( % )
BATTERY CURRENT Check the current of battery Display the current value ( A )
CURRENT RMS Check the motor current Display the current value ( A )
Check the difference between output
SLIP VALUE frequency of controller and the measured Display the current difference( Hz )
frequency
ENCODER Check the motor speed Display the current difference( Hz )
FREQUENCY Check the output frequency of controller Display the current frequency( Hz )
VOLTAGE BOOSTER - -
MOTOR VOLTAGE Check the motor voltage Display the current voltage ( V )
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8.10.4 Tester Menu
Steering Controller (EPS-DC0)
Parameters Description Remark

STEPPER MOTOR Check the voltage of stepper motor Display the current voltage ( V )
SET POINT POT Check the Potentiometer Display the current voltage ( V )
READ FBPT AT SW1 - -
SET POINT POT. - -
TRUCK SPEED - -
SLOPE PEAK - -
HZGH RESOL. AD - -
TRUCK MOVING - -
SM ALARM SWITCH - -
MM ALARM SWITCH - -
AUTO IN PROGRESS - -
ACW LIMIT LEVEL - -
CW LIMIT LEVEL - -
ENDSTROKE ACW - -
ENDSTROKE CW - -
ENC SPEED Check the speed of steering motor Display the current frequency( Hz )
MOTOR CURRENT Check the current of steering motor Display the current value ( A )
MOTOR VOLTAGE Check the voltage of steering motor Display the current voltage ( V )
FREQUENCY Check the output frequency of controller Display the current frequency( Hz )
MOTOR TEMPERAT Check the temperature of steering motor Display the current temperature ( ℃ )
TEMPERATURE Check the temperature of controller Display the current temperature ( ℃ )
FEEDBACK ENC. - -
FEEDBACK POT. - -
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8.10.5 Handheld Unit • The alarm code.

A Zapi Handset is available that is designed specifi- • The number of times that each alarm occurs con-
cally for use with the Zapi controller. It serves multiple secutively.
functions of reading diagnostic data, testing truck • The Hour Meter reading (value) when the latest
operation,setting options,adjustments and parameter event of every alarm occurred.
changes of the controller.
• The invert temperature when the latest event of
every alarm occurred.
This function permits a deeper diagnosis of problems
as the recent history can be revisited.
8.10.5.1.2 Logbook Access

To view the alarm logbook proceed as follows:
1. Connect the Zapi Handset, refer to paragraph
8.10
2. Press the Navigation keys to enter the
MAIN MENU.
3. Press the Navigation Key to find the ALARMS
display.
4. Press the ENTER button to view the alarms.
5. Press the ESC button to exit the alarms.
8.10.5.2 Testing Truck Operation

The Zapi Handset can be used to test certain truck
CND CNC CNB CNA operations as follows:
Figure 90534 Controller Terminals
8.10
8.10.5.1 Fault Detection
2. Press the Navigation keys to enter the
8.10.5.1.1General MAIN MENU.
The controller provides diagnostics information to 3. Press the Navigation keys to find the TESTER
assist technicians in troubleshooting problems. When display.
a fault is detected, an alarm is recorded in the log- 4. Press the ENTER button to view the tests.
book.It has a FIFO (First Input First Output) structure 5. To verify various switch functions, locate the
that means the oldest alarm is lost when the database switch on the display and then operate that funct-
is full and a new alarm occurs.The logbook is com- ion to verify operation.
posed of alarms with the following information:
6. Press the ESC button to exit the tests.
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8.10.6 Settings and Adjustments

8.10.6.1. Set Options
To set options proceed as follows and refer to
Table 4-2:
1. Connect the Zapi Handset, refer to paragraph Display
8.10
2. Press the Navigation Keys to find the
SET OPTIONS display.
3. Press the ENTER button to view the options. Power button
4. Press the Navigation Keys to find the option to be
Navigation
changed. Parameter
keys
5. Press the Parameter Adjustment buttons until the adjustment
desired value setting is reached. button
The option is now set at the desired value. Enter/OK
EXIT
7. Press the OK button to exit the options,
Press the Enter button to confirm the exit.
Figure 80513
Table 4-2 Set Options

Parameter Factory Setting Description
TILLER switch HANDLE This option handles the input CNB#3 (Table 4-5). This input opens
when the operator leaves the truck (released). It is connected to a
Keyswitch controlled voltage when the operator is present.
SET INPUT #1 OPTION #1 (Standard Version only). This option handles the digital input
CNA#15. It can be can be set as:
• OPTION #1: CNA is managed as a cutback speed input (SR#1).
• OPTION #2: CNA is managed as a digital handbrake input.
• OPTION #3: CNA is managed as an inching backward.
The input CNA#15 (Table 4-5) can only be used as Aux Lowering
request when the MDIPRC is PRESENT.
This input must be connected to a Keyswitch controlled voltage.
The SR#1 becomes active when CNA#15 (Table 4-5) is open.
The inching backward becomes active when the CNA#15 (Table 4-
5) is closed to a Keyswitch controlled voltage.
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Table 4-2 Set Options-Continued

SET INPUT #2 PRESENT It can be can be set as:
• PRESENT: CNA#14 (Table 4-5) is managed as a cutback speed
input (SR#2).
• OPTION #1: CNA#14 (Table 4-5) is managed as an inching back-
ward.
The input CNA#14 (Table 4-5) can only be used as Aux Lifting
request when the MDIPRC is PRESENT.
The SR#2 becomes active when CNA#14 (Table 4-5) is open.
The inching backward becomes active when the CNA#14 (Table 4-
5) is closed to a Keyswitch controlled voltage.
SET INPUT #4 OPTION #1 This option handles the digital input CNB#7 (Table 4-5). It can be
can be set as:
• BELLY CNB#7 (Table 4-5) is managed as a Belly Switch input.
• BRAKE CNB#7 (Table 4-5) is managed as service brake input.
This information can be used also to recognize when the operator
is driving with a pressed pedal braking.
• EX.HYDRO: CNB#7 (Table 4-5) is managed as Exclusive Hydro.
The Belly switch active level is specified on the QUICK INV LOGIC
below.
The service brake of the exclusive hydro becomes active when
CNB#7 is opened.
HOUR COUNTER RUNNING This option specifies the hour counter mode. It can be set as:
• RUNNING: The counter registers travel time only.
• key on: The counter registers when the keyswitch is closed.
BATTERY CHECK Level = 1 This option specifies the handling of the low battery charge detec-
tion. It can be set as:
• Level 0: Nothing happens, the battery charge level is ignored.
• Level 1: A BATTERY LOW alarm is raised when the battery level
is calculated being less than 10% of the full charge. A BATTERY
LOW alarm inhibits the Lifting function.
• Level 2: A BATTERY LOW alarm is raised when the battery level
is calculated being less than 10% of the full charge. A BATTERY
LOW alarm reduces the maximum truck speed down to 24% of
the full truck speed then, if the MDI-PRC is absent, inhibits the Lift-
ing function.
• Level 3 Equivalent to Level 1; a BATTERY LOW alarm is raised
when the battery level is calculated being less than 10% of the full
charge. A BATTERY LOW alarm inhibits the Lifting function.
HYDRO KEY ON OFF ON/OFF: If this options is programmed ON the traction Inverter
manages a hydraulic steering function when the keyswitch is
switched ON (only if the AUX OUTPUT #1 option is programmed
as HYDRO CONTACT or as WXCLUSIVE HYDRO).
STOP ON RAMP OFF Not used.
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Table 4-2 Set Options-Continued

AUX OUTPUT #1 BRAKE This option handles output CNA#3 (Table 4-5). It can be used as:
• BRAKE: CNA#3 (Table 4-5) drives an electromechanical Brake.
• HYDROCOMNT: CNA#3 (Table 4-5) drives the contractor for a
hydraulic steering function when the direction input or brake pedal
input are active or a movement of the truck is detected.
• EX.HYDRO: CNA#3 (Table 4-5) drives the contractor for a hydrau-
lic steering function when the exclusive hydro input is active.
• FREE: CNA#3 (Table 4-5) is not used.
The current this output can sink is up to 3Adc.
PEDAL BRAKING NONE The analog input CNA#18 (Table 4-5) has one of two functions:
• Pedal Braking input.
• Command input for lifting/lowering proportional valves in MDIPRC
version.
To turn from the first to the second function is just enough to set
PEDAL BRAKING to HNONE.
This option handles the analog input CNA#18 (Table 4-5) when
used as pedal braking input:
• ANALOG: With this setting it is possible to modulate the strength
of the braking when the accelerator is released. The strength of
the braking is proportional to the brake pedal potentiometer con-
nected to this input. When the pedal potentiometer voltage is
equal/less than the SET POT BRK MIN, the minimum release
braking strength is applied (following the RELEASE BRAKING
setting).
When the pedal potentiometer voltage is equal/higher than the
SET POT BRK MAX, the maximum release braking strength is
applied (following the PEDAL BRAKING setting). In the intermedi-
ate position, the electrical braking strength is a linear function
between the minimum (RELEASED BRAKING) and maximum
(PEDAL BRAKING) intensity. When there is also a switch con-
nected to the pedal braking (i.e. SET INPUT #4 to level BRAKE), it
must be closed, otherwise the release braking is stuck to the mini-
mum strength disregarding the pedal potentiometer position.
• DIGITAL: No pedal potentiometer is expected. Only when both the
SET INPUT #4 is Level BRAKE and the brake switch connected to
CNB#4 (Table 4-5) is closed, the release electrical braking follows
the PEDAL BRAKING setting (maximum strength); in all of the
other conditions the release electrical braking follows the
RELEASE BRAKING setting (minimum strength).
• NONE: The analog input CNA#18 (Table 4-5) is not used for the
release braking modulation.
QUICK INVERSION BELLY This option specifies the quick inversion mode when the SET
INPUT #4 is set BELLY. It can be set as:
• NONE: The quick inversion function is not managed (no effect
when CNB#7 (Table 4-5) switches over).
• TIMED: The quick inversion function is timed.
• BELLY: The quick inversion function is managed but not timed.
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ELECTRICAL SYSTEM
8.10.6.2 Adjustments
To change an adjustment proceed as follows and
refer to Table 4-3:
8.10.1.1.
2. Press the ROLL up button (1, Figure 90536) and Display
the SET up button (5) at the same time to enter
the CONFIG MENU.
3. Press the ROLL down button (1) or the ROLL up
button (2) to find the ADJUSTMENTS display. Power button
4. Press the ENTER button (3) to view the adjust- Navigation Parameter
ments. keys adjustment
5. Press the ROLL down (2) or the ROLL up button button
(1) to find the adjustment to be changed.
EXIT Enter/OK
6. Press the SET up button (5) or the SET down but-
ton (6) until the desired value setting is reached.
The adjustment is now set at the desired value.
7. Press the OUT button (4) to exit the adjustments,
Press the Enter button to confirm the exit.
Figure 80513
Table 4-3 Adjustments

SET POT BRK MIN 0.5 V This setting records the minimum value of braking pedal potentiom-
eter when the braking pedal switch is closed; the procedure is
similar to the PROGRAM VACC function. This procedure must be
carried out only if the PEDAL BRAKING option is programmed as
ANALOG. No adjustment is necessary when PEDAL BRAKING
options is programmed as NONE.
SET POT BRK MAX 4.5 V This setting records the maximum value of braking pedal potentiom-
eter when the braking pedal is fully pressed; the procedure is
similar to the PROGRAM VACC function. This procedure must be
carried out only if the PEDAL BRAKING option is programmed as
ANALOG. No adjustment is necessary when PEDAL BRAKING
options is programmed as NONE.
SET BATTERY 24V Selects the nominal battery voltage.

TYPE
ADJUST BATTERY XX V Do not modify - Factory adjusted (Fine adjustment of the battery
voltage measured by the controller.)
THROTTLE 0 ZONE 9% Establishes a deadband in the accelerator input curve.
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ELECTRICAL SYSTEM
Table 4-3 Adjustments-Continued

THROTTLE X 45% This parameter together with the THROTTLE Y POINT, changes
POINT the characteristic of the accelerator input curve: when the acceler-
ator is de-pressed to X point percent, the corresponding truck
speed is Y point percent of the Maximum truck speed. The rela-
tionship between the accelerator position and the truck 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 slopes (Figure 90537).
THROTTLE Y 68% This parameter together with the THROTTLE X POINT, changes
POINT the characteristic of the accelerator input curve: when the acceler-
ator is de-pressed to X point percent, the corresponding truck
speed is Y point percent of the Maximum truck speed. The rela-
tionship between the accelerator position and the truck 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 slopes (Figure 90537).
ADJUSTMENT #01 LEVEL = 5 Adjust the upper level of the battery charge table (Level 0 to 9).
ADJUSTMENT #02 LEVEL = 5 Adjust the lower level of the battery charge table (Level 0 to 9).
LOAD HM FROM OFF When set On, the Hourmeter of the Controller is transferred and
MDI recorded on the Hourmeter of the Standard MDI (connected on
the Serial Link).
CHECK UP DONE OFF Turn it On when asked Maintenance service has been executed to
cancel the CHECK UP NEEDED warning.
CHECK UP TYPE NONE It specifies the handling of the CHECK UP NEEDED warning:
• NONE: No CHECK UP NEEDED warning.
• OPTION#1: CHECK UP NEEDED warning on the handset and
MDIPRC 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.
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8.10.6.3 Parameter Change

To change a parameter proceed as follows and refer
to Table 4-4:
8.10
2 . Press the ENTER button t o f i n d Display
PA R A M E T E RCHANGEdisplay.
3. Press the ENTER button again to view the
parameters.
4. Press the Navigation keys to find the parameter
to be changed. Power button
5. Press the Parameter Adjustment button until the Navigation Parameter
desired value setting is reached. keys adjustment
The parameter is now set at the desired value. button
6. Press the OK button to exit the parameters, Enter/OK
EXIT
Press the OK button to confirm the exit.
Figure 80513
Table 4-4 Parameter Adjustments

ACCELER. DELAY LEVEL = 8 Level 0 to 9. It determines the acceleration ramp. At Level 9 the
truck takes a long time to accelerate.
RELEASE LEVEL = 5 Level 0 to 9. It controls the deceleration ramp when the travel
BRAKING request is released. At Level 9 the truck brakes abruptly.
INVERS. BRAKING LEVEL = 4 Level 0 to 9. It controls the deceleration ramp when the direction
switch is inverted during travel. At Level 9 the truck brakes
abruptly.
PEDAL BRAKING LEVEL = 9 Level 0 to 9. It controls the deceleration ramp when the travel
request is released and the brake pedal switch is pressed to its
maximum. At Level 9 the truck brakes abruptly.
SPEED LIMIT BRK LEVEL = 1 Level 0 to 9. It controls the deceleration ramp when the accelerator
has turned down but not completely released. At Level 9 the truck
decelerates abruptly.
BRAKE CUTBACK LEVEL = 5 Level 0 to 9. It controls the deceleration ramp when the a speed
reduction input becomes active and the motor slows down. At
Level 9 the truck decelerates abruptly.
MAX SPEED FORW 100 Hz Typically from 90 Hz to 160 Hz. It determines the maximum speed
in forward direction.
MAX SPEED BACK 100 Hz Typically from 90 Hz to 160 Hz. It determines the maximum speed
in backward direction.
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Table 4-4 Parameter Adjustments-Continued

CUTBACK SPEED 100% Typically from 10% to 100%. It determines the percentage of the
max speed applied when the cutback switch 1 (SR#1 on CNA#15
(Table 4-5) is active. When set to 100% the speed reduction is
ineffective.
CUTBACK SPEED 2 68% Typically from 10% to 100%. It determines the percentage of the
max speed applied when the cutback switch 2 (SR#2 on CNA#14
(Table 4-5) is active. When set to 100% the speed reduction is
ineffective.
HS CUTBACK 100% Typically from 10% to 100%. It determine the percentage of the max
speed applied when the Hard & Soft function (H&S switch on
CNB#4 (Table 4-5) is active. When set to 100% the speed reduc-
tion is ineffective.
FREQUENCY 5.00 Hz Hz value. This is the minimum speed applied when the forward or
CREEP reverse switch is closed, but the accelerator at its minimum. In the
ACO sense Coils this setting is higher equal than 5 Hz.
RPM CREEP 100% A Percentage value. Set to 100% and not Used.
MAXIMUM 96% It specifies the percentage of the absolute current at which

CURRENT the current will be limited. Normally MAXIMUM CURRENT is
100%. DO NOT CHANGE.
INCHING SPEED 0 Hz Hz value. It determines the speed when the “Inching function” is
active.
INCHING TIME LEVEL = 0 Level 0 to 9. It determines the duration time when the “Inching func-
tion” is active.
AUXILIARY TIME 1 Time units value (seconds). For the encoder version, it determines
the time duration (in seconds) in which the frequency was arrived
to zero.
ANTIROLLBACK 80% A Percentage of the Maximum Current. This setting increases the
phase current when low frequency during starting operation. It is
used to push up, in feedforward way, the torque when it is not
possible to control the flux, in feedback way, because of the low
frequency.
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8.11 Controller Error Message code (see Chapter 9 - Troubleshooting); while

the when the components failures which may
Electrical faults are mainly caused by electrical affect the ON/OFF of control circuit occur to
components failure or electrical circuit failure. the electrical circuit, the controller will alarm for
Wherein, when some components failures error, and fault information will be displayed on
which may not affect the ON/OFF of control the instrument.
circuit occur, the instrument won't display fault
8.11.1 Traction Controller
Error Message
Possible cause Fault elimination
Error Error text
It occurs when the embedded

Check the continuity of
WATCH DOG protection is not able
UVW. If the alarm occurs
either to cut off the power stage
8 WATCHDOG permanently, it is necessary
when not triggered or it is not able
to replace the controller.
to activate the power stage when
triggered.
It occurs due to a HW or SW defect Try to execute a CLEAR

of the non-volatile embedded EEPROM operation,if the
13 EEPROM KO
memory supporting the controller alarm still there,please
regulations. replace the controller.
It is probably a power failure or a It is necessary to replace

17 LOGIC FAILURE #3
logic failure the controller.
It occurs when the circuit, to

It is necessary to replace
18 LOGIC FAILURE #2 compensate for the dead times of
the controller.
the sine waves, is failed.
Check the battery voltage, if

it is too low, please charge
the battery. Check the all
This alarm signals that an over-
connection of the B+ and
19 LOGIC FAILURE #1 voltage / undervoltage protection
B-,the short time disconnect
operation has occurred.
will cause the alarm,if the
alarm always there,please
replace the controller.
Before to switch the main contactor

Check the connection of
on, the SW turns on sequence
phase UVW from controller
the Top side Power Mosfets and
to motor,check UVW is not
30 V M N LOW expects the phase V voltage
short to B- ,if the connection
increases toward the rail capacitor
is ok,please replace the
value. If the phase V does not
controller
increases this alarm occurs.
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Error Message
Error Error text
Before to switch the main contactor Check the connection of

on, the SW turns on sequence the phase UVW from controller
Bottom side Power Mosfets and to motor,check UVW is not
31 V M N HIGH
expects the phase V voltage falls to short to B+,if the connection
GND value. If the phase V remains is ok,please replace the
high level this alarm occurs. controller
The controller checks if the MC

contact is closed when the coil It is suggested to check
isn’t driven, trying to discharge the contactor contact, if it
37 CONTACTOR CLOSED
the capacitor bank. If they don’t is mechanically stuck or
discharge, the fault condition is pasted.
entered.
Two possible reasons:

the wires to the coil are
The main contactor coil has been
interrupted or not well
38 CONTACTOR OPEN driven by the logic board, but the
connected or the contact of
contactor does not close.
the contactor is not properly
working.
This test is carried out when the The problem could be in

motor is running, and it verifies that the current sensor or in
49 I=0 EVER
the current feedback sensor is not the related circuit.please
constantly stuck to 0. replace the controller.
This diagnosis is executed only

when the main contactor is opened
and asked to be closed (e.g. at key
on or when the main contactor is
If the alarm occurs perman-
opened and a new motion request
53 STBY I HIGH ently, it is necessary to
turns active). Then the outputs of
replace the controller.
the Current amplifiers must be in
a narrow window close to 2.5 Vdc
(from 2.26 V to 2.74 V). Otherwise
this STBY I HIGH alarm occurs.
In working condition, a resistance

1: At least a motor phase
connected between the key and
is not connected to the
the Rail Capacitors, keeps the Rail
controller or broken.
Capacitors charged before the Main
2: A Power failure or a
60 CAPACITOR CHARGE Contactor closes. When the voltage
Logic Failure occurred in
on the Rail Capacitors (measured
the controller.In this case it
on the phase V) is low and does not
is necessary to replace the
increase when the main contactor
controller.
is opened this alarm occurs.
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ELECTRICAL SYSTEM
Error Message
Error Error text
Higher than 78 °C. Then the

maximum current decreases
proportionally with the temperature Improve the air cooling of
61 HIGH TEMPERATURE
increases from 78 °C up to 100 °C. the controller.
At 100 °C the current is limited to 0
Amps.
Check the temperature

It occurs when the temperature of sensor,if it is ok,and the
65 MOTOR TEMPERAT. the motor winding overtakes the motor is very hot,please
MOTOR OVERTEMP setting. improve the air cooling of
the motor.
It occurs when the battery charge

is calculated being less than 10%
66 BATTERY LOW Get the battery charged.
of the full charge and the BATTERY
CHECK setting is other than 0.
69 CURRENT SENS. KO Current sensor failure
the controller.
This alarm occurs when the voltage Probably it is necessary

on the Main Contactor is higher to replace the controller
74 DRIVER SHORTED than expected: this means that the because the driver of the
Main Contactor Coil has a high Main Contactor is short
voltage although it is not supplied. circuited.
Check the coils of the Main

This alarm occurs when the voltage Contactor (CNA#1) is not
on the Main Contactor is smaller short circuited. If it isn’t,
75 CONTACTOR DRIVER than expected: this means that probably it is necessary
the Main Contactor Coil has a null to replace the controller
voltage when supplied. because the driver of the
Main Contactor is broken.
Check the coils of the main

This alarm occurs when there is an contactor (CNA#1), of the
overload on one of the following electromechanical brake
76 COIL SHORTED
connections: CNA#1, CNA#3, (CNA#3), of the pump
CNA#4 and CNA#6. contactor (CNA#4), of the
electric valve (CNA#6).
(CPOT) voltage higher than VACC

78 VACC NOT OK MIN +1V while the traction enable Do the program Vacc
switch is open
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ELECTRICAL SYSTEM
Error Message
Error Error text
Enter TESTER to facilitate

the troubleshooting):
a) A travel demand active
before key on
This is just a warning for an incorr- b) The tiller switch active
79 INCORRECT START
ect starting sequence. before key-on
c) The H&S input active
before key-on
d) The Quick inversion
active before key-on
The forward sw and backward sw Check the acclerator and

80 FORW + BACK
closed together the wire.
This alarm occurs when the PLD It is necessary to replace

99 INPUT ERROR #1
device has a failure the controller.
Pump contactor is not closed when Check whether the pump

230 PUMP CONT. OPEN
it should close contactor is failed.
Check whether the pump

231 PUMP CONT.CLOSED Pump contactor closed before key.
contactor is stick.
If after done the program

vacc ,the alarm still
232 VACC OUT RANGE Try to do PROGRAM VACC.
there ,please replace the
accelerator.
Check the detail alarm

234 EPS RELE OPEN There is some alarm in the EPS.
information in EPS.
The traction can't get information Check the CAN bus line
235 CAN BUS KO EPS
from the EPS by CAN from AC0 to EPS AC0.
Use voltage meter to

When the key is turned ON, the check battery voltage,if it
controller check the battery voltage is ok,please check power
236 WRONG SET BAT.
and verifies it is within a window supply cable,if every thing
around the nominal value. is ok,please replace the
controller.
This is just a warning when a Check the statue of lift and

238 LIFT LOW. ACTIVE Lifting/Lowering request is active lower sw,it should open
before key-on. when release.
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ELECTRICAL SYSTEM
Error Message
Error Error text
This is just a warning when Lifting Never push lift and lower sw
239 LIFT + LOWER
and Lowering sw closed together. together
First of all, check the wiring.

If it is OK, try to disconnect
one to one the module
connected to the CAN Bus
It occurs if the controller does not
and check if this alarm
248 CAN BUS KO receive any message from the CAN
disappears. When you are
Bus line.
quite sure the problem is
in the present module, it is
necessary to replace the
controller.
When the output of the thermal

sensor on the base plate is higher
250 THERMIC SENS. KO than 4.95 V or lower than 0.1 V, the
the controller.
sensor is assumed failed and this
alarm occurs.
The controller expects to receive

Check the communication
a message from a remote module
via CAN between the
252 WAITING FOR NODE via CAN Bus. When this message
controller and the other
is not received after a time out this
modules.
alarm occurs.
Check both the electric and

Two consecutive readings of the the mechanical encoder
253 ENCODER ERROR encoder speed are too much functionality.if there is no
different in between. mechanical loosen,please
replace a new one.
This alarm occurs when the

feedforward PWM generated
Check the all connection of
by the controller to supply the
the B+ and B-,the short time
Electromechanical Brake and the
disconnect will cause the
254 AUX OUTPUT KO actual feedback voltage on the
alarm,if the alarm always
Electromechanical Brake are not
there,please replace the
matched in between. The diagnosis
controller.
is made only when the Tiller Switch
is active.
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ELECTRICAL SYSTEM
8.11.2 Steering Controller (EPS-DC0)
Error Message
Error Error text
Main uC and Slave uC
communicate via a local serial
interface. This alarm occurs when It is necessary to replace
6 SERIAL ERR #1
the slave uC does not receive the the controller.
communication from the main uC
through this serial interface.
It occurs if a test to write and read

one location in EEPROM fails. The
SW expects to read the written
value. It occurs also when the
hour counter gives different values It is necessary to replace
13 EEPROM KO
between the three redundant the controller.
locations in which it is recorded. It
occurs also when the busy bit of
the EEPROM does not rise within
12 msec.
This alarm occurs in the rest state if

the output of the voltage amplifier of It is necessary to replace
16 LOGIC FAILURE #4
the phase Vw-Vv have a drift larger the controller.
than ±0.25 V.
This alarm occurs in the rest state if

the output of the voltage amplifier of It is necessary to replace
17 LOGIC FAILURE #3
the phase Vu-Vw have a drift larger the controller.
than ±0.25 V.
This alarm occurs when the real

voltage between phases W and V It is necessary to replace
18 LOGIC FAILURE #2
of the motor is different from the the controller.
desired.
This alarm occurs when the real
voltage between phases W and U It is necessary to replace
19 LOGIC FAILURE #1
of the motor is different from the the controller.
desired.
This alarm occurs in the initial rest
state after key on if the outputs of It is necessary to replace
32 VMN NOT OK
the motor voltage amplifiers are not the controller.
in the window from 2.2 to 2.8 Vdc.
This alarm occurs only when the

setting CAN BUS is PRESENT.
Then the eps-ac0 waits for a via Find, on the traction
CAN information that the traction controller, the reason for
48 MAIN CONT. OPEN
controller has closed the main keeping the main contactor
contactor. If this information lacks open.
more than about 1.5 secs, this
alarm occurs.
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ELECTRICAL SYSTEM
Error Message
Error Error text
This alarm occurs two ways:
1) In the initial rest state after key
on, if the outputs of the current
amplifiers are not comprised in the It is necessary to replace
53 STBY I HIGH window 2.2 to 2.8 Vdc. the controller.
2) After the initial diagnosis this
alarm occurs when the outputs of
the current amplifiers at rest have a
drift larger than ±0.15 V.
Improve the cooling of the

This alarm occurs if the
controller; otherwise it is
61 HIGH TEMPERATURE temperature of the controller base
plate overtakes 75 degrees.
controller.
This alarm occurs only when DIAG

M O TO R T E M P i s o n a n d t h e
thermal sensor inside the motor
measures a temperature higher Check the thermal sensor in
than 150 degrees. It occurs also the motor is right working. If
65 MOTOR TEMPERAT.
when trying to acquire the motor it is, improve the cooling of
resistance with a temperature in the the motor.
motor higher than 150 degree
(still with DIAG MOTOR TEMP to
ON).
This alarm occurs if the circuit to Check the motor is suited to

limit via hardware the current in the work with the eps-ac0 (not
70 HIGH CURRENT motor is either always active at key- oversized). Otherwise it is
on or repeatedly active when the necessary to replace the
motor is turning. controller.
Check the power fuse is OK.

Check the battery positive
This alarm occurs when the current arrives to the controller.
in the phase V of the motor is zero Check the continuity of
71 POWER FAILURE #3
and the motor is commanded for the wire in the phase V of
moving. the motor. Otherwise it is
controller.

in the phase U of the motor is zero Check the continuity of
72 POWER FAILURE #2
and the motor is commanded for the wire in the phase U of
controller.
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ELECTRICAL SYSTEM
Error Message
Error Error text
in the phase W of the motor is zero Check the continuity of
73 POWER FAILURE #1
and the motor is commanded for the wire in the phase W of
controller.
It occurs in applications with
toggle switches when the applied Swap in between the two
83 BAD ENCODER SIGN frequency (FREQUENCY) and the encoder channels (CNB#7
motor speed (ENC SPEED) with CNB#8).
have opposite sign.
This alarm occurs if the command

potentiometer (CPOC1 on CNA#9
or CPOC2 on CNA#8) changes with
84 STEER SENSOR KO a jerk larger than MAX SP SLOPE Change the twin pot.
(see 12.4.6.3). This alarm is used to
catch a discontinuity in the voltages
of the command potentiometer.
This is just a warning to inform that
the steering controller is limiting
85 STEER HAZARD the angle in the steering direction. ——
No speed reduction occurs on the
traction.
The main uC sends an analog
signal towards the slave uC to reset
the slave uC on demand. When the
slave uC detects this analog signal It is necessary to replace
218 CLOCK PAL NOT OK
external to a window from 2.2 to 2.8 the controller.
and not in the range to generate
the reset on demand, the slave uC
raises this alarm.
When the safety contacts
are open, the voltage on
CNA#4 is expected to be
close to 0 Vdc and this is
independent from whether
the safety contacts are
It occurs when the voltage on connected to a plus battery
CNA#4 (NK1: Lower Potential or to a minus battery . In the
99 INPUT ERROR #1 Terminal of the Safety Contacts first case (safety contacts
(see 7.6) is higher than 12 V before connected to a plus
to turn the safety contacts closed. battery), when the safety
contacts are open, CNA#4
is connected to a minus
battery through a load. Only
a harness mistake may
connect NK1 to a higher
than 12 V voltage.
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ELECTRICAL SYSTEM
Error Message
Error Error text
It occurs when the encoder

counting of the main uC is not It is necessary to replace
212 MICRO SLAVE #8
matched with the encoder counting the controller.
of the slave uC.
This alarm occurs if the frequency

and the amplitude of the voltages
from the stepper motor lines are
mismatched in between In normal It is necessary to replace
219 STEPPER MOTOR MISM
condition when the amplitude of the controller.
the stepper motor lines increases,
the frequency of the stepper motor
lines must increase too.
Search for a mechanical

This alarm occurs if the current in
problem locking the motor.
the steering motor stays close to
220 MOTOR LOCKED To make easier the fault
the maximum current longer than 1
catching, set DEBUG
sec.
OUTPUT to level 11.
It occurs in one of the following

conditions:
(Open loop application only) If the
slave uC detects the stator voltage
phasor rotates in the opposite
direction respect to the sign of the
221 MICRO SLAVE #4 stepper motor speed, this alarm
the controller.
occurs. (Closed loop application
only) If the slave uC detects the
stator voltage phasor rotates in the
opposite direction respect to the
commanded position, this alarm
occurs.
In application with the

feedback potentiometer,
verify the feedback
In application with a feedback
potentiometer is not
potentiometer, this alarm occurs if
mechanically loosened.
the feedback potentiometer (CPOT
Check there is not a
on CNB#6) does not change (or
mechanical block of the
changes in the opposite direction)
steered wheel. Be sure the
its value even if commanded
222 FB POT LOCKED wiper has not reached its
to change. In application with
own electrical limit because
toggle switches with ENCODER
of too much angle of the
CONTROL to off, this alarm occurs
steered wheel. Besides,
if the feedback encoder counting
this alarm may occur at
does not change its value even if
the installation when the
commanded to change.
motor rotates in the wrong
direction turning away from
the wished
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ELECTRICAL SYSTEM
Error Message
Error Error text
This alarm occurs if the feedback

potentiometer (CPOT on CNB#6)
changes with a jerk larger than 0.3 Change the feedback
223 JERKING FB POT
V in 16 msec. This alarm is used to potentiometer.
catch a discontinuity in the voltages
of the feedback potentiometer.

parameters to compensate for It is necessary to send the
the gain of the current amplifiers controller to Zapi to perform
225 CURRENT GAIN
(ADJUSTMENT #03 and the maximum current
ADJUSTMENT #04) have the regulation.
default values
Every 16msec, inside the code

cycle, the main uC rises and then
lowers an input for the slave uC
(SYNC). When the slave uC detects
no edge for more than 100 msec on
226 NO SYNC this input, this alarm occurs. This is
the controller.
just a watch dog function: when the
main uC does not execute the code
cycle it does not update the SYNC
signal and the slave uC cuts off the
steer and traction.
Main uC and Slave uC

communicate via a local serial
interface. This alarm occurs when It is necessary to replace
227 SLAVE COM. ERROR
the main uC does not receive the the controller.
communication from the slave uC
through this serial interface.
This warning occurs only if

CAN BUS is PRESENT. At key-
on the eps-ac0 asks to the
traction controller to send a list of
parameters via CAN Bus. From
237 WAITING DATA ——
the request until the parameters
are correctly relieved, this warning
occurs. The steer is not activated
yet, and the safety relays remain
open when this warning is present.
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ELECTRICAL SYSTEM
Error Message
Error Error text
Check the potentiometer

connected to CNB#6 is right
working. If toggle switches
are connected to CNA#2
and CNA#3, verify they
are right working and the
setting AUX FUNCTION
11 is correct. Verify also
This alarm occurs for an error in
the sensor bearing in the
228 POSITION ERROR the redundant test of the feedback
motor (encoder) has not a
sensors.
slip (the sensor bearing has
two rings: one is connected
to the rotor shaft; the other
is connected to the motor
frame. Check these two
rings are strictly connected
to their structure without
slip.
This is a real alarm that cut off

the traction. It occurs at the initial
alignment if the straight-ahead
condition is not matched within
238 EPS NOT ALIGNED ——
6sec. Throughout this 6 secs delay,
the steer is not activated yet, the
safety relays are open and the
traction is stopped.
At key-on the eps-ac0 needs an

assent from the traction controller
to close the safety contacts and to
turn onto operational mode.
239 WAITING FOR TRAC Until this assent is not relieved, this ——
warning occurs. The steer is not
activated yet and the safety relays
remain open when this warning is
present.
This condition is several

t i m e s d u e t o e i t h e r, a
mismatching between the
Encoder resolution used
It occurs when ENCODER
in the SW and the real
CONTROL is set ON and the real
241 ENCODER ERROR encoder resolution, or a
frequency does not pursuit the
wrong connection between
commanded frequency
the two encoder channels.
In this latest case exchange
in between the two encoder
channels.
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ELECTRICAL SYSTEM
Error Message
Error Error text
Check the continuity of the

This alarm occurs when the mean stepper motor connections.
voltage on the Quadrature line In particular the resistance
of the stepper motor (connection between CNA#8 and the
242 Q LINE SENSOR KO
CNA#8) is not null: the voltage on minus battery (with the
every stepper motor line is a sine stepper motor at rest) is
wave with null mean voltage. expected being very low
(close to 30 ohms).
Check the continuity of the

This alarm occurs when the mean stepper motor connections.
voltage on the Direct line of the In particular the resistance
stepper motor (connection CNA#9) between CNA#9 and the
243 D LINE SENSOR KO
is not null: the voltage on every minus battery (with the
stepper motor line is a sine wave stepper motor at rest) is
with null mean voltage. expected being very low
(close to 30 ohms).

acquiring the motor resistance or
when adjusting the parameters
245 DATA ACQUISITION Recycle the key.
to compensate for the gain of
the current amplifiers (maximum
current factory adjusted).
The parameters to compensate

for the gain of the current
amplifiers (ADJUSTMENT #03 and
ADJUSTMENT #04) are recorded
It is necessary to send the
in a not volatile memory (eeprom)
controller to Zapi to execute
244 GAIN EEPROM KO with a redundant handling. In fact
the maximum current
every adjustment is recorded in
regulation.
three eeprom locations. If the
values in these three locations
are different in between this alarm
occurs.
In stepper motor application, this

alarm occurs if the main uC is
detecting a direction of the stepper
motor not matched with the one
that the slave uC is detecting. In
closed loop application, this alarm
occurs if the main uC is detecting It is necessary to replace
246 MICRO SLAVE KO
a direction of the steering error not the controller.
matched with the one that the slave
uC is detecting. Furthermore, this
alarm occurs also if the main uC
is detecting no steering limitation
meanwhile the slave uC is detecting
e steering limitation.
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ELECTRICAL SYSTEM
Error Message
Error Error text
This alarm occurs only when the

setting CAN BUS is PRESENT. Check the CAN Bus
Then the eps-ac0 must receive the communication system and
247 CAN BUS KO event messages from the traction analyse the frames from
controller. If these messages lack the traction controller to the
more than about 1 sec, this alarm steer controllers.
occurs.
This alarm occurs for a fault on the

command potentiometer (CPOC1
on CNA#9, CPOC2 on CNA#8).
When a single command pot is Check the connections of
chosen, the alarm occurs if its wiper the potentiometer. This
248 S.P OUT OF RANGE (CPOC1) exits the range from 0.8 alarm occurs when one
Vdc to 4.2 Vdc. When the twin connection of the command
pot is chosen, the alarm occurs if potentiometer is broken.
the sum of the two wiper voltages
(CPOC1+CPOC2) exits the range
from 4.5 Vdc to 5.5 Vdc.
This alarm occurs for a fault on the Check the connections of

feedback potentiometer (CPOT on the feedback potentiometer.
249 F.B OUT OF RANGE CNB#6). This alarm occurs if CPOT This alarm occurs when one
exits the range from 0.3 Vdc to 4.7 connection of the feedback
Vdc. potentiometer is broken.
It occurs when the information on

the status bus between the main
uC and the slave uC is frozen It is necessary to replace
250 MICRO SLAVE
to the 0xFF value (the slave uC the controller.
does not update the status bus
configuration).
This alarm occurs if the slave uC

detects the safety contact, of the It is necessary to replace
251 KM OPEN
main uC, open when expected the controller.
being closed.
This alarm occurs if the main uC

detects the safety contact, of the It is necessary to replace
252 KS OPEN
slave uC, open when expected the controller.
being closed.
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ELECTRICAL SYSTEM
Error Message
Error Error text

connection CNA#5 (K1) is
around a voltage of 12 Vdc
when switching on the key.
This alarm occurs at key on if the
In fact, when the safety
slave uC detects the safety contact,
253 KM CLOSED contacts are open, K1 is
of the main uC, closed prior to be
expected being connected
commanded.
to a battery voltage (not 12
V). Search for a harness
problem or replace the
controller.

connection CNA#4 (NK1)
is around a voltage of 12
Vdc when switching on the
This alarm occurs if the main
key. In fact, when the safety
uC detects the safety contact, of
254 KS CLOSED contacts are open, NK1 is
the slave uC, closed prior to be
expected being connected
commanded.
to a minus battery voltage
(not 12 V). Search for a
harness problem or replace
the controller.
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ELECTRICAL SYSTEM
8.12 Cable Wiring Diagrams
No. Name No. Name

1 Connector Battery Gray 8 Driving Motor Cable U
2 Pump Power Cable - 9 EPS Cable- C3
3 Pump Power Cable+ 10 B Cable-
4 Steering Motor Cable W 11 EPS Cable+ C2
5 Steering Motor Cable U 12 E-S Cable
6 Driving Motor Cable W 13 Controller Cable+ C1
7 Driving Motor CableV
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ELECTRICAL SYSTEM
8.13 Wiring Harness and Connectors
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ELECTRICAL SYSTEM
8.14 Electrical Schematic Diagrams
1 2 3 4 5
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ELECTRICAL SYSTEM
8.14 Electrical Schematic Diagrams
4
3
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9. TROUBLESHOOTING
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TROUBLESHOOTING
9.1 Preparation Before Troubleshooting

CAUTION
- Park the truck on level ground and block the
If the battery voltage is still abnormal after being
wheels with wooden wedges;
charged: open the battery compartment, check
- Fully lower the fork and press the emergency the voltage of each battery and its connection
stop switch. circuit respectively:
- Turn off the key switch;
1) Check if the voltage of single battery is
- Open the cover and check the controller.
normal;
(See Service Manual : Maintenance-free
CAUTION 2) Battery)
Check if the cables for connections between
- Even if key switch is turned off, the controllers
each battery are normal, check for open circ-
are still energized.
uit and if the connection between connectors
- Before checking or repairing the controllers, is secure.
make sure th e b a tte ry p lug has b e e n
unplugged and the electrical circuit is - Battery leakage check: disconnect the battery
disconnected. connection, black probe (-) connected to
(-) terminal of battery plug; red probe (+)
connected to the chassis. Read the voltage
9.1.1 Check the Voltage of Battery reading on the meter.
No voltage (0V): normal;
- Unplug the battery plug;
With voltage: battery leakage (remove battery
- Measure the battery voltage with a multim- compartment, check each battery and cables)
eter: black probe (-) connected to (-) terminal
of battery plug; red probe (+) connected to
the (+) terminal of battery plug. Read the
voltage reading on the meter.
- Identify if the battery voltage is normal
according to the measured voltage.
As shown in the following table:
Battery Voltage Judgment
Greater than 24V Normal

24V Needs to be
Less than 24V
charged
i NOTE
Enter TESTER Menu to check the battery
voltage.(see Section 8.10)
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TROUBLESHOOTING
9.2 Troubleshooting Solutions of Common Faults

Table 9.1 lists the common faults that may occur and handling
methods. Mainly consists of the following items:
Table 9.1 Troubleshooting of Common Faults
Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures

Power supply 1. Whole vehicle a. Power supply failure 1) Check the voltage of storage
failure power outrage b. Fuse failure battery (see Section 9.1.1)
2) Check the fuses
c. Emergency stop switch or circuit (see Section 8.2)
failure 3) Check key switch and its circuit
d. Key switch or circuit failure (see Section 8.5)
4) Check emergency stop switch
and its circuit
Travel Fault 1. Forward and rever- a. Interlock switch or its circuit Controller failure error, carry out
se moving failures of connection failure troubleshooting according to the
the vehicle, but other b. Electromagnetic brake locked fault code information on the
functions are normal (Non-mechanical failure, the instrument (see Section 8.11).
instrument will display fault code) 1) Check if the interlock switch or
the connection of its circuit is
c. Travel Switch or its circuit normal; (See Section 8.7)
connection failure 2) Electromagnetic brake and its
d. Drive motor carbon brush connecting circuit;
failure (see Section 5.2)
3) Check the travel switch and its
e. Controller failure
connection circuit;
(see Section 6.3)
4) Check the drive motor and its
connection circuit;
(see Section 5.3)
5) Replace the controller.
2. The vehicle can Failures due to external factors: Controller failure error, carry out
travel at low speed, a. Electromagnetic brake locked troubleshooting according to the
but cannot travel at (Non-mechanical failure, the fault code information on the
instrument will display fault code) instrument (see Section 8.9).
high speed
b. Motor bearing blocked 1) Check the voltage of storage
battery (see Section 9.1.1)
c. Gearbox bearing blocked 2) Check the drive motor;
3) Check the electromagnetic
Failures due to internal factors: brake or its connection circuit
a. Battery voltage deficiency (see Section 5.2)
b. Speed mode switch failure 4) Check whether Safety Gate is
c. Speed encoder of drive motor open, speed mode switch and
d. Controller failure its connection circuit;
(see Section 6.5)
5) Check he Speed encoder and
its connection circuit;
6) Remove the gearbox, check if
the gear rotation is smooth and
if there is blocking;
(see Section 5.4)
7) Replace the controller
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TROUBLESHOOTING
Table 9.1 Troubleshooting of Common Faults (continued)

Hydraulic 1. The vehicle cannot 1. Pump motor does not work: 1. Pump motor does not work:
Failure lift a. Pump motor or its circuit 1) Check the pump motor and its
connection failure connection circuit;
b. Pump contactor or its circuit (see Section 7.3)
connection failure 2) Check the pump contactor and
c. Lifting switch or its circuit (see Section 7.4)
connection failure 3) Check the lifting switch and its
d. Lifting limit switch or its circuit connection circuit;
connection failure (see Section 6.2)
4) Check the lifting limit switch
and its connection circuit;
(see Section 8.4)
2. Pump motor works: 2. Pump motor works:

a. Overload 1) Refer to the rated capacity
b. Insufficient hydraulic oil marked on the nameplate;
2) Lower the mast to the bottom,
c. Hydraulic pipeline leakage check if the amount of oil in the
d. Pump motor reverse rotation oil tank can meet the requireme-
e. Cylinder failure (blocked) nts (see Section 2.2.3);
3) Check the pipe and hydraulic
f. Solenoid valve blocked and components for oil leaks;
cannot reset 4) Check the pump motor wiring;
g. Valve body failure: 5) Check the cylinder for damage
excessive wear of gear pump, or deformation, remove the
serious internal leaks, insufficient cylinder to check for wear or
pressure of relief valve or aged seals inside;
blocked, check valve blocked (see Section 7.6)
6) Wash or replace the solenoid
spool (see Section 7.5)
7) Wash or replace the valve body
2. The vehicle cannot a. Solenoid valve or its circuit 1) Check the lowering button and
be lowered connection failure its connection circuit;
b. Lowering switch or its circuit (see Section 6.2)
connection failure 2) Check the solenoid valve and
c. Valve failure; (see Section 7.5)
d. Cylinder deformation or blocked 3) Check the cylinder for
deformation, remove the
cylinder to check if the internal
assembly is normal ;
(see Section 7.6)
4) Clean or replace the valve;
* Carry out trouble shooting in accordance with the order listed

in the table, it can help you quickly identify problems and
resolve accordingly.
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TROUBLESHOOTING
Table 9.1 Troubleshooting of Common Faults (continued)

Lift Failure 3. Slow Lifting of a. Overload 1) Refer to the rated capacity
Vehicle b. Hydraulic pipeline leakage marked on the nameplate;
2) Check the pipe and hydraulic
c. Valve failure: components for oil leaks;
Gear pump wear, internal 3) Wash or replace the valve body
leakage occurs
Insufficient relief valve pressure
or blocked
4. Slow Lowering of a. Solenoid valve blocking 1) Wash or replace the solenoid
Vehicle b. Valve body failure: throttle valve spool (see Section 7.5)
failure or blocked 2) Wash or replace the valve body
5. Unstable Lifting / a. Lifting mechanism loosening or 1) Check if the lifting mechanism

Lowering of Vehicle wear; is normal;
b. Poor lubrication of lifting (see Section 4.5)
mechanism;
Steering Fault 1. The vehicle cannot a. Potentiometer or its circuit Controller failure error, carry out
be steered (the connection failure troubleshooting according to the
vehicle can travel) b. Steering motor or its circuit fault code information on the
connection failure instrument (see Section 8.9).
1) Check if the mechanical
c. Proximity switch or its circuit connection between the
connection failure potentiometer and rocker
d. Steering controller failure is solid;
(see Section 6.4)
2) Check the potentiometer or its
connection circuit;
(see Section 6.4)
3) Check the steering motor or its
connection circuit;
(see Section 5.6)
5) Check the speed encoder or
its connection circuit.
(see Section 5.7)
5) Check the proximity switch or
its connection circuit.
(see Section 5.5)
6) Replace the controller.
Other Failures 1. Horn does not a. Horn switch or its circuit 1) Check the horn button and its
sound connection failure connection circuit;
b. Horn failure (see Section 6.2)
2) Check the horn and its
connection circuit.
(see Section 6.2)
* Carry out trouble shooting in accordance with the order listed

in the table, it can help you quickly identify problems and
resolve accordingly.
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10. MAST
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MAST
10.1 Two-stage Mast
10.1.1 Lifting Chains

10.1.1.1 Chain Adjustment
- Lower the mast to the bottom;
- Press the emergency stop switch and discon-
nect the key switch;
CAUTION
Switch off the power supply before any adjust-
ments or operations!
- Loosen the upper and lower lock nuts (2) on
chain bolt;
- Through screwing upward the adjusting nut
(9) in the middle, the chain will slowly tension;
- When the chain is adjusted to be tensioned
with no obvious loosening, fasten the upper
and lower lock nuts;
CAUTION
When the adjustment is completed, there sh-
ould be an adjustable distance of at least three
pitches over the chain bolts.
- Pull out emergency stop switch and turn on
the key switch;
- Through repeatedly lifting/lowering the mast
to test if the chain is tensioned. If the chain is
still loose, repeat the steps above.
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MAST
10.1.1.2 Chain Replacement

- Block the truck wheels with wooden wedges,
raise the fork carriage with lifting tools to
make the chains loose for the following rem-
oval;
CAUTION
Please place supporting under the fork carriage
to prevent it from falling, resulting in personal
injury.
- Remove the cotter pin (7, Figure 90603) and

unscrew the lock nut (2) and adjusting nut (9)
from the chain joint (1) ;
Remove the cotter pin (3) and flat washer (8),
- pull out the pin shaft (4), separate the chains
(5) from the chain joint (6) and joint (1);
Remove the chain assembly from the chain
- sprocket;
Replace with new chains and hang the new
- chain assembly onto the chain sprocket;
Put the chain connector (6) through chain
- hole of fork frame , inert the pin shaft (4) and
pin (3);
- Put the chain connector (1) through the outer
mast chain-hanging plate, screw the adjusting
nut (9) and lock nut (2),inert the pin shaft (7)
and pin (1);
- Adjust the chains according to Section
10.1.1.1.
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MAST
10.1.2 Lift Cylinder When removing joints or tubings, place a clean

container under it for discharge of hydraulic oil.
10.1.2.1 Cylinder Removal
Lift Cylinder Removal - Unscrew the bolt (1, Figure 30602) ,remove
cushion(5)、cushion(6)、Cylinder Support（4）
- Block the truck wheels with wooden wedges, Cylinder Clip（3）;
raise the fork frame with lifting tools to make
the chains loose for the following removal; CAUTION
Before going on with the next step, please fix
the cylinder properly first. Be sure to avoid the
CAUTION falling of cylinder during removal, resulting in
Please place supporting under the loading rack personal injury.
injury. - Unscrew the mounting bolt (7) from the
bottom of the cylinder;
Engage the emergency stop switch and turn
off key switch; - Unscrew the bolt (11), lift the cylinder (8) up
and remove it from the truck.
- Unscrew the joint of pipe(3, Figure 30601),re- - Remove the right oil cylinder in the same
move the joint(1), separate pipe (3) from the
way;
cylinder;
CAUTION
Hydraulic oil may damage truck parts and
contaminate the environment.
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MAST
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MAST
10.1.2.2 Cylinder Maintenance
CAUTION
- Use suitable hose clamps to avoid cylinder
deformation caused by severely tight hose
clamp.
- Carry out the maintenance work in a clean
environment to prevent impurities from
entering into cylinder, causing cylinder
damage.
the same specifications must be used for
cleaning or lubrication.
- Secure the cylinder to hose clamp and gently

clamp the cylinder bottom;
- Unscrew the cylinder cap (3, Figure 30603)
with cylinder wrench;
- Remove the dust ring (1) and O-ring (2) from
the cylinder cap;
- Pull out the piston rod (4) from the cylinder
tube(9);
- Remove the support ring (7),ring(5),seal(8)
and piston (6) from the piston rod;
Clean with hydraulic oil of the same specifica-
- tions;
Replace the problem parts and assembly in
- reverse steps. 10.1.2.3 Cylinder Installation
- Install the cylinder according to the reverse
order of removal according to A1-2.1;
- Add hydraulic oil of the same specifications
into the tank, see Section 2.2.3;
CAUTION - Pull out emergency stop switch and turn on
If the piston rode or cylinder tube is damaged, the key switch;
please replace the entire cylinder.
- Repeat Lift - Lower cylinder to discharge the
If the seals are aged or damaged, please air within the tubings and cylinder;
replace the complete set of seals.
- Check the hydraulic oil level and make sure
that the liquid is at standard level.
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MAST
10.2 Two-stage Full Free Mast

CAUTION
chain bolt;
CAUTION
the key switch;
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MAST

- Block the truck wheels with wooden wedges,
raise the fork carriage with lifting tools to
make the chains loose for the following rem-
oval;
CAUTION
Please place supporting under the fork carriage
injury.
- Remove the cotter pin (7, Figure 90603) and

unscrew the lock nut (2) and adjusting nut (9)
from the chain joint (1) ;
Remove the cotter pin (3) and flat washer (8),
- pull out the pin shaft (4), separate the chains
(5) from the chain joint (6) and joint (1);
Remove the chain assembly from the chain
- sprocket;
Replace with new chains and hang the new
- chain assembly onto the chain sprocket;
Put the chain connector (6) through chain
- hole of fork frame, inert the pin shaft (4) and
pin (3);
- Put the chain connector (1) through the inside
mast chain-hanging plate, screw the adjusting
nut (9) and lock nut (2),inert the pin shaft (7)
and pin (1);
- Adjust the chains according to Section
10.2.1.1.
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MAST

CAUTION
falling of cylinder during removal, resulting in
injury.
- Unscrew the mounting bolt (9) from the
Engage the emergency stop switch and turn bottom of the cylinder;
- Unscrew the joint (3, Figure 30604), separate - Remove the right oil cylinder in the same
pipe (2) from the cylinder;
way,before remove the right oil cylinder,
remove bolt (11, Figure 30604)，separate
CAUTION joint（12）from the right oil cylinder .
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MAST
Full Free Middle Cylinder - Loosen the bolt (9, Figure 30604) to separate
the middle cylinder and joint (10);
Cylinder Removal Remove the fork carriage chains according to
- Section A2-1.2;
- Block the truck wheels with wooden wedges, Unscrew the bolts（11，Figure30605),remove
raise the fork frame with lifting tools to make - the Chain Bracket (12）、Roller Bracket and
the chains loose for the following removal; Roller;
- Unscrew the bolts(13,Figure30605),separate
CAUTION the cylinder and inside Mast(3);
Remove the cylinder(14) from the truck;
Please place supporting under the loading rack
injury.
CAUTION
off key switch;
personal injury.
CAUTION
contaminate the environment. When removing
joints or tubings, place a clean container under
it for discharge of hydraulic oil.
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MAST
CAUTION
clamp.
damage.
Left Lifting Cylinder

- Unscrew the Connection Rod,Unscrew the
cylinder cap (3, Figure 30608) with cylinder
- wrench;
Remove the Connection Rod (1) 、 O-ring (2)
and (10)、dust ring(4)、Snap Ring（6）and (11)
seal (7)、Bearing（8）、Bushing（9）;
-
Pull out the piston rod (3) from the cylinder
- tube(19),remove the screw (14）;
Remove the support ring (15),spring(18),slee-
ve(17), seal (13) ,Plug(12)and piston(16)
- from the piston rod;
tions;
-
reverse steps.
Right Lifting Cylinder

- Remove the O-ring (8) and (10)、dust
ring(2)、Snap Ring（4）and (9)、seal (5)、
Bearing（6）、Bushing（7）;
tube(17),remove the screw (12）;
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MAST
- Remove the support ring (13),spring(16),slee-

ve(15), seal (11) ,Plug(10) and piston(14)
from the piston rod;
- Clean with hydraulic oil of the same specifica-
tions;
- Replace the problem parts and assembly in
reverse steps.
CAUTION
If the piston rode or cylinder tube is damaged,
If the seals are aged or damaged, please
Middle Cylinder Maintenance
CAUTION
clamp.
damage.
the same specifications must be used for CAUTION
cleaning or lubrication. If the piston rode or cylinder tube is damaged,
- Secure the cylinder to hose clamp and gently please replace the entire cylinder.
clamp the cylinder bottom; If the seals are aged or damaged, please
- Unscrew the cylinder cap (6, Figure 30606) replace the complete set of seals.
- Remove the dust ring (2) 、 shutter (3) and 10.2.2.3 Cylinder Installation
Ring(4) from the cylinder cap; - Install the cylinder according to the reverse
- Pull out the piston rod (1) from the cylinder order of removal according to A2-2.1;
tube(11); - Add hydraulic oil of the same specifications
- Remove the support ring (15),ring(13),seal into the tank, see Section 2.2.3;
（14）and piston (12) from the piston rod; - Pull out emergency stop switch and turn on
the key switch;
- - Repeat Lift - Lower cylinder to discharge the
tions;
air within the tubings and cylinder;
- reverse steps. - Check the hydraulic oil level and make sure
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MAST
10.3 Three-stage Mast

CAUTION
chain bolt;
CAUTION
the key switch;
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MAST
10.3.1.2.1Mast Chain 10.3.1.2.2 Fork carriage Chain
- Block the truck wheels with wooden wedges, - Block the truck wheels with wooden wedges,
raise the fork carriage with lifting tools to raise the fork carriage with lifting tools to
make the chains loose for the following rem- make the chains loose for the following rem-
oval; oval;
CAUTION CAUTION
Please place supporting under the fork carriage Please place supporting under the fork carriage
to prevent it from falling, resulting in personal to prevent it from falling, resulting in personal
injury. injury.
- Remove the cotter pin (7, Figure 90603) and - Remove the cotter pin (7, Figure 90603) and
unscrew the lock nut (2) and adjusting nut (9) unscrew the lock nut (2) and adjusting nut (9)
from the chain joint (1) ; from the chain joint (1) ;
Remove the cotter pin (3) and flat washer (8), Remove the cotter pin (3) and flat washer (8),
- pull out the pin shaft (4), separate the chains - pull out the pin shaft (4), separate the chains
(5) from the chain joint (6) and joint (1); (5) from the chain joint (6) and joint (1);
Remove the chain assembly from the chain Remove the chain assembly from the chain
- sprocket; - sprocket;
Replace with new chains and hang the new Replace with new chains and hang the new
- chain assembly onto the chain sprocket; - chain assembly onto the chain sprocket;
Put the chain connector (6) through the chain Put the chain connector (6) through the chain
- hole of inside mast, inert the pin shaft (4) and - hole of fork frame, inert the pin shaft (4) and
pin (3); pin (3);
- Put the chain connector (1) through the mast - Put the chain connector (1) through the chain
chain-hanging plate, screw the adjusting nut hole of middle Cylinder, screw the adjusting
(9) and lock nut (2),inert the pin shaft (7) and nut (9) and lock nut (2),inert the pin shaft (7)
pin (1); and pin (1);
- Adjust the chains according to Section - Adjust the chains according to Section
10.3.1.1. 10.3.1.1.
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MAST

CAUTION falling of cylinder during removal, resulting in
injury.
- Unscrew the mounting bolt (4) from the
Engage the emergency stop switch and turn bottom of the cylinder;
- Unscrew the joint (1, Figure 30610), separate - Remove the right oil cylinder in the same
pipe (2) from the cylinder;
way.
CAUTION
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MAST
Full Free Middle Cylinder - Loosen the bolt (12, Figure30610) to separ-
ate the middle cylinder and joint (5);
Cylinder Removal Remove the fork carriage chains according to
- Section A3-1.2.2;
- Block the truck wheels with wooden wedges, Unscrew the bolts（13，Figure30609),remov-
raise the fork frame with lifting tools to make - e the Chain Bracket (14）、Roller Bracket
the chains loose for the following removal; and Roller;
- Unscrew the bolts(15,Figure30609),separate
CAUTION the cylinder and inside Mast(3);
Remove the cylinder(16) from the truck;
Please place supporting under the loading rack
injury.
CAUTION
off key switch;
CAUTION personal injury.
contaminate the environment. When removing
joints or tubings, place a clean container under
it for discharge of hydraulic oil.
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MAST
CAUTION
clamp.
damage.
- Remove the dust ring (1) and O-ring(2) from
the cylinder cap;
tube(9);
- Remove the support ring(6),ring(5),seal（8）
and piston(7) from the piston rod;

tions;
reverse steps.
CAUTION
If the piston rode or cylinder tube is damaged,
If the seals are aged or damaged, please
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MAST
Middle Cylinder Maintenance
CAUTION
clamp.
damage.
- Remove the dust ring (1) and O-ring(2) from
the cylinder cap;
tube(8);
- Remove the support ring (5),seal（7）and
shutter (6) from the piston rod;

tions;
reverse steps.
10.3.2.3 Cylinder Installation
- Install the cylinder according to the reverse
CAUTION order of removal according to 10.3.2.1;
If the piston rode or cylinder tube is damaged, - Add hydraulic oil of the same specifications
please replace the entire cylinder. into the tank, see Section 2.2.3;
If the seals are aged or damaged, please - Pull out emergency stop switch and turn on
replace the complete set of seals. the key switch;
- Repeat Lift - Lower cylinder to discharge the
air within the tubings and cylinder;
- Check the hydraulic oil level and make sure
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11. SCHEDULE
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Schedule
Operator's Daily Checklist
Date Operator
Truck No. No.
Department
Runtime
Meter Reading
Daily Check Items O.K.( √ ) Remark
Drive Wheel
Load Wheel / Casters
Horn
Lifting / Lowering Control Functions
Optional Features
Forward / Reverse Control Functions
Steering control functions
Braking Functions
Check hydraulic system for leaks:

cylinders, fittings, tubings, oil tank, etc.
SM-EU110 05/18
148

Sm Eu110 Psx16 Service Manual Psx 2018 05

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Sm Eu110 Psx16 Service Manual Psx 2018 05

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Service Manual

This manual applies to:

Model Specifications LOT

Safety signs and instructions:

Please strictly adhere to these safety instructions to avoid personal injury.

Please pay attention to the important safety instructions.

Copyright of Service Manual belongs to Clark Europe GmbH

Clark Europe GmbH

REV. SM-EU110 05/18

3. STRUCTURE & FUNCTIONS ........................................ 25

5. DRIVE SYSTEM ............................................................. 35

7.4 Solenoid Valve ........................................................... 70

8. ELECTRICAL SYSTEM ................................................. 76

8.7 Interlock Switch .......................................................... 90

9. TROUBLESHOOTING ................................................. 124

10. SERVICE MANUAL - MAST ........................................ 129

10.1 Two-stage Mast ........................................................... 130

11. SCHEDULE ................................................................ 147

No. Name No. Name

The truck is driven forward or backward by AC

The truck is equipped with interlock switch at

1.2 Common Tools

No. Name Remark

1.3 General Tightening Torques

Screws/Bolts Performance Levels

5.8 5.8 grade Low carbon steel M6 ~ M48

Quenched and tempered medium

Quenched and tempered medium

Quenched and tempered medium

Table 1.3.2 Metric Screws/Bolts Tightening Torque Table (n•m)

Nominal Diameter 5.8 8.8 10.9 12.9

2.2 Maintenance Regular inspection and maintenance under

Forks thickness at heel x

Forks permanent deformation, left and right forks

Forks cracks at heel and mountings x

Cylinder leakage, deformation, mounting looseness,

2) Drive unit and brakes

Service brake, braking performance x

Parking brake, braking performance x

Brake system: check for damage and cable looseness x

Brake system: check for functionality, distance and wear x

Check wheel condition (Damage, screws and nuts,

Replace drive unit oil x

Check drive unit oil level (First : 50 hours) x

Check drive unit mounting and fasteners x

Control lever linkage looseness and functionality x

Battery condition, restraint and data x

Emergency shut off x

Electrical wiring and fuses x

Lift system creep test x

Oil leakage and damage, unusual noise x

Replace hydraulic oil x

6) Vehicle frame and safety equipment

Frame, safety equipment check deformation, damage and

Functions of the switches x

Operability of the directional lever x

Movement of the tiller handle x

Check safety marking and decals x

* In heavy conditions the service intervals must be reduce accordingly

Hydraulic oil injection nozzle

Gear oil injection nozzle

Gear oil discharge nozzle

Table 2.2 Lubricants

Code Type Specification Amount Position