Electrical System

SECTION 7 ELECTRICAL SYSTEM
Group 1 Component location --------------------------------------------------------------------------------------- 7-1

Group 2 Electrical circuit ----------------------------------------------------------------------------------------------- 7-2
Group 3 Electric components --------------------------------------------------------------------------------------- 7-3
SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
21
20
22
24
25
23
26
19
18
2
3
10
11
6
5 13
4
12
14
15
9
4
7
16
17 8 40B9EL02
1 Combination switch 10 Pump controller 19 Beacon lamp (opt)

2 Parking micro switch 11 Traction controller 20 Beacon switch (opt)
3 Accelerator assy 12 SBR switch assy 21 Working lamp switch (opt)
4 Fan assy 13 Fan assy 22 Head lamp switch (opt)
5 High horn 14 Contactor 23 Socket assy
6 Drive motor 15 Back up alarm 24 Emergency switch assy
7 E/M contactor 16 Flasher unit assy 25 Display
8 Fuse box assy 17 Relay 26 DC-DC converter
9 Pump motor 18 Working lamp (opt)
7-1
GROUP 2 ELECTRICAL CIRCUIT
余ELECTRICAL CIRCUIT (1/14, NON-UL, ZAPI, 50B-9 : #0001-0004)
FUSE BOX ASS'Y ( UL #1 )
F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

10A 5A 5A 5A 5A 5A 5A 5A 5A 10A 10A
20 23 24 27 26 26A 25 55 52 52A FAN 28

25A 6 8
25C FR+ RELAY
BRAKE FLAS WORK BEACON
02C B
C- E -HER LAMP LAMP SEAT
LAMP 220 SOC
KO HEAD UNIT S/W S/W HEATING
EMERGENCY SWITCH L OPT KET
LAMP BACK SWITCH
SWITCH S/W 41
21B 22 BUZZER
33 40 T/S SWITCH
INPUT OUTPUT 43 44 133 75
44A S/W
49 49B HEATER H
EMERGENCY 7
42A
CONTACTOR 42 HORN 59 47 5 FR-
45A 45 46A RELAY
DC-DC
2 CONVERTER
5A 5B 5D 5D 5C
B- 43A 43A 44A 46A 59A 47A
32 49A 49B 49C
46
GND GND M M M M
KEY (IN) (OUT)
S/W LAMP TAIL STOP T/S B/U TAIL STOP T/S B/U T/S T/S HORN TNR REAR LAMP BEA LAMP FAN- FAN- FAN- FAN-
02A LH RH TNR
-S/W LAMP LAMP WORK -S/W CON -S/W RH CONT LH RH
COMBI. COMBI. BACKUP LAMP MOTOR MOTOR
-LH -RH LAMP
LAMP LAMP BUZZER
21 21C 21F 00A 02H
02U 02D 02J -LH -RH 02H 02U 02J 02E 02G 02B 02H 02N 02H 02U 02L 02S 02K 02P 02F 02Y 02R 02T
KO VI FI B- C-
PUMP LC
TRACTION LC
10W 300
TRACTION TRACTION PUMP
RIGHT LEFT INVERTER
10W 300 AC-3 AC-3 AC-3
B+ 21C 21D B+ 21E B+
KEY A33 KO KO A33 KEY LEFT KO A33 KEY
RIGHT TRACTION PUMP
TRACTION MOTOR MOTOR
400A 122 75 400A 222 400A
MOTOR U COMMON A30 PPOT A32 U A30 COMMON U
M V FWD S/W V M LIFT S/W V M

90 122A LOAD SENSING 74 222A 60
W FORWARD A5 CPOT A21 W A5 LIFT ENABLE
POTENTIOMETER W
REV S/W TILT S/W
196 91 05 396 222F 61 296
A25 PTHERM BACKWARD A6 NPOT A20 PTHERM A25 A6 TILT MOT TH A25
ACCEL S/W AUX1 S/W

195 95 122C 221 395 222F 62 295
A24 NTHERM ACCEL A7 A27 PLC NTHERM A24 A9 AUX 1 -BATT A24
TEMP SENSOR TEMP SENSOR TEMP SENSOR
BRAKE S/W MCV SOL. AUX2 S/W
194 98 122D 08 394 63 294
A1 (ENCODER VCC) PB A8 A26 NLC ENCODER VCC A1 A8 AUX 2 ENCODER VCC A1
TILT
PARKING LEVELING
192 99 122E 301 392 222B 66 292
A2 (ENCODER GND) PARKING A9 A12 SAFETY ENCODER GND A2 A4 TILT ENCODER GND A2
LEVELING
BRAKE OIL SBR
B+ 193 69 122F 393 222D 68 293
A13 (ENCODER A) BRAKE OIL A11 A34 -BATT ENCODER A A13 A7 SBR ENCODER A A13
LIFT
SEAT S/W
LIMIT
191 92 122F 391 222C 67 291
A14 (ENCODER B) SEAT A4 ENCODER B A14 A11 LIFT ENCODER B A14
LIMIT
121 92A ELECTRIC FORKLIFT DISPLAY 222E 65

A29 PLC A4 SEAT A10 INVERTER PPOT A3
LIFT
PUMP 21A 00A SELECT
POTENTIOMETER
LC COIL KO KEY A6 A1 -BATT B-
09 SAFETY A12 11 220 64
A28 NLC A28 SAFETY OUT FR+ A29 PFR CPOT A16
E/M 21E
SWITCH BATT+ A5 A20 SBR
93 120 420 7 NPOT A15 03
A3 PPOT PMC A27 FR- A28 NFR
126D
CAN-T A4
ACCELERATOR 94 01 202 203
BATTERY A16 CPOT NMC A26 A12 SAFETY MODE A31
PEDAL
80V CAN-H CAN-L
TRACTION
BATTERY A2 A3
07 LC COIL
36/48V A15 NPOT A34 -BATT A35
126B 125B
97 126D 72
A32 PPOTB CAN T A17 PPOTAUX A32
TILT ANGLE
POTENTIOMETER
STEERING 96 126C 126A A18 CAN H 126 70
SENSOR A21 CPOTB CAN H A18 A18 CAN H CPOTAUX A21
06 125 A19 CAN L 125B 04

A20 NPOTB CAN L A19 A19 CAN L NPOTAUX A20
125A
104 B- B-
MODE A31
-BATT A35
B-
B- 21B3-90022-00
7-2
余ELECTRICAL CIRCUIT (2/14, NON-UL, ZAPI, 40B-9 : #0001-0009, 45B-9 : #0001-0004, 50B-9 : #0005-0011)
F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

10A 5A 5A 5A 5A 5A 5A 5A 5A 10A 10A
20 23 24 27 26 26A 25 55 52 52A FAN 28

25A 6 8
25C FR+ RELAY
02C B
C- E -HER LAMP LAMP 220 SEAT
LAMP SOC
LAMP BACK SWITCH
SWITCH S/W 41
21B 22 BUZZER
33 40 T/S SWITCH
INPUT OUTPUT 43 44 133 75
44A S/W
49 49B HEATER H
EMERGENCY 7
42A
45A 45 46A RELAY
DC-DC
2 CONVERTER
5A 5B 5D 5D 5C
B- 43B 43B 43A 44A 44A 46A 59A 47A
32 49A 49B 49C
46
GND GND M M M M
KEY (IN) (OUT)
S/W LAMP TAIL STOP T/S B/U TAIL STOP T/S B/U T/S HORN TNR REAR LAMP BEA LAMP FAN- FAN- FAN- FAN-
02A LIC. LH RH T/S TNR
-S/W LAMP WORK -S/W CON -S/W RH CONT LH RH
LAMP LAMP
COMBI. COMBI. BACKUP LAMP LAMP MOTOR MOTOR
-LH -RH
21 21C 21F LAMP LAMP BUZZER
00A 02W 02U 02D 02J -LH 02H -RH 02H 02U 02J 02E 02G 02B 02H 02N 02H 02U 02L 02S 02K 02P 02F 02Y 02R 02T
KO VI FI B- C-
PUMP LC
O2R O2U O2U
TRACTION LC
10W 300
RIGHT LEFT INVERTER
10W 300 AC-3 AC-3 AC-3
B+ 21C 21D B+ 21E B+
RIGHT TRACTION PUMP
400A 122 75 400A 222 400A

W FORWARD A5 CPOT A21 W A5 LIFT ENABLE W
POTENTIOMETER
REV S/W TILT S/W
196 91 05 396 222F 61 296
ACCEL S/W AUX1 S/W

195 95 122C 221 395 222F 62 295
194 98 122D 08 394 63 294
TILT
PARKING LEVELING
192 99 122E 301 392 222B 66 292
LEVELING
BRAKE OIL SBR
B+ 193 69 122F 393 222D 68 293
LIFT
SEAT S/W
LIMIT
191 92 122F 391 222C 67 291
LIMIT
121 92A ELECTRIC FORKLIFT DISPLAY 222E 65

A29 PLC A4 SEAT A10 INVERTER PPOT A3
LIFT
PUMP 21A 00A SELECT
POTENTIOMETER
09 11 220 64
A28 NLC SAFETY A12 A28 SAFETY OUT FR+ A29 PFR CPOT A16
E/M 21E
SWITCH BATT+ A5
93 120 420 7 NPOT A15 03
126D
CAN-T A4
ACCELERATOR 94 01 202 MODE A31 203
BATTERY A16 CPOT NMC A26 A12 SAFETY
PEDAL
80V TRACTION CAN-H CAN-L
07 LC COIL A2 A3
A15 NPOT A34 -BATT A35
126B 125B
97 126D 72
TILT ANGLE
POTENTIOMETER
STEERING 96 126C 126A A18 CAN H 70
06 125 A19 CAN L 125B 04

125A
104 B- B-
MODE A31
-BATT A35
B-
B- 21B3-90022-01
7-2-1
余ELECTRICAL CIRCUIT (3/14, NON-UL, ZAPI, 40B-9 : #0010-0011)
F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

10A 5A 5A 5A 5A 5A 5A 5A 5A 10A 10A
20 23 24 27 26 26A 25 55 52 52A 28
25A FAN 6 8
221B 25C WORK BEACON FR+
BRAKE B FLAS RELAY
02C LAMP LAMP SEAT
LAMP C- E -HER
KO 26C 26C S/W S/W HEATING SOC
HEAD SWITCH L UNIT
EMERGENCY BACK BACK SWITCH OPT KET
LAMP
SWITCH S/W 41 BUZZER BUZZER
21B 22 S/W-
33 40 T/S SWITCH HORN
INPUT OUTPUT 43 44 44A 48 KNOB 133 RELAY
S/W
49 49B HEATER H
EMERGENCY 42A BACK
CONTACTOR 42 59 47 FR-
46A BUZZER
45A 45
DC-DC RELAY
2 CONVERTER
5A 5B 5D 5D 5C
B- 43B 43B 43A 44A 44A 46A 59A 47A
32 46B 49A 49B 49C
46
GND GND M M M M
KEY (IN) (OUT)
02A LIC. LH RH T/S TNR
LAMP -S/W LAMP WORK -S/W CON -S/W RH CONT LH RH
COMBI. LAMP BACKUP
COMBI. LAMP LAMP MOTOR MOTOR
-LH -RH BUZZER
21 21C 21F LAMP LAMP
00A 02W 02U 02D 02J -LH 02H -RH 02H 02U 02J 02E 02Z 02G 02B 02H 02N 02H 02U 02L 02S 02K 02P 02F 02Y 02R 02T
KO VI FI B- C-
PUMP LC
TRACTION LC
10W 300
RIGHT LEFT INVERTER
10W 300 AC-3 AC-3 AC-3
B+ 21C 21D B+ 21E B+
RIGHT TRACTION PUMP
400A 122 75 400A 222 400A

POTENTIOMETER
REV S/W TILT S/W
196 91 05 396 222F 61 296
A25 PTHERM BACKWARD A6 NPOT A20 PTHERM A25 F20 A6 TILT MOT TH A25
5A
ACCEL S/W AUX1 S/W
195 95 122C 221 395 222F 62 295
194 98 122D 08 394 63 294
TILT
PARKING LEVELING
192 99 122E 301 392 222B 66 292
LEVELING
BRAKE OIL SBR
B+ 193 69 122F 393 222D 68 293
LIFT
SEAT S/W
LIMIT
191 92 122F 391 222C 67 291
LIMIT
ELECTRIC FORKLIFT DISPLAY
121 92A A10 INVERTER 65
A29 PLC A4 SEAT PPOT A3
LIFT
PUMP 21A 00A SELECT
POTENTIOMETER
09 SAFETY A12 11 220 64
E/M 21E
SWITCH BATT+ A5
93 120 420 7 NPOT A15 03
125F
CAN-T A4
PEDAL
80V TRACTION CAN-H CAN-L 72
07 LC COIL A2 A3
126F 125E
97 126A 72
TILT ANGLE
POTENTIOMETER
STEERING 96 126 126D A18 CAN H 126E 70
A21 CPOTB CAN H A18 A18 CAN H CPOTAUX A21
SENSOR
06 125 A19 CAN L 125D 04

125C
104 B- B-
MODE A31
-BATT A35
B-
B- 21B3-90023-00
7-2-2
F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

10A 10A 5A 5A 5A 5A 5A 10A 5A 10A 10A
20 23 24 27 26 26A 25 55 52 52A FAN 28

25A 6 8
25C FR+ RELAY
BRAKE FLAS 221B WORK BEACON
02C B
LAMP C- E -HER LAMP LAMP 220 SEAT
HEAD SWITCH L UNIT
EMERGENCY BACK BACK SWITCH OPT KET
LAMP
21B 22
33 40 T/S SWITCH S/W- HORN
INPUT OUTPUT 43 44 44A 48 KNOB 133 RELAY
S/W
49 49B HEATER H
EMERGENCY 7
42A BACK
CONTACTOR 42 59 47 5 FR-
46A BUZZER
45A 45
DC-DC RELAY
2 CONVERTER
5A 5B 5D 5D 5C
B- 43B 43B 43A 44A 44A 46A 59A 47A
32 46B 49A 49B 49C
46
GND GND M M M M
KEY (IN) (OUT)
02A LIC. LH RH TNR
LAMP COMBI. COMBI. BACKUP
-LH -RH LAMP LAMP MOTOR MOTOR
LAMP LAMP BUZZER
21 21C 21F 00A 02H
02W 02U 02D 02J -LH -RH 02H 02U 02J 02E 02Z 02G 02B 02H 02N 02H 02U 02L 02S 02K 02P 02F 02Y 02R 02T
KO VI FI B- C-
PUMP LC
TRACTION LC
10W 300
RIGHT LEFT INVERTER
10W 300 AC-3 AC-3 AC-3
B+ 21C 21D B+ 21E B+
RIGHT TRACTION PUMP
10W 300 122 75 400A 222 400A
MOTOR U 400A COMMON A30 PPOT A32 U A30 COMMON U

POTENTIOMETER
REV S/W TILT S/W
196 91 05 396 222F 61 296
ACCEL S/W AUX1 S/W

195 95 122C 221 395 222F 62 295
194 98 122D 08 394 63 294
TILT
PARKING LEVELING
192 99 122E 301 392 222B 66 292
LEVELING
BRAKE OIL SBR
B+ 193 69 122F 393 222D 68 293
LIFT
SEAT S/W
LIMIT
191 92 122F 391 222C 67 291
LIMIT
121 92A 222E A10 INVERTER 65

LIFT
PUMP 21A 00A SELECT
POTENTIOMETER
09 SAFETY A12 11 220 64
E/M 21E
SWITCH BATT+ A5
93 120 420 7 NPOT A15 03
125F
B- CAN-T A4
PEDAL
07 LC COIL A2 A3
126F 125E
97 126A 72
TILT ANGLE
POTENTIOMETER
06 125 A19 CAN L 125D 04

125C
104 B- B-
MODE A31
-BATT A35
B-
B- 21B3-90023-01
7-2-3
F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

10A 10A 5A 5A 5A 5A TRF 5A 10A 5A 10A 10A
20 23 24 27 TRF
26 26A 25 55 52 52A FAN 28
25A 27A TILT 6 8
25C TR+ FR+ RELAY
BRAKE FLAS RELAY WORK BEACON
02C B
LAMP C- E -HER 320 LAMP LAMP 220 SEAT
HEAD SWITCH L UNIT
EMERGENCY BACK BACK 7 SWITCH OPT KET
LAMP
21B 22 S/W-
40 T/S SWITCH HORN
32 48 KNOB 133
INPUT OUTPUT 43 44 44A S/W RELAY
KEY 49 49B HEATER H
209 7
S/W 42A BACK 115
42 BUZZER TR- 59 47 5 FR-
45A 45 46A
33 DC-DC RELAY
2 CONVERTER
115B 115B 115A 5A 5B 5D 5D 5C
EMERGENCY 43B 43B 43A 44A 44A 46A 59A 47A
46B 49A 49B 49C
CONTACTOR
46
GND GND M M M M
21 (IN) (OUT)
LAMP TAIL STOP T/S B/U TAIL STOP T/S B/U HORN TNR TILT- TILT- REAR LAMP BEA LAMP FAN- FAN- FAN- FAN-
B- 02A LIC. LH RH T/S T/S TNR
-S/W IN OUT WORK -S/W CON -S/W RH CONT LH RH
LAMP LAMP LAMP BACKUP
COMBI. COMBI. VALVE VALVE LAMP LAMP MOTOR MOTOR
-LH -RH BUZZER
21 21C 21E 21F LAMP LAMP
00A 02W 02U 02D 02J 02H 02H 02U 02J 02E 02Z 02G 02B 02X 02T 02V 02H 02N 02H 02U 02L 02S 02K 02P 02F 02Y 02R 02T
-LH -RH
KO VI FI CA B- C-
PUMP LC
TRACTION LC PUMP
INVERTER
10W 300
AC-3
TRACTION TRACTION
RIGHT LEFT 21E B+
KO A33 KEY
10W 300 AC-3 AC-3 PUMP
MOTOR
B+ 21C 21D B+ 222
KO KO A33 KEY LEFT A30 COMMON 400A U
KEY A33
RIGHT TRACTION
MOTOR LIFT S/W V M
TRACTION
122 75 400A 222A 60
MOTOR U 400A COMMON A30 PPOT A32 U A5 LIFT ENABLE W
M V FWD S/W V M TILT S/W
90 122A LOAD SENSING 74 222F 61 296
W FORWARD A5 CPOT A21 W A6 TILT MOT TH A25
POTENTIOMETER
REV S/W AUX1 S/W
196 91 05 396 222F 62 295
A25 PTHERM BACKWARD A6 NPOT A20 PTHERM A25 A9 AUX 1 -BATT A24
TEMP SENSOR
ACCEL S/W AUX2 S/W TEMP SENSOR
195 95 122C 221 395 63 294
A24 NTHERM ACCEL A7 A27 PLC NTHERM A24 A8 AUX 2 ENCODER VCC A1
TEMP SENSOR TEMP SENSOR TILT
BRAKE S/W MCV SOL. LEVELING
194 98 122D 08 394 222B 66 292
A1 (ENCODER VCC) PB A8 A26 NLC ENCODER VCC A1 A4 TILT ENCODER GND A2
LEVELING
PARKING SBR
192 99 122E 301 392 222D 68 293
A2 (ENCODER GND) PARKING A9 A12 SAFETY ENCODER GND A2 A7 SBR ENCODER A A13
LIFT
BRAKE OIL LIMIT
B+ 193 69 122F 393 222C 67 291
A13 (ENCODER A) BRAKE OIL A11 A34 -BATT ENCODER A A13 A11 LIFT ENCODER B A14
LIMIT
SEAT S/W
191 92 122F 391 222E A10 INVERTER 65
A14 (ENCODER B) SEAT A4 ENCODER B A14 PPOT A3
LIFT
SELECT
POTENTIOMETER
121 92A 220 64
A29 PLC A4 SEAT FR+ A29 PFR CPOT A16
PUMP 21A 00A
09 SAFETY A12 11 7 NPOT A15 03
A28 NLC A28 SAFETY OUT FR- A28 NFR
E/M 21E
SWITCH BATT+ A5
93 120 420 202 MODE A31 203
A3 PPOT PMC A27 A12 SAFETY
125F
CAN-T A4
ACCELERATOR 94 01
BATTERY A16 CPOT NMC A26 A34 -BATT A35
PEDAL
07 LC COIL A2 A3 320
A15 NPOT TR+ A27 PTR
126F 125E
97 126A 209 72
A32 PPOTB CAN T A17 TR- A26 NTR PPOTAUX A32
TILT ANGLE
POTENTIOMETER
96 126 126D A18 CAN H 126E 70
STEERING A21 CPOTB CPOTAUX A21
CAN H A18 A18 CAN H
SENSOR
06 125 A19 CAN L 125D 04

125C
104 B- B-
MODE A31
-BATT A35
B-
B- 21B3-90024-00
7-2-4
F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

10A 10A 5A 5A 5A 5A TRF 5A 10A 5A 10A 10A
20 23 24 27 TRF 26 26A 25 55 52 52A 28

25A 27A FAN 6 8
25C TR+
TILT FR+
FLAS RELAY WORK BEACON RELAY
BRAKE 02C B
C- E -HER 320 LAMP LAMP 220 SEAT
LAMP 26C 26C SOC
LAMP BACK BACK SWITCH
21B 22 S/W-
40 T/S SWITCH HORN
32 48 KNOB 133
INPUT OUTPUT 43 44 44A S/W RELAY
KEY 49 49B HEATER H
209 7
S/W 42A BACK 115
42 TR- 59 47 5 FR-
46A BUZZER
45A 45
33 DC-DC RELAY
2 CONVERTER
115B 115B 115A 5A 5B 5D 5D 5C
46B 49A 49B 49C
CONTACTOR OPT
46
GND GND M M M M
21 (IN) (OUT)
LAMP TAIL STOP T/S B/U TAIL STOP T/S B/U HORN TNR TILT- TILT- REAR LAMP BEA LAMP FAN- FAN- FAN- FAN-
B- 02A LIC. LH RH T/S T/S TNR
LAMP -S/W IN OUT WORK -S/W CON -S/W RH CONT LH RH
LAMP LAMP BACKUP
COMBI. COMBI. VALVE VALVE LAMP LAMP MOTOR MOTOR
-LH -RH BUZZER
21 21C 21E 21F LAMP LAMP
00A 02W 02U 02D 02J 02H 02H 02U 02J 02E 02Z 02G 02B 02X 02T 02V 02H 02N 02H 02U 02L 02S 02K 02P 02F 02Y 02R 02T
-LH -RH
KO VI FI CA B- C-
PUMP LC
TRACTION LC PUMP
INVERTER
10W 300 AC-3
TRACTION TRACTION
RIGHT LEFT 21E B+
KO A33 KEY
MOTOR
B+ 21C 21D B+ 222
KEY A33
RIGHT TRACTION
MOTOR LIFT S/W V M
TRACTION
122 75 400A 222A 60
90 122A LOAD SENSING 74 222F 61 296
POTENTIOMETER
REV S/W AUX1 S/W
196 91 05 396 222F 62 295
TEMP SENSOR
ACCEL S/W AUX2 S/W TEMP SENSOR
195 95 122C 221 395 63 294
194 98 122D 08 394 222B 66 292
LEVELING
PARKING SBR
192 99 122E 301 392 222D 68 293
LIFT LIMIT
BRAKE OIL /TRAC CTB
B+ 193 69 122F 393 222C 67 291
A13 (ENCODER A) BRAKE OIL A11 A34 -BATT ENCODER A A13 A11 LIFT LIMIT/ ENCODER B A14
TRAC CUTBACK
SEAT S/W
191 122F 391 222E 65
A14 (ENCODER B) ENCODER B A14 A10 INVERTER PPOT A3
LIFT
SELECT
BUCKLE S/W POTENTIOMETER
121 92 892 220 64
A29 PLC SEAT A4 FR+ A29 PFR CPOT A16
PUMP 21A 00A
09 92A 7 NPOT A15 03
A28 NLC A4 SEAT FR- A28 NFR
21E
BATT+ A5
93 SAFETY A12 11 202 MODE A31 203
A3 PPOT A28 SAFETY OUT A12 SAFETY
125F
CAN-T A4
ACCELERATOR 94
BATTERY A16 CPOT A34 -BATT A35
PEDAL
80V CAN-H CAN-L
07 A2 A3 320
126F 125E
97 126A 209 72
TILT ANGLE
POTENTIOMETER
06 125 A19 CAN L 125D 04

125C
E/M
SWITCH B- B-
104 120 420
MODE A31 PMC A27
01
-BATT A35 NMC A26
TRACTION
LC COIL
B-
B-
21B3-90024-02
7-2-5
余ELECTRICAL CIRCUIT (7/14, NON-UL, ZAPI, 40B-9 : #0066-, 45B-9 : #0051-, 50B-9 : #0153-)
F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

10A 10A 5A 5A 5A 5A TRF 5A 10A 5A 10A 10A
20 23 24 27 TRF 26 26A 25 55 52 52A FAN 28

27A 6 8
26C 25C TILT FR+ RELAY
FLAS 26C TR+ WORK BEACON
BRAKE B RELAY
02C LAMP LAMP SEAT
LAMP C- E -HER BACK 320 220
KO BZC HORN S/W S/W HEATING SOC
HEAD SWITCH L UNIT HORN
EMERGENCY BUZZER SWITCH/ SWITCH OPT KET
LAMP BACK S/W-
SWITCH 41 S/W- REAR
S/W BUZZER KNOB/
21B 22 KNOB/ GRIP
40 T/S SWITCH F-TIP
32 48 F-TIP SW(OPT) 133
INPUT OUTPUT 43 44 44A S/W
KEY BZO
49 HEATER H
209 7
S/W 42A BACK HORN 115
42 TR- 59 47 5 FR-
45A 45 46A BUZZER RELAY
33 DC-DC RELAY
2 CONVERTER
115B 115B 115A 5A 5B 5D 5D 5C
46B 49A 49B 49C
CONTACTOR
46
GND GND M M M M
21 (IN) (OUT)
TAIL STOP T/S B/U TAIL STOP T/S B/U HORN TNR TILT- TILT- REAR FAN- FAN- FAN- FAN-
B- LH LAMP RH T/S T/S LAMP BEA LAMP TNR
02A LIC. IN OUT WORK RH CONT LH RH
LAMP -S/W LAMP LAMP BACKUP -S/W CON -S/W
COMBI. COMBI. VALVE VALVE /BLUE MOTOR MOTOR
-LH -RH BUZZER LAMP
LAMP LAMP SPOT
21 21C 21E 21F 00A 02H
02W 02U 02D 02J -LH -RH 02H 02U 02J 02E 02Z 02G 02B 02X 02T 02V LAMP 02N 02H 02U 02L 02S 02K 02P 02F 02Y 02R 02T
02H
KO VI FI CA B- C-
BZG
PUMP LC
TRACTION LC PUMP
INVERTER
10W 300 AC-3
TRACTION TRACTION
RIGHT 21E B+
LEFT A33 KEY
10W 300 AC-3 KO
AC-3 PUMP
MOTOR
B+ 21C 21D B+ 222
KEY A33
RIGHT TRACTION
MOTOR LIFT S/W V M
TRACTION
122 75 400A 222A 60
MOTOR U 400A COMMON A30 TDI PPOT A32 U A5 LIFT ENABLE W
90 122A LOAD SENSING 74 222F 61 296
POTENTIOMETER
FWI
REV S/W AUX1 S/W
196 91 05 396 222F 62 295
BWI
TEMP SENSOR
ACCEL S/W AUX2 S/W
195 95 122C 221 395 63 294
194 98 122D 08 394 222B 292
LEVELING
PARKING SBR
192 99 122E 301 392 222D 68 293
LIFT LIMIT
BRAKE OIL /TRAC CTB
B+ 193 69 122F 393 222C 67 291
TRAC CUTBACK
SEAT S/W
191 122F 391 222E 65
LIFT
SELECT
121 92 892 ELECTRIC FORKLIFT DISPLAY 220 64
PUMP 21A 00A
09 92A 7 NPOT A15 03
21E
BATT+ A5
93 SAFETY A12 11 202 MODE A31 203
125F
CAN-T A4
ACCELERATOR 94
PEDAL
80V CAN-H CAN-L
07 A2 A3 320
126F 125E
97 126A 209 72
TILT ANGLE
POTENTIOMETER
06 125 A19 CAN L 125D 04

A20 NPOTB CAN L A19 221 NPOTAUX A20
125C
E/M
SWITCH B- B-
104 120 420
MODE A31 PMC A27
01
-BATT A35 NMC A26
TRACTION
LC COIL
B-
B- 21B3-90025-00
7-2-6
余ELECTRICAL CIRCUIT (8/14, UL, ZAPI, 40B-9 : #0001-0009, 45B-9 : #0001-0004, 50B-9 : #0001-0011)
F3 F5 F6 F9 F8 F10 F11 F12 F4

10A 5A 5A 5A 5A 5A 5A 5A 5A
20 23 24 27 26 26A 25 55 52 52A FAN 28

25B 25C RELAY
BEACON FR+
BRAKE B FLAS WORK
02C -HER LAMP LAMP
LAMP C- E 220
KO HEAD UNIT S/W S/W SEAT
SWITCH L
EMERGENCY LAMP HEATING
BACK
SWITCH S/W 41 SWITCH
21B 22 BUZZER
33 40 T/S SWITCH
INPUT OUTPUT 43 44 133
44A S/W
49 49B HEATER
EMERGENCY 7
42A H
23A 45A 45 46A RELAY
DC-DC
2 CONVERTER
5A 5B 5D 5D 5C
B- 43A 43A 44A 44A 46A 59A 47A
32 49A 49B 49C
46
GND GND M M M M
KEY (IN) (OUT)
02A LH RH TNR
COMBI. BACKUP
COMBI. -LH -RH LAMP LAMP MOTOR MOTOR
LAMP BUZZER
21 LAMP
00A 02U 02D 02J -LH 02H 02H 02U 02J 02E 02G 02B 02M 02H 02N 02H 02U 02L 02S 02K 02P 02F 02Y
-RH
KO VI FI B- C-
PUMP LC
TRACTION LC
10W 300
RIGHT LEFT INVERTER
10W 300 AC-3 AC-3 AC-3
B+ 21C 21D B+ 21E B+
RIGHT F27 TRACTION PUMP
TRACTION 5A MOTOR MOTOR
400A 122 75 275 400A 222 400A

POTENTIOMETER
F15 F17 F23
REV S/W TILT S/W
5A 5A 5A
196 496 91 05 696 396 222F 61 596 296
F26
ACCEL S/W 5A AUX1 S/W
195 95 122C 221 521 395 222F 62 295
TEMP SENSOR F16 F18 TEMP SENSOR F24 TEMP SENSOR
5A BRAKE S/W MCV SOL. 5A AUX2 S/W 5A
194 494 98 122D 08 694 394 63 594 294
TILT
PARKING LEVELING
192 99 122E 301 392 222B 66 292
LEVELING
BRAKE OIL SBR
B+ 193 69 122F 393 222D 68 293
LIFT
SEAT S/W
LIMIT
191 92 122F 391 222C 67 291
LIMIT F25
291
BRAKE A20 ELECTRIC FORKLIFT DISPLAY 5A
121 92A 222E A10 INVERTER 265 65
LIFT
PUMP 21A 00A SELECT
POTENTIOMETER
09 SAFETY A12 11 220 64
F21 E/M 21E
5A SWITCH BATT+ A5
93 793 120 420 7 NPOT A15 03
222D
B- CAN-T A4
PEDAL
BATTERY LC COIL A2 A3
07
36/48V A15 NPOT A34 -BATT A35
F19 F22
5A 126B 125B 5A
97 797 126D 272 72
TILT ANGLE
POTENTIOMETER
STEERING 96 126C 126A A18 CAN H 126 70
06 125 A19 CAN L 125B 04

125A
221
104 B- B-
MODE A31
-BATT A35
B-
B- 21B3-90102-00
7-2-7
F3 F5 F6 F9 F8 F10 F11 F12 F4

10A 5A 5A 5A 5A 5A 5A 5A 5A
20 23 24 27 26 26A 25 55 52 52A FAN 28

25B 25C RELAY
BEACON FR+
BRAKE B FLAS WORK
02C LAMP LAMPF14
LAMP C- E -HER 220
KO HEAD UNIT 26C 26C S/W S/W 5A SEAT
SWITCH L
EMERGENCY LAMP BACK HEATING
41 BACK SWITCH
SWITCH S/W BUZZER
21B 22 BUZZER
40 S/W- HORN
33 T/S SWITCH 133
INPUT OUTPUT 43 44 48 KNOB RELAY
44A S/W
49 49B HEATER
EMERGENCY 7
42A BACK H
CONTACTOR 42 59 47 5 FR-
BUZZER
45A 45 46A
DC-DC RELAY
2 CONVERTER
5A 5B 5D 5D 5C
B- 43A 43A 44A 44A 46A 59A 47A
32 46B 49A 49B 49C
46
GND GND M M M M
KEY (IN) (OUT)
02A LH RH T/S TNR
COMBI. COMBI. BACKUP MOTOR MOTOR
-LH -RH LAMP LAMP
LAMP LAMP BUZZER
21 00A 02H
02U 02D 02J -LH -RH 02H 02U 02J 02E 02Z 02G 02B 02M 02H 02N 02H 02U 02L 02S 02K 02P 02F 02Y
KO VI FI B- C-
PUMP LC
TRACTION LC
10W 300
RIGHT LEFT INVERTER
10W 300 AC-3 AC-3 AC-3
B+ 21C 21D B+ 21E B+
10W 300 122 75 275 400A 222 400A

POTENTIOMETER
F15 F17 F23
REV S/W TILT S/W
5A 5A 5A
196 496 91 05 696 396 222F 61 596 296
F26
195 95 122C 221 521 395 222F 62 295
194 494 98 122D 08 694 394 63 594 294
TILT
PARKING LEVELING
192 99 122E 301 392 222B 66 292
LEVELING
BRAKE OIL SBR
B+ 193 69 122F 393 222D 68 293
LIFT
SEAT S/W
LIMIT
191 92 122F 391 222C 67 291
LIMIT F25
ELECTRIC FORKLIFT DISPLAY 5A
121 92A 222E A10 INVERTER 265 65
LIFT
PUMP 21A 00A SELECT
POTENTIOMETER
09 SAFETY A12 11 220 64
F21 E/M 21E
5A SWITCH BATT+ A5 A20 SBR
93 793 120 420 7 NPOT A15 03
125F
CAN-T A4
PEDAL
07 LC COIL A2 A3
F19 F22
5A 126F 125E 5A
97 797 126A 272 72
TILT ANGLE
POTENTIOMETER
06 125 A19 CAN L 125D 04

125C
104 B- B-
MODE A31
-BATT A35
B-
B- 21B3-90103-00
7-2-8
余 ELECTRICAL CIRCUIT (10/14, UL, ZAPI, 40B-9 : #0014-0020, 45B-9 : #0006-0007, 50B-9 : #0015-0020)
F3 F5 F6 F9 F8 F10 F11 F12 F28 F29 F4

10A 5A 5A 5A 5A 5A 5A 5A 5A 5A 5A
20 23 24 27 26 26A 25 55 52 81 82 28
25B 25C
02C B 81A 81B 81B
5C 82A 82B 82B
LAMP C- E -HER LAMP LAMP
EMERGENCY KO HEAD UNIT 26C 26C S/W S/W SEAT
SWITCH L
SWITCH LAMP BACK HEATING
41 BACK
S/W BUZZER M M TNR M M TNR SWITCH
32 21B 22 BUZZER
40 S/W- HORN
T/S SWITCH 133
INPUT OUTPUT 48 KNOB RELAY FAN- 72 FAN- FAN- FAN-
KEY 43 44 44A S/W
49 49B RH CONT LH RH HEATER
S/W 80C 80D MOTOR MOTOR
42A BACK 80B H
42 BUZZER 59 47
45A 45 46A 80A 80E
33 23A RELAY
DC-DC
2 FR+
CONVERTER
EMERGENCY 80 220
43A 43A 44A 44A 46A 59A 47A
CONTACTOR 46B 49A 49B 49C
46 FAN
GND GND RELAY
(IN) (OUT)
B- LAMP TAIL STOP T/S B/U TAIL STOP T/S B/U T/S HORN TNR REAR LAMP BEA
02A LH RH T/S LAMP
-S/W LAMP LAMP WORK -S/W CON -S/W
21 BACKUP 7
COMBI. COMBI. -LH -RH LAMP LAMP
BUZZER FR-
00A LAMP LAMP
02U 02D 02J 02H 02H 02U 02J 02E 02Z 02G 02B 02M 02H 02N 02H 02U 02Y
-LH -RH 02F
KO VI FI B- C-
PUMP LC
TRACTION LC
10W 300
RIGHT LEFT INVERTER
10W 300 AC-3 AC-3 AC-3
B+ 21C 21D B+ 21E B+
10W 300 122 75 275 400A 222 400A

POTENTIOMETER
F15 F17 F23
REV S/W TILT S/W
5A 5A 5A
196 496 91 05 696 396 222F 61 596 296
F26
95 122C 221 521 395 222F 62 295
194 494 98 122D 08 694 394 63 594 294
TILT
PARKING LEVELING
192 99 122E 301 392 222B 66 292
LEVELING
BRAKE OIL SBR
B+ 193 69 122F 393 222D 68 293
LIFT
SEAT S/W
LIMIT
191 92 122F 391 222C 67 291
LIMIT F25
ELECTRIC FORKLIFT DISPLAY 5A
121 92A 222E A10 INVERTER 265 65
PUMP 21A 00A SELECT
09 SAFETY A12 11 220 64
F21 E/M 21E
5A SWITCH BATT+ A5 A20 SBR
93 793 120 420 7 NPOT A15 03
125F
CAN-T A4
PEDAL
07 LC COIL A2 A3
F19 F22
5A 126F 125E 5A
97 797 126A 272 72
A32 PPOTB CAN T A17 PPOTAUX A32 TILT ANGLE
POTENTIOMETER
06 125 A19 CAN L 125D 04

125C
104 B- B-
MODE A31
-BATT A35
B-
B-
21B3-90103-01
7-2-9
F3 F5 F6 F9 F8 F10 F11 F12 F28 F29 F4

10A 5A 5A 5A 5A TRF 5A 5A 5A 5A 5A 5A
20 23 24 27 TRF 26 26A 25 55 52 8182B 82 28

27A TILT 25B
TR+ 25C WORK BEACON
BRAKE B FLAS RELAY
02C 81A 81B 82A 82B
LAMP C- E -HER 320 LAMP LAMP
SWITCH L
41 BACK
32 21B 22 BUZZER
S/W- HORN
40 T/S SWITCH 133
INPUT OUTPUT 48 KNOB RELAY FAN- FAN- FAN- FAN-
KEY 43 44 44A S/W
S/W BACK 209 80C 80D MOTOR MOTOR
42A 115 80B H
42 BUZZER TR- 59 47
45A 45 46A 80A 80E
33 DC-DC RELAY
2 FR+
CONVERTER
EMERGENCY 115B 115B 115A 80
43A 43A 44A 59A 47A 220
CONTACTOR 44A 46A 49A 49B 49C
46B
46 FAN
GND GND RELAY
(IN) (OUT)
B- TAIL STOP B/U TAIL STOP B/U TILT- TILT- TNR REAR
LH LAMP RH T/S T/S T/S T/S HORN LAMP BEA LAMP
02A IN OUT WORK
21 -S/W LAMP LAMP -S/W CON -S/W 7
COMBI. COMBI. BACKUP VALVE VALVE LAMP
-LH -RH LAMP
LAMP LAMP BUZZER FR-
00A 02U 02D 02J -LH 02H 02H 02U 02J 02E 02Z 02X 02T 02V 02G 02B 02M 02H 02N 02H 02U 02Y
-RH 02F
KO VI FI B- C-
PUMP LC
TRACTION LC PUMP
INVERTER
10W 300 AC-3
TRACTION TRACTION
RIGHT LEFT 21E B+
KO A33 KEY
MOTOR
B+ 21C 21D B+ 222
KEY A33
RIGHT F27 TRACTION
MOTOR LIFT S/W V M
TRACTION 5A
10W 300 122 75 275 400A 222A 60
V V F23
M FWD S/W M TILT S/W
222F 5A
90 122A LOAD SENSING 74 61 596 296
POTENTIOMETER
F15 F17
5A REV S/W AUX1 S/W
5A 222F
196 496 91 05 NPOT A20 696 396 62 295
A25 PTHERM BACKWARD A6 PTHERM A25 A9 AUX 1 -BATT A24
F26 F24 TEMP SENSOR
ACCEL S/W 5A AUX2 S/W 5A
195 95 122C 221 521 395 63 594 294
TEMP SENSOR F16 F18 TEMP SENSOR TILT
5A BRAKE S/W MCV SOL. 5A LEVELING
194 494 98 122D 08 694 394 222B 66 292
LEVELING
PARKING SBR
192 99 122E 301 392 222D 68 293
LIFT
BRAKE OIL
B+ 193 69 122F 393 222C LIMIT 67 291
A13 (ENCODER A) BRAKE OIL A11 A34 -BATT ENCODER A A13 A4 LIFT ENCODER B A14
LIMIT F25
SEAT S/W
5A
191 92 122F 391 222E A10 INVERTER 265 65
A14 (ENCODER B) SEAT A4 ENCODER B A14 PPOT A3
LIFT
SELECT
POTENTIOMETER
121 92A 220 64
A29 PLC A4 SEAT FR+ A29 PFR CPOT A16
PUMP 21A 00A
09 SAFETY A12 11 7 NPOT A15 03
A28 NLC A28 SAFETY OUT FR- A28 NFR
F21 E/M 21E
5A SWITCH BATT+ A5
93 793 120 420 MODE A31 203
A3 PPOT PMC A27 A12 SAFETY
125F
CAN-T A4
ACCELERATOR 94 01
BATTERY A16 CPOT NMC A26 A34 -BATT A35
PEDAL
07 LC COIL A2 A3 320
F19 F22
5A 126F 125E 5A
97 797 126A 209 272 72
TILT ANGLE
POTENTIOMETER
06 125 A19 CAN L 125D 04

125C
104 B- B-
MODE A31
-BATT A35
B-
B-
21B3-90104-00
7-2-10
F3 F5 F6 F9 F8 F10 F11 F12 F28 F29 F4

10A 5A 5A 5A 5A TRF 5A 5A 5A 5A 5A 5A
20 23 24 27 26 26A 25 55 52 8182B 82 28
TRF 27A TILT 25B
TR+ 25C WORK BEACON
BRAKE B FLAS RELAY
02C 81A 81B 82A 82B
LAMP C- E -HER 320 LAMP LAMP
SWITCH L
41 BACK
32 21B 22 BUZZER
40 T/S S/W-
SWITCH
48 KNOB 133 HORN FAN- FAN- FAN- FAN-
KEY INPUT OUTPUT 43 44 44A S/W RELAY
S/W BACK 209 80C 80D MOTOR MOTOR
42A 115 80B H
42 BUZZER TR- 59 47
45A 45 46A RELAY 80A 80E
33 DC-DC
2 FR+
CONVERTER
EMERGENCY 115B 115B 115A 80
43A 43A 44A 59A 47A 220
CONTACTOR 44A 46A 49A 49B 49C
46B
46 FAN
GND GND RELAY
(IN) (OUT)
B- LAMP TAIL STOP T/S B/U TAIL STOP T/S B/U T/S T/S TILT- TILT- HORN TNR REAR LAMP BEA LAMP
02A LH RH
-S/W LAMP LAMP IN OUT WORK -S/W CON -S/W
21 COMBI. BACKUP 7
COMBI. -LH -RH VALVE VALVE LAMP LAMP
LAMP LAMP BUZZER FR-
00A 02U 02D 02J 02H -RH 02H 02U 02J 02E 02Z 02X 02T 02V 02G 02B 02M 02H 02N 02H 02U 02Y
-LH 02F
KO VI FI B- C-
PUMP LC
TRACTION LC PUMP
INVERTER
10W 300 AC-3
TRACTION TRACTION
21E B+
RIGHT LEFT KO A33 KEY
MOTOR
B+ 21C 21D B+ 222
KEY A33
RIGHT F27 TRACTION
MOTOR LIFT S/W V M
TRACTION 5A
10W 300 122 75 275 400A 222A 60
V V F23
M FWD S/W M TILT S/W
222F 5A
90 122A LOAD SENSING 74 61 596 296
POTENTIOMETER
F15 F17
5A REV S/W AUX1 S/W
5A 222F
196 496 91 05 NPOT A20 696 396 62 295
F26 F24 TEMP SENSOR
ACCEL S/W 222 AUX2 S/W
5A 5A
195 95 122C 221 521 395 63 594 294
TEMP SENSOR F16 F18 TEMP SENSOR TILT
5A BRAKE S/W MCV SOL. 5A LEVELING
194 494 98 122D 08 694 394 222B 66 292
LEVELING
PARKING SBR
192 99 122E 301 392 222D 68 293
LIFT LIMIT
BRAKE OIL /TRAC CTB
B+ 193 69 122F 393 222C 67 291
TRAC CUTBACK F25
SEAT S/W 5A
191 122F 391 222E 265 65
LIFT
SELECT
121 92 892 220 64
PUMP 21A 00A
09 92A 7 NPOT A15 03
F21 21E
5A BATT+ A5
93 793 SAFETY A12 11 202 MODE A31 203
125F
CAN-T A4
ACCELERATOR 94
PEDAL
80V CAN-H CAN-L
07 A2 A3 320
F19 70 F22
5A 126F 125E 5A
97 797 126A 209 272 72
TILT ANGLE
POTENTIOMETER
STEERING 96 126 126D A18 CAN H 70
A21 CPOTB CAN H A18 A18 CAN H CPOTAUX A21
SENSOR
06 125 A19 CAN L 125D 04

E/M 125C
SWITCH B- B-
104 120 420
A31 MODE PMC A27
01
A35 -BATT NMC A26
TRACTION
LC COIL
B-
B-
21B3-90104-01
7-2-11
余ELECTRICAL CIRCUIT (13/14, UL, ZAPI, 40B-9 : #0066-, 45B-9 : #0051-, 50B-9 : #0153-)
F3 F5 F6 F9 F8 F10 F11 F12 F28 F29 F4

10A 5A 5A 5A 5A TRF 5A 5A 5A 5A 5A 5A
20 23 24 27 TRF
26 26A 25 55 52 8182B 82 28
27A TILT
26C 26C TR+ 25C WORK BEACON
BRAKE B FLAS RELAY
02C 81A 81B 82A 82B
LAMP C- E -HER BZC 320 HORN LAMP LAMP
EMERGENCY KO BACK S/W- S/W SEAT
HEAD SWITCH L UNIT S/W
SWITCH BUZZER KNOB/ HEATING
LAMP BACK HORN
S/W 41 S/W- F-TIP TNR TNR SWITCH
32 21B BUZZER SWITCH/ M M M M
22 KNOB/ BLUE
40 T/S SWITCH REAR 133 HORN SPOT
INPUT OUTPUT 48 F-TIP FAN- FAN- FAN- FAN-
KEY 43 44 44A S/W BZO GRIP RELAY JUMPER RH CONT LH RH
S/W 49 SW(OPT) HEATER
209 80B 80C 80D MOTOR MOTOR
42A 115 H
42 TR- 59 47
45A 45 46A BACK 80A 80E
33 DC-DC
BUZZER FR+
2 CONVERTER
RELAY 115B 115B 115A 80
EMERGENCY 43A 220
43A 44A 44A 46A 59A 47A
CONTACTOR 46B 49A 49B 49C
46 FAN
GND GND RELAY
(IN) (OUT)
B- TAIL STOP B/U TAIL STOP B/U TILT- TILT- TNR REAR
LH LAMP RH T/S T/S T/S T/S HORN LAMP BEA LAMP
02A IN OUT WORK
21 -S/W LAMP LAMP -S/W CON -S/W 7
COMBI. COMBI. BACKUP VALVE VALVE /BLUE
-LH -RH LAMP
LAMP LAMP BUZZER SPOT FR-
00A 02U 02D 02J -LH 02H -RH 02H 02U 02J 02E 02Z 02X 02T 02V 02G 02B 02M LAMP 02N 02H 02U 02Y
02H 02F
KO VI FI B- C-
BZG PUMP LC
TRACTION LC PUMP
INVERTER
10W 300 AC-3
TRACTION TRACTION
RIGHT LEFT 21E B+
KO A33 KEY
MOTOR
B+ 21C 21D B+ 222
KEY A33
RIGHT F27 TRACTION
MOTOR LIFT S/W V M
TRACTION 5A
10W 300 122 75 275 400A 222A 60
MOTOR U 400A COMMON A30 TDI PPOT A32 U A5 LIFT ENABLE W
V V F23
M FWD S/W M FINGER TIP/ TILT S/W
222F 5A
90 122A LOAD SENSING 74 DIRECTION KNOB OPTION 61 596 296
POTENTIOMETER
F15 FWI F17 FNR
5A REV S/W AUX1 S/W
5A CONTROLLER FNR 222F
196 496 91 05 NPOT A20 696 396 62 295
SWITCH
BWI F26 00 F24 TEMP SENSOR
ACCEL S/W B- B5 BAT- AUX2 S/W
5A 920 5A
95 122C 221 521 395 26 B1 +5V 63 594 294
A24 NTHERM ACCEL A7 A27 PLC NTHERM A24 BZC A1 +12V A8 AUX 2 ENCODER VCC A1
TEMP SENSOR TEMP SENSOR 901
F16 F18 48 B2 SIG 1 TILT
5A BRAKE S/W MCV SOL. 5A BZO A2 NO LEVELING
194 494 98 122D 08 694 394 902 222B 66 292
A1 (ENCODER VCC) PB A8 A26 NLC ENCODER VCC A1 02 B3 SIG 2 A4 TILT ENCODER GND A2
BZG A3 -12V LEVELING
900
PARKING 90 B6 GND SBR
192 99 122E 301 392 FWI A4 FWD 222D 68 293
91 LIFT LIMIT
BWI A5 BWD
BRAKE OIL /TRAC CTB
B+ 193 69 393 122 222C 67 291
122F TDI B4 BAT+ A11 LIFT LIMIT/ ENCODER B A14
A13 (ENCODER A) BRAKE OIL A11 A34 -BATT ENCODER A A13
TRAC CUTBACK F25
SEAT S/W 5A
191 122F 391 222E 265 65
LIFT
SELECT
121 92 892 220 64
PUMP 21A 00A
09 92A 7 NPOT A15 03
F21 21E
5A BATT+ A5
93 793 SAFETY A12 11 202 MODE A31 203
125F
CAN-T A4
ACCELERATOR 94
PEDAL
80V CAN-H 00C CAN-L
07 A2 A3 320
F19 F22
5A 126F 125E 5A
97 797 126A 209 272 72
TILT ANGLE
POTENTIOMETER
06 125 A19 CAN L 125D 04

E/M 125C
SWITCH B- B-
104 120 420
A31 MODE PMC A27
NPOT A30
01
A35 -BATT NMC A26
TRACTION
LC COIL
B-
B- 21B3-90105-00
7-2-12
余ELECTRICAL CIRCUIT (14/14, FINGERTIP, 40B-9 : #0034-, 45B-9 : #0016-, 50B-9 : #0022-)
CAN TILLER MHYRIO CB
FT LIFT
00B 500 500A 21/922 324
B- B2 -BATT NPOT C3 1 GND VI B2 PAUX C2 +
LIFT UP
V/V
00B 520 520A 21/321 301
A16 -BATT PPOT A9 2 POWER FI B1 KEY C3 -
560 00A 324A

SIG A C2 3 VOUT A B- B3 -BATT +
LOWERING
FT AUX V/V
501A 561 00A 302
GND 1 SIG B A10 4 VOUT B C23 -BATT C1 -
A12 NPOT
FT TILT
520C 500A 325
POWER 2 A9 PPOT 1 GND C5 +
AUX IN
V/V
569 520B 303
VOUT A 3 C8 AUX2 2 POWER C4 -
562 325A
VOUT A 4 TILT DOWN A11 3 VOUT A +
AUX OUT
V/V
564 304
TILT UP A13 4 VOUT B C6 -
FT SIDE SHIFT
501 326
NPOT A12 1 GND C8 +
TILT UP
V/V
126A 520C 305
B4 CAN_H 2 POWER C15 -
125A 567 326A

B1 CAN_L AUX1 C7 3 VOUT A +
TILT DOWN
V/V
722 306
B3 +12 4 VOUT B C7 -
722 329
B10 PPOS C13 +
SHIFT
RIGHT
125 307 V/V
B4 CAN_L C14 -
126 329A
B13 CAN_H +
SHIFT
LEFT
308 V/V
C12 -
125A
126A
CAN H A18
CAN L A19
PUMP
INVERTER
AC3
21B3-90032-00
7-2-13
GROUP 3 ELECTRIC COMPONENTS
1. FUNCTIONS OF BATTERY FORKLIFT TRUCK AND ELECTRIC COMPONENTS

The major functions of forklift truck can be divided into DRIVING FUNCTION and LOADING and
UNLOADING FUNCTION.
All the components that work DRIVING and LOADING & UNLOADING functions are driven by AC
motors. And as the BATTERY works as power source of these motors, a charging device is needed.
To drive the fork lift truck, a DRIVING CONTROL SYSTEM and some electric components such as
direction change lever (forward/reverse section switch) and accelerator are required to select the
driving direction and to control the speed of driving motor.
The CONTROL SYSTEM includes some protective circuits that protect the equipment and
components from malfunctioning.
A MONITORING SYSTEM is installed in the monitor panel, which monitors the equipment and
working condition, and let the operator take proper action. For the monitoring system, there are many
sensors such as current sensors, potentiometer sensors, and temperature sensors. The HYUNDAI
Battery forklift trucks are equipped with the most advanced DRIVING CONTROL SYSTEM currently
available world-widely. The operator friendliness features enable him to set the truck conditions
properly according to each working circumstance easily on his seat, and the SELF-DIAGNOSTIC
function displays current status of truck in working.
7-3
2. BATTERY
1) STRUCTURE
6 4
1
2
3
8 12
10
11
40B9EL03
1 Cells 6 Cable connector

2 Steel box 8 Negative leading cable
3 Cell connector 10 Handle (red)
4 Row connector 11 Plug
5 Terminal connector 12 Positive leading cable
7-4
2) GENERAL
As in the battery forklift, the battery is an
energy source, the handling of the battery
is very important.
The life and performance of the battery
greatly depend on the ordinary handling
and maintenance. Therefore, be sure to
check and maintain the battery so that it
may be kept best. 40B9EL04
3) SPECIFICATION AND SERVICE DATA
Item Unit 40/45/50B-9

Type - Lead Acid
Rated voltage V 80
Capacity AH/hr 700
Electrolyte - WET
Dimension (W×D×H) mm 1025×996×784
Connector - Black
Weight kg 2095/2435
Fully charged specific gravity 1.280 (25°C)

End of discharge specific gravity 1.120 (25°C)
Discharge end voltage 80V
Electrolyte Refined dilute sulfuric
Replenishment fluid Refined (pure) water
Insulation resistance 1MΩ
7-5
4) SAFETY PRECAUTIONS
(1) When sulfuric acid contact with skin
For acid contact with skin, eye or clothing, flush with water immediately. If swallowed, drink a large
amount of water or milk. Seek medical attention immediately. When handling acid, always wear
eye goggles or a face shield and rubber gloves.
(2) Strict prohibition of fire and ventilation
Since batteries generate explosive hydrogen gas, no fire should be drawn near. Before the battery
charging, keep the battery cover open and check the ventilation status. Charging in an enclosed
space can cause an explosion.
(3) Never place metallic articles on the batteries
If done so, it may cause "short circuit" accidents (dangerous especially while charging)
(Especially dangerous while charging).
Sparks will be generated which is equally dangerous as open fires.
(4) Handling of charger
When connecting or disconnecting a battery from a charger or attempting maintenance, make
sure switches are all off. Ensure that the charger and the battery are matched. If a 300Ah battery
is used with a charger designed to charge a 500Ah battery, it will severely overcharge the battery.
5) OPERATION PRECAUTIONS
(1) Avoid over-discharge
If over-discharged, it will be difficult to restore the batteries to the original state by recharge. In
order to maintain the batteries in use for long period of time, it is recommended to use the
batteries with discharge amount not exceeding 80% of the rated capacity. Further care should be
taken for preventing the unit cell voltage from falling below 1.5V.
(2) Avoid over-charge
If overcharged, the rise in battery temperature will become excessive, resulting in deterioration of
plates and other parts and markedly shortening of battery life.
(3) Avoid excessive elevation of temperature
Be sure to open the cover of battery housing tray before charging. If there is a possibility of
temperature to exceed 55°C, discontinue the charge operation temporarily, or reduce the charge
current.
6) CHECKING
(1) Unpacking
Electric traction storage batteries (herein after refer to as "batteries") are delivered to customers in
dry-charged condition. At unpacking, check whether the batteries and accessories have been
damaged. If there are observed defects, you should notify the condition to our branch office or
agent. Never remove the sealing plug until the battery is put into service.
7-6
(2) Performance and maintenance of batteries
① Initial charge
Wet-charged battery gradually decreases its capacity during storage. In order to provide
sufficient discharge capacity in the first discharge, the good initial charge is required. The
conditions of initial charging are seen as below at room temperature.
a. By modified constant voltage charger
Connect the battery to the charger and turn on the equalizing charge "ON." The battery will be
fully charged and terminated automatically.
b. By constant voltage constant current charger (standard)
Connect the battery to the charger and turn on the equalizing charge "ON." The battery will be
fully charged and terminated automatically.
c. By constant current charger
Connect the charger to the battery and charge the battery by 0.1C×5 hour rate nominal
capacity current for 24 hours or more. The charge shall be terminated when one of the following
conditions is identified.
·When a constant value is indicated for more than 1 hour after the battery voltage has
reached the maximum value.
·When more than 1 hour of charge is continued after the electrolyte specific gravity has risen
fully and becomes constant.
② Discharge and capacity
The capacity of batteries is indicated at 5 hour rate capacity which means the battery can be
discharged for 5 hours with the discharge current calculated by dividing the capacity value by 5
until the unit cell mean voltage reaches down to 1.7V at the electrolyte temperature of 30°C.
That is, the capacity is indicated by AH (ampere hour) being calculated as the product of ampere
(A) and time (H). However, even if it is the same type of batteries, the capacity varies with the
discharge conditions (discharge current, battery temperature and specific gravity of electrolyte).
Even if the batteries discharged its full capacity, if immediately charged to full, there will be no
harmful effects remained. Ideal charging amount (AH) is 110-125% of the amount of previous
discharge.
③ Specific gravity of electrolyte
Specific gravity of electrolyte drops at discharge and rises at charge. When the batteries are fully
charged, it becomes almost constant and shows no further rise. The specific gravity value varies
with the change in temperature. Therefore specific gravity measurement should be made with
temperature of electrolyte at the same so the measured specific gravity value could be corrected
to that at the standard temperature of 25°C by the following formula.
S25 = St + 0.0007 (t-25)
Where, S25 : Specific gravity at 25°C
St : Actually measured specific gravity at t°C
t : Electrolyte temperature (°C)
The standard specific gravity for this type of battery is 1.280±0.01(25°C) at full charge condition.
If the electrolyte is decreased naturally while using, distilled water shall be replenished up to the
specified level. (Never refill sulfuric acid).
Only when large quantity of electrolyte is lost due to spillage, etc., dilute sulfuric acid specified in
gravity shall be added.
7-7
④ Normal charge
Charge the discharged batteries as quickly as possible. The temperature of electrolyte before
starting the charging operation shall preferably be below 45°C, and the temperature during the
charge should be maintained at no higher than 55°C. (Under any unavoidable situations, it
should never be above 55°C). Methods of charging vary in precise meaning with the types of
chargers used. A standard charging method is described hereunder. (If a special method is
mentioned to be adopted, follow that instruction).
a. Charging by modified constant voltage automatic charger
There is almost automatic charger today which completes the charging just only connecting the
plug between battery and charger without outer operating timer. But if your charger has it, after
setting the timer for 3-4 hours and turn on the charger and the charger is left as it is, then the
charge will be made automatically. In principle, regardless of the amount of previous discharge,
it is not required to alter the setting of timer time. The recommendable current value of this type
of charger is "5 hour rate current ×1.0~1.5" at the start of charging, and at the final stage it is "5
hour rate current ×0.15~0.25". Normally the charge is terminated within 8~12 hours
automatically.
b. Charging by constant current constant voltage automatic charger
After a lapse of specified charging time after the switch is turned on, the charge will be
completed by turning off the switch. The charging time can be calculated by the following
formula.
Amount of previous discharge(AH)
Charging time = + 2~3(H)
Capacity of charger(A)
When the amount of previous discharge is not known, use the 5 hour rate rated capacity of the
batteries. At immediately after charging, the charge current is allowed up to 3 times 5 hour rate
current. For charger provided with a timer, the charge will terminate automatically if the timer is
set at the specified time according to the operation manual.
c. Charging by constant current charger
Connect the charger to the battery and charge the battery by 0.1C×5 hour rate nominal
capacity current for 24 hours or more. The charge shall be terminated when one of the following
condition is identified.
⑤ Equalizing charge
When large number of cells are used in a set of battery, the voltage and specific gravity of
respective cells tend to become unequal, resulting in necessity of charging all the cells at an
appropriate time in order to equalize them. This is called equalizing charge. Normally the
equalizing charge should be carried out once every month. The methods are in normal type
charger, extend the charge for 5 more hours after full charge at the final stage current, and in
automatic charger which is in most cases provided with timer, extend the time setting for 3-6
more hours.
7-8
⑥ Replenishment of distilled water
Only the water content of electrolyte is decreased due to electrolysis of distilled water during
charge and natural evaporation. If a battery used with the electrolyte decreased excessively,
plates will deteriorate resulting in markedly shortening of battery life. Be sure to check the
electrolyte level once every week. If the electrolyte level is lowered, replenish distilled water up to
the specified level. In this case, never attempt to replenish sulfuric acid or tap water. Use only
distilled water for battery replenishment. If the amount of water required for weekly addition to a
unit cell for 100AH of battery capacity is in excess of 45 cc, it is assumed that the cell is receiving
overcharge. Accordingly, be sure to reduce slightly the daily charge amount. Under the normal
conditions, the addition of water per week is 45 cc or less. Incidentally, distilled water
replenishment should be made before charging to the content of minimum level. (For the
purpose of uniform stirring of electrolyte by charging).
If the electrolyte level is improper after completion of charging, you may topping up the
electrolyte level to the maximum level.
a. Determination of replenishment time and methods (cell with ONE TOUCH CAP)
Confirm the electrolyte level by looking at the float in the ONE TOUCH CAP. If too low as shown
in figure, replenish distilled water. Replenishment shall be performed after opening the cover of
the plug using syringe and jug. When refilling is completed, close each cover completely until
"click" sound is heard.
Minimum Level Maximum Level
Cell cover
Cell cover
Float Float
B153EL041 B153EL042
7-9
⑦ Cleaning
If electrolyte spills or the cells are polluted with dust or stains, it will cause generation of leak
current. Wipe off dust and stains with moist cloth and clean in such a manner that the cells are
kept in dry condition. In the case of plastic containers or covers, never use such organic solvents
as paint thinner and gasoline. If used, the plastic containers or covers may suffer cracking. If you
are forced to use them, be sure to use white kerosene.
⑧ Notice on charging
The charging area must be well ventilated to facilitate exhaust of gas generated from the battery
during charging. Charge the battery in an area free from iron working, welding, etc. Further the
battery generates hydrogen, oxygen, acid mist and on rare occasions, hydrogen sulfide during
charging depending on the case. Special care may be required in the case of equipment and
objects near the battery that may contaminated or damaged. Do not pull out the charging plug
during charging, as it will cause sparks. Since hydrogen gas generated during charging may
remain in the area surrounding the battery after charging, never bring fire or flame close to this
area. In case of counter-balance type vehicles, open the battery cover before charging.
⑨ Repair of failure cell
a. To remove a cell from the circuit or battery from steel tray, it is first necessary that the intercell
connector be removed.
b. Before performing any repairs, you must open one-touch caps for gas purging of all cells. After
you have finished that, must remove connector covers and on-touch caps from failure cell
including surrounding cells. All vent holes of cells removed of one-touch caps must cover by
four layers of water dampened cloth and then proceed with repairs. Using an acid syringe
withdraw sufficient electrolyte from failure cell to reduce the liquid levels until minimum level
indicating of one touch caps.
c. The safe and most efficient method of removing a connector from failure cell as well as all
surrounding cells is with hand or electric drill (25 mm).
You must make sure to clear of explosive hydrogen gas in the cells before repairs. Be
careful not to drill to far into the cell and damage the unit. During drilling operation make
sure lead curls produced do not contact opposite cell poles and cause a spark.
d. Upon completion of drilling the intercell connectors, can be lifted off.
e. Lifted off the failure cell from circuit after removing of intercell connector.
f. Installing new cell and connector.
g. With surfaces properly cleaned and neutralized, position the connectors.
h. Place damp rags around each lead head. Hold tip of the welder in center of post move welder
completely around top of post and out to the area where the post meets the connector. Move
welder back to center of post and add molten lead until area is filled to top of connector. Again,
move welder completely around area, with tip on molten lead. If you have jig for welding
connector, have easier and better welding work.
i. When replacing electrolyte in a repaired cell, use sulphuric acid of the same specific gravity that
is found in the balance of the battery.
j. Finally, rejoin connector covers and one-touch caps to the cells.
7-10
⑩ Summary of daily maintenance
a. Avoid overcharge. After discharge, charge the batteries immediately. The standard frequency of
equalizing charge is more than once every month.
b. Be sure to check the electrolyte level once every week. If found decreased, replenish distilled
water up to the specified level.
c. The top surface of battery cells should be kept clean and dry.
d. Be sure to keep open the cover of battery housing tray during charge.
e. Never draw near open fires such as lighted cigarettes or burning matches during charge.
(3) Others
① Storage of batteries
When batteries are stored, keep them away from room heaters or other heat generating sources.
Clean, cool and dry place where no direct sunlight is suited for battery storage. Before putting
into storage, it is important to charge the batteries and keep the electrolyte level at the specified
level.
When the temperature in storage location is higher than 20°C, check the specific gravity once a
month, and when lower than 0°C, check it once every two months. If the measurements show
values lower than 1.230 (20°C), it is required to charge the battery in accordance with the
method described in NORMAL CHARGE.
② Maintenance record
It is recommended to keep maintenance record in order to know the operational conditions of
batteries. Daily charge and discharge, equalizing charge requirements, and distilled water
replenishment requirements can be clarified at a glance. Measurements of specific gravity and
temperatures once every two to four months after equalizing charge and maintenance thereof
will serve for battery health diagnosis.
③ Electrolyte temperature
The operating temperature range of batteries is -10~45°C (temperature of electrolyte). If the
batteries are exposed to cold atmosphere in discharged condition, the electrolyte may freeze, and
in extreme cases, the capacity will be decreased, but, if not frozen, no adverse effects will be
exerted.
Contrarily if the temperature is high, especially if used at above 55°C, the battery life will be
considerably shortened. Care must be taken so that the temperature during charge will be
maintained at 55°C or lower. Even under unavoidable circumstances it should not exceed 55°C.
7-11
7) TROUBLESHOOTING
Nature of trouble Symptoms Causes Corrective Action
Deformation · Deformation of container. · Excessive temperature · Replace
Lid or one touch cap rising or external impact
Breakage · Electrolyte leakage acco- · External impact, improper · Replace or install a new
rding to breakage of cont- handling, excessive vibrat- one
ainer, lid or one touch cap ion
· Termination of connector · Excessive temperature · Replace
or pole post etc. rising or external impact
Sulfate · Specific gravity drops and · When left in state of disch- · Need equalizing charge
capacity is decreased. arge or left long without
equalizing charge.
· Charge voltage rises rapi- · Insufficient charge. · Need equalizing charge
dly with immature gassing · When electrolyte is so de- · Need equalizing charge
in earlier stage but specific creased that plate is de-
gravity does not rise and posed.
charge can't be carried · When concentration of · Adjust specific gravity
out. electrolyte rises.
· When impurities are mixed · Replace electrolyte
in electrolyte.
Decrease and · May be easily detected by · Rise of temperature due to · Replace
falling of specific measurement of the spec- such trouble.
gravity ific gravity. · When left long period with- · Refill water in regular per-
out refilling of water. iod
· Short circuit. · Replace
Rise of specific · May be easily detected by · Diluted sulfuric acid is · Adjust specific gravity after
gravity measurement of the spec- used in refilling. full charge.
ific gravity. · When the electrolyte level · Refill distilled water.
excessively drops.
Mixing of · Decrease of capacity. · Metals such as iron, copper · Under a fully discharged
impurities nickel and manganese. condition, pour out the
· Drop of charge and disch- · Impurities such as sea electrolyte. Then pour in
arge voltage. water, chloric acid, nitric an acid of the specific
acid etc. gravity higher by 0.03~0.05
· Odor of generated gas and · Filling of impure water. than that of the drained
coloring of the electrolyte. acid. Charge fully and
adjust the specific gravity to
the specified value.
7-12
3. DRIVE MOTOR
1) STRUCTURE
9
4
3 10
12
11
40B9EL07
1 Rotor 5 Block-Terminal A 9 Bearing

2 Stator 6 Speed sensor kit 10 Bearing
3 Endbell De 7 Stud bolt 11 Oil seal
4 Endbell 8 Protector-Terminal 12 O-ring
7-13
2) SPECIFICATION
Item Unit Specification

Type - AQDU4001
Rated voltage Vac 50
Rated output kW 10.0
Insulation - Class F
3) MAINTENANCE INSTRUCTION
※ Before starting the maintenance please disconnect the power supply.
(1) Ball bearing
Both ball bearing are maintenance free. Should it be necessary to remove the bearings in case of
repair, they should be replaced. In any case the sealing parts (shaft sealing ring etc.) have to be
replaced.
If a bearing which is to be replaced has only one sealing lip, this should be greased with quality
bearing grease.
After approximately 10,000 operating hours the bearings have to be replaced.
(2) Disassembly and assembly
The motor is assembled and disassembled according to the relevant drawing and part list. (See
page 7-13)
7-14
4. PUMP MOTOR
1) STRUCTURE
4
5
9
7
1
9
10
40B9EL08
1 Rotor 5 Block-Terminal A 9 Bearing

2 Stator 6 Speed sensor kit 10 Oil seal
3 Endbell De 7 Stud bolt
4 Endbell 8 Protector-Terminal
7-15
2) SPECIFICATION
Type - AQDV4001
Rated voltage Vac 50
Rated output kW 28
Insulation - Class F
3) INTERNAL INVOLUTE SPLINE DATA
Flat root side fit - Class 7

No of teeth EA 13
Spline pitch mm 16/32
Pressure angle Degree 30
Major diameter mm 22.8854
Form diameter mm 22.3266
Minor diameter mm 19.152
Pin diameter mm 2.7432
4) MAINTENANCE INSTRUCTION
※ Before starting the maintenance please disconnect the power supply.
(1) Ball bearing
Both ball bearing are maintenance free. Should it be necessary to remove the bearings in case of
repair, they should be replaced. In any case the sealing parts (shaft sealing ring etc.) have to be
replaced.
If a bearing which is to be replaced has only one sealing lip, this should be greased with quality
bearing grease.
After approximately 10,000 operating hours the bearings have to be replaced.
(2) Disassembly and assembly
The motor is assembled and disassembled according to the relevant drawing and part list. (See
page 7-15)
7-16
5. CONTROLLER SYSTEM
1) STRUCTURE
35B7EL10
(1) Specifications
Model Model Application Type Power Current limit
AC3 Traction MOSFET 80V, 600A 600A/3min

40/45/50B-9
AC3 Pump MOSFET 80V, 600A 600A/3min
7-17
2) OPERATIONAL FEATURES
(1) Features
① Speed control.
② Optimum behavior an a slope due to the speed feedback:
·The motors speed follows the accelerator, starting a regenerative braking if the speed
overtakes the speed set-point.
·The system can perform an electrical stop on a ramp (the machine is electrically hold on a
slope) for a programmable time.
③ Electronic differential feature with torque balance between external and internal wheel.
④ Regenerative release braking based upon deceleration ramps.
⑤ Regenerative braking when the accelerator pedal is partially released (deceleration).
⑥ Direction inversion with regenerative braking based upon deceleration ramp.
⑦ Regenerative braking and direction inversion without contactors: only the main contactor is
present.
⑧ Optimum sensitivity at low speeds.
⑨ Voltage boost at the start and with overload to obtain more torque (with current control).
⑩ Hydraulic steering function:
·The traction inverter sends a "hydraulic steering function" request to the pump inverter on the
can-bus line.
⑪ Backing forward and reverse options are available, with the tune and the speed of the function
programmable with Zapi console or buttons on a display.
⑫ High efficiency of motor and battery due to high frequency commutations.
⑬ Modification of parameters through the programming console or buttons on a display.
⑭ Internal hour-meter with values that can be displayed on the console.
⑮ Memory of the last five alarms with relative hour-meter and temperature displayed on the
console.
16 Diagnostic function with Zapi console for checking main parameters.
17 Built in BDI feature.
18 Flash memory, software downloadable via serial link and via CANBUS.
(2) Diagnosis
The microcontrollers continually monitor the inverter and carry out a diagnostic procedure on the
main functions. The diagnosis is made in 4 points.
① Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor charging,
phase's voltages, contactor drivers, can-bus interface, if the switch sequence for operation is
correct and if the output of accelerator unit is correct, correct synchronization of the two μCS,
integrity of safety related inputs hardware.
② Standby diagnosis in standby that checks: Watchdog circuit, phase's voltages, contactor driver,
current sensor, can-bus interface.
③ Diagnosis during operation that checks: Watchdog circuits, contactor driver, current sensors, can-
bus interface.
④ Continuous diagnosis that checks: Temperature of the inverter, motor temperature.
Diagnosis is provided in two ways. The digital console can be used, which gives a detailed
information about the failure; the failure code is also sent on the Can-Bus.
7-18
3) DESCRIPTION OF THE CONNECTORS
(1) Traction controller (Master)
Rubber cap
(No. of pin B1~B8)
A12
A1
A13 A23
A24 A35
VIEW A
35B7EL14
7-19
No. of Pin Function Description
A1 +12V Positive of encoder power supply.

A2 +12V Negative of encoder power supply.
A3 PPOT Accelerator potentiometer positive : 10V output; keep load > 1kΩ.
A4 SEAT SEAT input; it must be connected to the SEAT microswitch; it is active high.
A5 FORWARD Forward direction request input. It must be connected to the forward
direction microswitch; active high.
A6 BACKWARD Backward direction request input. It must be connected to the backward
direction microswitch; active high.
A7 EX.HYDRO/ Exclusive hydro or accelerator enable function input. It must be connected
ACCEL ENABLE to the exclusive hydro microswitch or to the accelerator enable switch; active
high.
Brake request input. It must be connected to the brake pedal switch; active
A8 PB
high.
A9 SR/HB Speed reduction (handbrake) input; Active low (switch opened).
A11 BRAKE OIL Brake oil switch input active high
If not connected to -SLAVE A28 (safety out), MC coil power output will be
A12 SAFETY
disabled. It can also be used as a general purpose input.
A13 ENC A Phase A of encoder.
A14 ENC B Phase B of encoder.
A15 NPOT Negative of accelerator unit, tested for wire disconnection diagnosis.
A16 CPOT Accelerator potentiometer wiper.
CAN-Termination; conect to CAN H (A18) to insert can termination
A17 CAN T
resistance
A18 CAN H High level CAN-BUS voltage I/O.
A19 CAN L Low level CAN-BUS voltage I/O.
A20 NPOTB -Batt.
A21 CPOTB Steering potentiometer wiper.
A24 NTHERM -Batt.
A25 PTHERM Input for motor temperature sensor.
A26 NMC Negative of main (traction) contactor coil.
A27 PMC Positive of main (traction) contactor coil.
A28 NLC Negative of pump line contactor coil.
A29 PLC Positive of pump line contactor coil.
A30 CM Common of FW / BW / HB / PB / SEAT / Brake oil / ENABLE microswitches.
A31 MODE MODE: Closed(connected with A35): Traction master.
A32 PPOTB Steering potentiometer positive : 10V output; keep load > 1 k
7-20
Connected to the power supply through a microswitch (CH) with a 10A fuse
A33 KEY
in series.
A34 -BATT -Batt.
B1 PCLRXD Positive serial reception.
B2 NCLRXD Negative serial reception.
B3 PCLTXD Positive serial transmission.
B4 NCLTXD Negative serial transmission.
B5 GND Negative console power supply.
B6 +12 Positive console power supply.
B7 FLASH It must be connected to B8 for the Flash memory programming.
7-21
Encoder installation
① Traction controller card is fit for different types of encoder. To control AC motor with Zapi inverter,
it is necessary to install an incremental encoder with 2 phases shifted of 90˚. The encoder power
supply can be +12V. It can have different electronic output.
C11/C1 : +12V : Positive of encoder power supply.
C12/C2 : GND : Negative of encoder power supply.
C22/C13 : A : Phase A of encoder.
C23/C14 : B : Phase B of encoder.
② Connection of encoder with open collector output; +12V power supply.
20B7EL26
③ The encoder power supply voltage and output electronic has to be communicated to ZAPI in
order to correctly set the selection jumpers in the logic card.
7-22
(2) Traction controller (Slave)
Rubber cap
(No. of pin B1~B8)
A12
A1
A13 A23
A24 A35
VIEW A
35B7EL14
7-23
A1 +12V (+5V) Positive of encoder power supply.

A2 +12V (+5V) Negative of encoder power supply.
A4 SEAT SEAT input; it must be connected to the SEAT microswitch; it is active high.
A12 SAFETY OUT If not connected to -Batt (A34) MC coil power output will be disabled. It can
also be used as a general purpose input.
A20 NPOTB -Batt. Negative of load sensing potentiometer (optional).
(Load sensor)
CPOTB Load sensing potentiometer wiper (optional).
A21
(Load sensor)
A24 NTHERM -Batt.
A25 PTHERM Input for motor temperature sensor.
A26 NMC Negative of MCV sol coil.
A27 PMC Positive of MCV sol coil.
A28 SAFETY OUT If not connected to MASTER A12 (SAFETY), MC coil power output will be
disabled. It can also be used as a general purpose input.
A31 MODE Open(No connection): Traction slave.
A32 PPOTB Load sensing potentiometer positive : 10V output; keep load > 1kΩ.
(Load sensor)
A33 KEY Connected to the power supply through a microswitch (CH) with a 10A fuse
in series.
A34 -BATT -Batt.
B5 GND Negative console power supply.
B6 +12 Positive console power supply.
7-24
Encoder installation
① Traction controller card is fit for different types of encoder. To control AC motor with a inverter, it is
necessary to install an incremental encoder with 2 phases shifted of 90。. The encoder power
supply can be +12V. It can have different electronic output.
C11/C1 : +12V : Positive of encoder power supply.
C12/C2 : GND : Negative of encoder power supply.
C22/C13 : A : Phase A of encoder.
C23/C14 : B : Phase B of encoder.
② Connection of encoder with open collector output; +12V power supply.
20B7EL26
7-25
(3) Pump controller
22B7EL14
A1 +12V Positive of encoder power supply.

A2 ENC GND Negative of encoder power supply.
A3 PPOT Lift potentiometer positive: 10V output; keep load > 1kΩ.
A4 TILT LEVELING Tilt levelling switch input; it is active HIGH.
A5 LIFT ENABLE Input for potentiometer lifting enable input; it is active HIGH.
A6 TILT UP/DOWN Input for tilt up and tilt down digital input; it is active HIGH.
A7 SBR SBR (side battery removal) switch input; it is active HIGH.
A8 AUX IN/OUT Input for aux in and aux out digital input; it is active HIGH.
A9 SHIFT RGT/LFT Input for shift right and shift left digital input; it is active HIGH.
A10 INVERTER SELECT Inverter selection input; Active low.
A11 LIFT LIMIT Lift limit switch input; Active low.
A12 SAFETY If not connected to -batt the MC coil power output will be disabled. It can
also be used as a general purpose input.
A15 NPOT Negative of accelerator unit, tested for wire disconnection diagnosis.
A16 CPOT Lift potentiometer wiper.
A17 CAN T CAN termination; connect to CAN H (A18) to insert can termination
resistance.
7-26

A20 NPOT-AUX (TILT ANGLE) Negative of tilt angle potentiometer.
A21 CPOT-AUX (TILT ANGLE) Tilt angle potentiometer wiper.
A22 ENC A* Phase A inverted of encoder (encoder with differential output).
A23 ENC B* Phase B inverted of encoder (encoder with differential output).
A24 -BATT -Batt.
A25 MOT TH Input for motor temperature sensor.
A26 NTR Negative of tilt relay coil.
A27 PTR Positive of tilt relay coil.
A28 NFR Negative of fan relay coil.
A29 PFR Positive of fan relay coil.
A30 CM Common of digital microswitches.
A31 MODE This input allows the customer to select the software for traction or
lifting application. To be connected with A35.
A32 PPOT-AUX Tilt angle potentiometer positive: 10V output; keep load > 1kȳ.
A33 KEY Connected to the power supply through a microswitch(CH) with a
10A fuse in series.
A34 -BATT -Batt.
A35 -BATT -Batt/To be connected with A31.
B5 GND Negative console supply.
B6 +12V Positive console supply.
B7 FLASH It must be connected to B8 for the flash memory programming.
B8 FLASH It must be connected to B7 for the flash memory programming.
7-27
4) FUNCTION CONFIGURATION
■ TRACTION CONTROLLER-MASTER
Using the CONFIG MENU of the programming console, or using a display, the user can configure
the following functions.
(1) Submenu "SET OPTIONS"
① Hour counter
- RUNNING : The counter registers travel time only.
- KEY ON : The counter registers when the "key" switch is closed.
② Battery check
- ON : The battery discharge level check is carried out; when the battery level reaches 10%, an
alarm is signalled and the maximum current is reduced to the half of the programmed
value.
- OFF : The battery discharge level check is carried out but no alarm is signalled.
③ Traction cutout
When the alarm "BATTERY LOW" appears, if this option is programmed to ON the traction
maximum speed is reduced to 60Hz.
④ Lift cutout
When the alarm "BATTERY LOW" appears, if this option is programmed to ON the lift function is
disabled.
⑤ Hydro key on
- ON / OFF : If this option is programmed ON the traction inverter manages an hydraulic steering
function when the "key" is switched ON.
⑥ Stop on ramp
- ON : The stop on ramp feature (truck electrically hold on a ramp) is managed for a fixed time (6
sec.).
- OFF: The stop on ramp feature is not performed.
⑦ Aux input #1
- EXCLUSIVE HYDRO : Input C10 activates hydraulic steering function, output A31 is activated.
- OPTION #1 : Input C10 is the input for an handbrake device, active low (open switch).
- OPTION #2 : Input C10 is the input for a speed reduction device, active low (open switch).
⑧ Pedal braking
- DIGITAL : The truck does not have a potentiometer installed on the mechanical brake pedal, but
only a switch; when the accelerator pedal is released and the brake pedal is pushed
(brake switch closed), the inverter performs an electrical braking following "Pedal
braking" parameter.
⑨ Set temperature
- DIGITAL : A digital (ON/OFF) motor thermal sensor is connected to A24-A25 input.
- ANALOG : An analog motor thermal sensor is connected to A24-A25 (the curve can be
customized on a customer request).
- NONE : No motor thermal sensor switch is connected.
⑩ Steer table
This parameter is used to set the correct steering table.
- OPTION #1 : The steering table is the one for 4.0~5.0 ton truck.
7-28
⑪ Display
If this option is set to on the communication with the graphic display is enabled.
⑫ S.R.O.
If this option is set to on the static return to off is requested for starting the truck. The required
sequence is :
·Seat-direction lever-accelerator pedal or :
·Seat-accelerator pedal-direction lever within the seq. delay time
If this option is set to off the required sequence to start the truck is :
·Direction lever-accelerator pedal or :
·Accelerator pedal-direction lever within the seq. delay time
⑬ Pedal brake stop
This parameter defines how truck drive if accel pedal & brake pedal is pressed simultaneously.
If set to on, truck is stopped when the pedal brake is pressed.
If set to off, the traction current is reduced to half of the maximum current.
(2) Submenu "ADJUSTMENTS"
① Set battery type
It selects the nominal battery voltage.
② Adjust battery
Fine adjustment of the battery voltage measured by the controller. Please increase or decrease
the value 1 by 1 and check the voltage.
③ Max steer right (only available on console)
This is the function to record in the controller EEPROM the steering poti output voltage when the
wheels are fully turned right (maximum of the steering poti range).
④ Max steer left (only available on console)
wheels are fully turned left (minimum of the steering poti range).
⑤ Set steer 0-pos. (only available on console)
wheels are straight.
⑥ Set steer right
This parameter sets the max steering angle in right direction.
⑦ Set steer left
This parameter sets the max steering angle in left direction.
7-29
⑧ Throttle 0 zone
It establishes a deadband in the accelerator input curve (see also curve below).
⑨ Throttle X point
This parameter changes the characteristic of the accelerator input curve.
⑩ Throttle Y point
This parameter changes the characteristic of the accelerator input curve.
SPEED f(Hz)
MAX SPEED
TROTTLE Y
POINT
FREQ. CREEP
V
VACC THROTTLE 0 THROTTLE X VACC

MIN ZONE POINT MAX
20B7EL17
VACC MIN and VACC MAX are values programmable by the "Program Vacc" function.
⑪ Adjustment #2 bdi
It adjusts the lower level of the battery discharge table. Higher level means higher voltage.
⑫ Adjustment #1 bdi
It adjusts the upper level of the battery discharge table. Higher level means higher voltage.
⑬ Adjustment #03 :
Set an increment of battery charge above actual value. If battery voltage exceed this total value
the software recognize charging, and battery charge percentage increase to correct value also if
battery isn't fully charged.
⑭ PWM on main contactor
-OFF : The inverter applies the battery voltage to the main contactor coil on A27 output.
-ON : The PWM reduces the voltage to the set value.
⑮ PWM on aux output
-OFF : The inverter applies the battery voltage to the pump cantactor coil on A28 output.
-ON : The PWM reduces the voltage to the set value.
16 Adjustment #04 :
This parameter determines the motor temperature level at which the "Motor temperature" alarm
is signalled. This parameter must be adjusted only if the "Set temperature" (menu "Set option")
parameter is programmed "Analog".
17 Speed factor
It adjusts the speed coefficient to have the correct speed indication on the display. This coefficient
has to be regulated depending on truck mechanic characteristics. It results from the following
formula :
Speed factor = 88 * rr * p /Ø
where :
rr = total gearbox ratio
Ø= traction wheel diameter (cm)
P = number of pair poles of the motor
7-30
(3) Parameter change
① Acceler. delay
It determines the acceleration ramp.
Less value means better acceleration performance.
② Release
elease braking
It controls the deceleration ramp when the travel request is released.
Less value means better braking performance.
③ Invers. braking
It controls the deceleration ramp when the direction switch is inverted during travel.
④ Pedal braking
It determines the deceleration ramp when the travel request is released and the brake pedal
switch is closed.
⑤ Speed limit brk.
Deceleration ramp when the pedal position is changed but not completely released.
⑥ Brake cutback
It determines the deceleration ramp when the speed reduction input becomes active and the
motor slow down.
⑦ Max speed forw
It determines the maximum speed in forward direction.
⑧ Max speed back
It determines the maximum speed in backward direction.
⑨ Cutback speed 1
Speed reduction when the cutback switch is active.
⑩ Turtle speed
Hz. It determines the truck maximum speed when the turtle mode is activated.
⑪ Curve cutback
Speed reduction when the truck is doing a curve. The parameter sets the speed setpoint when
the maximum steering angle is reached (4 wheels truck, the internal wheel is stopped). In
intermediate steering angles, the speed setpoint will be within a range between the straight wheel
speed and the CURVE CUTBACK SPEED.
7-31
⑫ Frequency creep
Minimum speed when the forward or reverse switch is closed, but the accelerator is on a
minimum position.
⑬ Maximum current
This changes the maximum current of the inverter.
⑭ Acc. smooth
It gives a parabolic shape to the acceleration ramp.
⑮ Inv. smooth
It gives a parabolic shape to the acceleration ramp after a direction inversion.
16 Stop smooth
Hz. It sets the frequency where the smooth effect of the parabolic acceleration ends.
17 Seat delay time
It determines the delay time between the opening of the seat switch on CNC#5 digital input and
the start of the truck electrical braking.
18 Sequence de. time
It sets the maximum delay time between the accelerator is pressed and the direction lever is
moved out of the neutral position.
If this time is expired the truck stops with warning : “SEQUENCE FAULT”.
19 CHAT TIME
After no travel or pump request is active for the chat time the line contactor is automatically
opened. To restart, the the operator needs to press the accelerator pedal or activate the hydraulic
levers.
7-32
■ TRACTION CONTROLLER-SLAVE
Using the config menu of the programming console, or using a display, the user can configure the
following functions.
① Hour counter
-RUNNING : The counter registers travel time only.
-KEY ON : The counter registers when the "key" switch is closed.
② Aux output #1
③ Set temperature
-DIGITAL : A digital(ON/OFF) motor thermal sensor is connected to A25 input.
-ANALOG : An analog motor thermal sensor is connected A25(the curve can be customized on a
customer request).
-NONE : No motor thermal sensor switch is connected.
④ OPSS coil
-ON : OPSS function is ON. lift down function is for bidden unless operator is on seat.
-OFF : Lift down function is available regardless present of operator.

① Set battery type
It selects the nominal battery voltage.
② Adjust battery
Fine adjustment of the battery voltage measured by the controller. Please increase or decrease
the value 1 by 1 and check the voltage.
③ PWM ON AUX OUT. 2
- 80V : The inverter applies the battery voltage to the coil on A27 output.
- 12V : The PWM reduces the voltage to 12 volt.
④ PWM ON AUX OUT.
- OFF : The inverter applies the battery voltage to the coil on A29 output.
- ON : The PWM reduces the voltage to the set value.
⑤ LOAD SENSOR (Option (Option)
- ON : Load sensing function is activated.
- OFF : Load sensing function is disactivated.
⑥ REF. LOAD WEIGHT (O (Option
ption)
This parameter is used to show and configurate the reference load weight.
⑦ Overload weight (option)
This parameter is used to show and configurate the trigger condition for OVER LOAD alarm.
If the loaded weight exceeds the weight indicated in this paramter, OVER LOAD alarm and
function limitation will occur accroding to OVERLOAD TYPE paramter.
7-33
⑧ Overload type (option)
This option specifies how overload alarm works in overloaded situation.
NONE : There would'n be any kind of alarms or limitations.
If re-configuration of V.A.S.S LOAD is required, please set this parameter as NONE, then
proceed re-configuration.
Option #1 : If the weight of load filed on forks exceeds the overload weight set in overload
parameter, OVER LOAD alarm will be displayed and followed by traction & pump limitation
except lift down & steering function.
Option #2 : If the weight of load filed on forks exceeds the overload weight set in overload
parameter, OVER LOAD alarm will be displayed.
⑨ Load speed UPD (option)
For accuracy, Load Sensor only works when the traction motor speed is lower than as set in this
parameter.
(3) Submenu "PARAMETER CHANGE"

① Maximum current
The maximum current of the inverter.
■ PUMP CONTROLLER
Using the config menu of the programming console or using a display, the user can configure the
following functions.
① Hour counter
- RUNNING : The counter registers travel time only.
- KEY ON : The counter registers when the "key" switch is closed.
② Set temperature
- DIGITAL : A digital (ON/OFF) motor thermal sensor is connected to A25 input.
- ANALOG : An analog motor thermal sensor is connected A25 (the curve can be customized on
a customer request).
- NONE : No motor thermal sensor switch is connected.
③ Digital lift
- OFF : The lift sensor includes a lift switch and an analogue lift sensor. Lift speed can be
controlled proportionally with lever position.
- ON : The lift sensor includes a lift switch only. Lift speed cannot be controlled proportionally.
④ Joystick (Option)
- OFF : The truck model includes mechanical lever distributor (default)
- ON : The truck model includes electro-hydraulic distributor and finger tips. Can communication
with Can tiller and Hydro CB zapi modules is enabled.
⑤ Shift function (Option)
- ON : Fingertip Side Shift function is activated.
- OFF : Fingertip Side Shift function is disactivated.
⑥ Aux function (Option)
- ON : Fingertip Aux function is activated.
- OFF : Fingertip Aux function is disactivated.
7-34
① Set battery type : Selects the nominal battery voltage.
② Adjust battery : Fine adjustment of the battery voltage measured by the controller. Please
increase or decrease the value 1 by 1 and check the voltage.
③ Throttle 0 zone : Establishes a deadband in the accelerator input curve (see also curve below).
④ Throttle X zone : This parameter changes the characteristic of the accelerator input curve.
⑤ Throttle Y zone : This parameter changes the characteristic of the accelerator input curve.
SPEED f(Hz)
MAX SPEED
TROTTLE Y
POINT
FREQ. CREEP
V
VACC THROTTLE 0 THROTTLE X VACC

MIN ZONE POINT MAX
20B7EL17
VACC MIN and VACC MAX are values programmable by the "PROGRAM VACC" function.
⑥ Cooling fan work
Cooling fans installed on nearby motors and controllers will work as follows;
Option #1 : fans work always
Option #2 : fans work in case a temperature of controller or motor exceeds a temperature set in
START TEMP. FAN menu
Options #2 : fans work when motors work.
⑦ Start TEMP. FAN
if COOLING FAN WORK menu is set as option #2, This menu is used to set a temperature
limitation which allows fans to work when a temperature of controller or motor exceeds the
limitation.
⑧ PWM on main contactor
- OFF: The inverter applies the battery voltage to the coil on A28 & A29.
- ON: The PWM reduces the voltage to the set value.
⑨ PWM on aux output
- OFF: The inverter applies the battery voltage to the coil on A26 & A27.
- ON: The PWM reduces the voltage to the set value.
⑩ Adjustment #04 : This parameter determines the motor temperature level at which the "MOTOR
TEMPERATURE" alarm is signalled. This parameter must be adjusted only if the "SET
TEMPERATURE" (menu "SET OPTION") parameter is programmed "ANALOG"
⑪ Fork leveling
- ON : AUTO TILT LEVELING function is activated.
- OFF : AUTO TILT LEVELING function is disactivated.
7-35
(3) Parameter change
① Acceler delay
More value means better deceleration performance.
② Deceler delay
More value means better deceleration performance.
③ Max speed up
Determines the maximum lifting speed with a potentiometer control.
④ Min speed up
Determines the minimum lifting speed with a potentiometer control when the lifting enable switch
is closed.
⑤ Cutback speed
Determines the lift speed reduction in percentage when the speed reduction switch is activated.
⑥ Tilt speed
Tilt speed, fine regulation.
⑦ Shift speed
Shift speed, fine regulation.
⑧ Aux speed
Auxiliary function speed, fine regulation.
⑨ Hyd speed fine
Hydro speed, fine regulation.
⑩ Maximum
aximum current
The maximum current of the inverter.
⑪ Idle
dle time
Time delay when an hydraulic steering function request is switched off.
■ DISPLAY
Using a display, the user can configure following functions in the truck menu.
(1) Password
assword
User password function activation parameter.
- ON : User password function is activator.
The default password is "0000", password can be changed in the user menu.
- OFF : User password function is deactivated.
(2) Maintenance
Maintenance function activation parameter.
- ON : Maintenance alarm function is activated. Have to set the maintenance time.
When the maintenance time is up to "0 hr" maintenance alarm pop up on the display at the
every key ons.
- OFF : Maintenance alarm function is deactivated.
※ If you reset the maintenance time, select "ON" and set the time again.
(3) Hour counter
Determine the default hourmeter on the display.
① Key on : Truck key on time.
② Traction : Traction motor running time.
③ Pump : Pump motor running time.
7-36
5) PROGRAMMING & ADJUSTMENTS
There are two ways to adjust parameter via a console or buttons on a display.
※ Adjustments via buttons on a display, please refer to the display section. (page 7-54)
ADJUSTMENTS VIA CONSOLE (Option)
Adjustment of parameters and changes to the inverter's configuration are made using the digital
console. The console is connected to the "B" connector of the inverter.
(1) Descriptions of console
Inverter B
connector
Console connector
Display
Buttons
20B7EL15
※ Please connect and disconnect it from the inverter after a key switch off.
7-37
(2) Description of standard console menu
① Traction controller-Master
zl{GwlkhsGiyhrl huhsvnVkpnp{hs
wlkhsGiyhrlGz{vw vuVvmm
tv{vyG{ltwlyh{
zsh}lGtv{UG{ltwU
Y[VZ]V[_V^YV_WV`]
iyhrlGvpsGz~p{jo vuVvmm
w~tGvuGthpuGjvu{ vuVvmm
w~tGvuGh|Gv|{ vuVvmm
40B9EL18
7-38
② Traction controller-Slave
thpt|tGj|yylu{
ov|yGjv|u{ly y|uupunVrlGvu
h|Gv|{w|{GJX iyhrlVuvul
zl{G{ltwlyh{|yl huhsvnVkpnp{hs
Vuvul
vwzzGjvps vuVvmm
Y[VZ]V[_V^YV_WV`]
w~tGvuGh|Gv|{GY UUU}
w~tGvuGh|Gv|{ vuVvmm
svhkGzluzvy vuVvmm
tv{vyG{ltwlyh{U ylmUGsvhkG~lpno{ UUU
yh{lkGsvhkG~U UUU
v}lysvhkG~lpno{ UUU
v}lysvhkG{wl uvulVvw{pvuGJX
svhkGwv{ } vw{pvuGJY
svhkGzwllkG|wk UUUo¡
40B9EL19
7-39
③ Pump controller
jvuulj{G{vG\
j|{ihjrGtvkl
zopm{Gm|uj{pvu
h|Gm|uj{pvu
tv{vyG{wl z{hukhykGw|twVvw{pvuJX
Y[VZ]V[_V^YV_WV`]
jvvspunGmhuG~vyr vw{pvuJXVJYVJZ
spm{Gzluz } z{hy{G{ltwGmhu
klzjlu{Gz~p{jo
Xz{GzwllkGz~p{jo
{ps{Gwv{
YukGzwllkGz~p{jo
zopm{Gwv{
ZykGzwllkGz~p{jo
h|Gwv{
[{oGzwllkGz~p{jo
40B9EL20
7-40
(3) Description of the console SAVE function
The SAVE function allows the operator to transmit the parameter values and configuration data of
the chopper into the console memory. It is possible to load 64 different programmers.
The information saved in the console memory can then be reloaded into another chopper using
the RESTORE function.
The data that is available via the SAVE function is as follows:
- All parameter values (Parameter change).
- Options (Set. options).
Flow chart showing how to use the SAVE function of the digital console.
① Opening Zapi display. AC3M2BF 9HY1.00

80V 600A 00000
② Press ENTER to go into the general menu.
③ The display will show:
④ Press ROLL UP or ROLL DOWN button until

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

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

whilst the SAVE routine is happening.
⑪ When finished, the console shows :
⑫ Press OUT to return to the opening Zapi display.
40B9EL21
7-41
(4) Description of the console RESTORE function
The RESTORE PARAM function allows transfer of the console's stored data into the memory of
the chopper. This is achieved in a fast and easy way using the method previously used with the
SAVE PARAM. function.
The data that is available via the RESTORE PARAM. function is as follows :
- All Parameter Values (Parameter change).
- Options (Set options)
When the RESTORE operation is made, all data in the chopper memory will be written over
and replace with data being restored.
Flow chart showing how to use the RESTORE function of the digital console.

80V 600A 00000

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

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

the chopper memory whilst the RESTORE
routine is happening
⑫ When finished, the console shows :
⑬ Press OUT to return to the opening Zapi display.
40B9EL22
7-42
(5) Description of alarms menu
The microprocessor in the controller records the last five alarms that have occurred. Items
remembered relative to each alarm are: the code of the alarm, the number of times the particular
Alarm occurred, the hour meter count, and the inverter temperature.
This function permits a deeper diagnosis of problems as the recent history can now be accessed.
Flow chart showing how to use the ALARMS function via the digital console.

80V 600A 00000

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

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

press OUT to exit the ALARMS menu.
⑪ The display will ask "CLEAR LOGBOOK?".
⑫ Press ENTER for yes, or OUT for NO.
⑬ Press OUT to return to the opening Zapi display.
40B9EL23
7-43
(6) Description of console program vacc function
This function looks for and remembers the minimum and maximum potentiometer wiper voltage
over the full mechanical range of the pedal. It enables compensation for non symmetry of the
mechanical system between directions.
The operation is performed by operating the pedal after entering the PROGRAM VACC function.
Flow chart showing how to use the PROGRAM VACC function of the digital console:
AC3M2BF 9HY1.00
① Opening Zapi display. 80V 600A 00000

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

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

40B9EL24
menu.
7-44
(7) DESCRIPTION OF CONSOLE USING
① Access to SET MODEL menu.
The only parameter present in SET MODEL function is CONNECTED TO.
By setting this parameter, operator can connect ZAPI console to every ZAPI product connected
to CAN-BUS line. This functionality allows completely control of every ZAPI product without
changing the position of the console connector.
AC3M2BF 9HY1.00
a. Opening Zapi menu.
80V 600A 00000
b. Press ROLL UP & SET UP buttons to enter

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

CONNECTED TO option is present in this menu. 3
f. Press SET UP or SET DOWN buttons in order

to select the desired value for selected option.
g. New desired value appears. 5
h. Press OUT to exit the menu.
i. The display will ask "ARE YOU SURE?"
j. Press ENTER for YES, or OUT if you do not

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

and reconnects.
m. Display now shows the opening Zapi Menu of AC3P2BF 9HY1.00

the ZAPI product corresponding to option 80V 600A 00000
selected at point g.
40B9EL28
7-45
② Flow chart showing how to make changes to option menu :
AC3M2BF 9HY1.00
a. Opening Zapi menu.
80V 600A 00000
b. Press ROLL UP & SET UP Buttons to enter

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

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

menu.
g. The display will show the first option. HOUR COUNTER

RUNNING
h. Press ROLL UP or ROLL DOWN buttons until

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

to modify the value for selected option.
k. New value for selected option appears. BATTERY CHECK

OFF
l. Press OUT to exit the menu.
m. Confirmation request appears.
n. Press ENTER to accept the changes, or press

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

opening Zapi menu.
40B9EL29
7-46
③ Flow chart showing how to use the tester function of the digital console:
AC3M2BF 9HY1.00
a. Opening Zapi menu. 80V 600A 00000
b. Press ENTER to go into the MAIN MENU.
c. The display will show: PARAMETER CHANGE.
d. Press ROLL UP or ROLL DOWN until TESTER

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

display. 0%
h. Press either ROLL UP or ROLL DOWN buttons.
FREQUENCY
i. Next variable for measurement appears. O H2
j. When you have finished press OUT.
k. The Display will show: TESTER.
l. Press OUT again and return to opening Zapi

menu.
40B9EL30
Remember it is not possible to make any changes using TESTER.

All you can do is measure as if you were using a pre-connected multimeter.
7-47
6) MORNITORING MENU
In Console, This menu appears as “TESTER” MENU
(1) Traction controller-Master
① Motor voltage
This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full
voltage (which depends of the battery voltage).
② Frequency
This is the frequency of the voltage and current supplied to the motor.
③ Encoder
This is the speed of the motor, expressed in the same unit of the frequency; this information
comes from the speed sensor.
④ Slip value
This is the difference of speed between the rotating field and the shaft of the motor, expressed in
the same unit of the frequency.
⑤ Current rms
Root Mean Square value of the motor current.
⑥ Temperature
The temperature measured on the aluminum heat sink holding the MOSFET devices.
⑦ Motor temperature
This is the temperature of the right motor; if the option is programmed "None" (see page 7-29) it
shows 0°.
⑧ Slave mot. temperature
This is the temperature of the left motor; if the option is programmed "None" (see page 7-29) it
shows 0°.
⑨ Accelerator
The voltage of the accelerator potentiometer's wiper (CPOT).
⑩ Steer angle
This is the indication of the angular position of the steered wheel.
⑪ Internal wheel cutback
This is the indication of the speed reduction applied to the internal wheel; in other words, it shows
the ratio of the two speeds.
⑫ Forward switch
The level of the forward direction digital input FW.
- ON / +VB = Input active, switch closed.
- OFF / GND = Input non active, switch open.
⑬ Backward switch
The level of the reverse direction digital input BW.
⑭ Enable switch
The level of the enable digital input:
⑮ Seat switch
The level of the seat microswitch digital input.
7-48
16 Cutback switch
The level of the speed reduction microswitch.
- ON / GND = Input active, switch opened.
- OFF / +VB = Input non active, switch closed.
17 Brake switch
The level of the pedal brake microswitch.
18 Brake oil switch
The level of the brake oil switch.
19 Exclusive hydro
Status of the exclusive hydro switch.
20 Brake pedal pot.
Voltage of the brake potentiometer's wiper (CPOTB). The parameter is active only if the PEDAL
BRAKING parameter is set ANALOG.
21 Hand brake
The level of the handbrake microswitch.
- ON / GND = Input active, switch opened.
- OFF / +VB = Input non active, switch closed.
22 Voltage booster
This is the booster of the voltage supplied to the motor in load condition; it is expressed in a
percentage of the full voltage.
23 Battery voltage
Level of battery voltage measured at the input of the key switch.
24 Battery charge
The percentage Charge level of the battery.
(2) Traction controller-Slave

① Motor voltage
② Frequency
③ Encoder
④ Slip value
⑤ Current rms
Root mean square value of the motor current.
7-49
⑥ Temperature
The temperature measured on the aluminum heat sink holding the MOSFETdevices.
This is the temperature of the left motor.
⑧ Voltage booster
⑨ Battery voltage
Level of battery voltage measured at the input of the key switch.
⑩ Seat switch
The level of the seat microswitch digital input.
- OFF / GND = Input non active, switch opened.
⑪ Load pot
Voltage value of load sensor.
7-50
(3) Pump controller
① Motor voltage
② Frequency
③ Encoder
④ Slip value
⑤ Current rms
Root Mean Square value of the motor current.
⑥ Temperature
The temperature measured on the aluminum heat sink holding the MOSFET devices.
This is the temperature of the motor; if the option is programmed "None" it shows 0˚C.
⑧ Lifting sens
The voltage of the lift potentioneter's wiper (CPOT).
⑨ Lifting switch:
Status of the lifting switch.
- ON / +VB = Active entry of closed switch.
- OFF / GND = Non active entry of open switch.
⑩ Descent switch:
Status of the descent switch.
⑪ 1st speed switch:
Status of the 1st speed switch.
⑫ Tilt pot:
Level of the tilt analogue signal. The voltage is shown on the left hand side of the display and the
value in percentage on the right hand side.
⑬ 2nd speed switch:
Status of 2nd speed switch.
⑭ Shift pot:
Level of the shift analogue signal. The voltage is shown on the left hand side of the display and
the value in percentage on the right hand side.
⑮ 3rd speed switch:
Status of 3rd speed switch.
7-51
16 Aux pot:
Level of the auxiliary analogue signal. The voltage is shown on the left hand side of the display
and the value in percentage on the right hand side.
17 4th speed switch:
Status of 4th speed switch.
18 Cutback switch:
Status of the speed reduction switch.
- ON / GND = Active entry of open switch.
- OFF / +VB = Non active entry of closed switch.
19 Voltage booster:
20 Battery voltage:
Level of battery voltage measured at the input to the key switch.
21 Fork lvl. switch:
Status of the fork leveling activation switch (auto tilt leveling switch).
22 Fork lvl. pot:
Level of the fork tilting angle (tilt angle potentioneter) siginal.
7-52
7) GENERAL SUGGESTION FOR SAFETY
For a proper installation take care of the following recommendations:
After operation, even with the key switch open, the internal capacitors may remain charged for
some time. For safe operation, we recommend that the battery is disconnected, and a short circuit
is made between battery positive and battery negative power terminals of the inverter using a
resister between 10 ohm and 100 ohm.
Do not connect the inverter to a battery with a nominal value different from the value indicated on
the controller plate. If the battery value is greater, the MOS may fail; if it is lower, the control unit
does not "power up"
During battery charge, disconnect the controller from the battery.
Do not connect the controller to a battery with a nominal voltage different than the value indicated
on the controller label. A higher battery voltage may cause power section failure. A lower voltage
may prevent the logic operating.
Before doing any operation, ensure that the battery is disconnected and when all the installation
is completed start the machine with the drive wheels raised from the floor to ensure that any
installation error do not compromise safety.
Take care all the inductive devices in the truck (horn, solenoid valves, coils, contactors) have a
proper transient suppression device.
※ The method of discharging internal capacitor

Bofore checking controllers, motors, cables and etc., discharge the internal capacitor in controllers
by following below steps ;
① Disconnect the battery cable.
② Emergency contactor on and key on.
③ Wait untill all warning lamps (red LED) on display become off.
④ Discharging process is finished.
7-53
6. INSTRUMENT PANEL : DISPLAY
1) STRUCTURE
The DISPLAY has 6 red LEDs indicating the status information of the lift truck to the driver.
Spare #1 Spare #2
Oil level Park brake

Wrench Seat belt
Thermometer Seat
22BH9OM65
7-54
2) WARNING LAMP
(1) Brake oil level warning lamp
Lights when the brake oil level in the reservoir is below the lower
limit.
22BH9EFD01
(2) Wrench warning lamp

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

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

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

(1) This LED blinks in following 2 cases.
① When operator starts the truck, LED blinks for 5 seconds,
which means initial diagnosis is on going, and buttons on
display will work properely just after the diagnosis is
completed.
22BH9EFD05 ② LED blinks when the seat belt is not correctly fastened.
(6) Handbrake warning lamp
(1) This LED lights when the handbrake is activated.
22BH9EFD06
7-55
3) BUTTONS
(1) UP button
Press to select upward move
22BH9EFD07
(2) DOWN button (DOWN/TURTLE button)

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

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

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

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

Press to select Enter
22BH9EFD12
7-56
4) LCD FUNCTION (MAIN SCREEN)
MAIN SCREEN
22BH9EFD13
1 Current time 6 Hour meter

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

The number shows the current time according to the setting, which can be changed by DISPLAY
Setting [6. 5), Page 7-59].
(2) Turtle mode
The turtle symbol is normally off. When this symbol appears, the Turtle Mode is activated
regardless of the Power Mode of the truck to reduce the maximum speed to the setpoint. This
mode can be activated by pressing the button.
7-57
(3) Truck speed pointer
The speed of the truck is indicated with a pointer.
(4) Speed level
This indicator shows the truck speed same as the (3) Speed pointer.
(5) Truck speed
The truck speed is shown in number. According to the DISPLAY setting km/h or mph unit is
available.
(6) Hour meter

The number shows the hours worked. The letter present near the hour meter shows which hour
meter is displayed.
- hK: the Key Hour shows the truck Key ON time;
- hT: the Traction Hour shows the Gate ON (driven) time of the traction motor.
- hP: the Pump Hour shows the Gate ON (driven) time of the pump motor.
(7) Wheel position and running direction
The arrow point is up when the truck is forward running and points down when the truck is
reverse running. The arrow point is moved to the leftward or the rightward according as the
direction of the steering angle.
(8) Power mode
The letter; H, N, or E, shows the Power Mode which is being used in the controller. The mode can
be scrolled by pressing the button sequentially. When a mode is selected, the related
information will be sent via CAN-BUS to traction and pump controllers that will manage this data.
H (High) - corresponds to the highest performance
N (Normal) - corresponds to normal performance
E (Economic) - corresponds to economic performance
(9) BDI (Battery
( attery Discharge Indicator)
The battery state of charge is shown by ten bars. Each bar represents the 10% of the battery
charge. As the battery becomes discharged, the bars turn off progressively, one after another, in
proportion to the value of the residual battery charge. When the residual battery charge is 20% or
under, the bars displayed become red.
※ How to adjust BDI
If necessary, service man can a adjust BDI with adjustment #1, #2 BDI menu.
① Adjustment #1 BDI
It adjusts the upper level of the battery discharge table. Higher level means higher voltage.
② Adjustment #2 BDI
It adjusts the lower level of the battery discharge table. Higher level means higher voltage. (for
detail menu, please refer to page 7-30)
7-58
5) HOW TO USE DISPLAY MENU
22BH9EFD14
7-59
22BH9EFD15
7-60
6) DESCRIPTION OF THE TRUCK MENU
(1) Access to truck menu
If this button is pressed long, the PASSWORD dialog appears.
Enter correct PASSWORD, then on MAIN SCREEN, Press button to access the controller
“TRUCK MENU”
(2) How to change detail menus
The detail items of menu can be changed as follows ;

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

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

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

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

22B9EL24
Selection can be made in 4 methods as follows ;
- ON/OFF Selection
0$67(5
%$77(5<&+(&.
21
2))
22B9EL25
Select a desired value with , button, then save with button or press button to escape
without saving.
- Type Selection
0$67(5
&22/,1*)$1:25.
237,21
237,21
237,21
22B9EL30
without saving.
7-61
- Figure input
22B9EL31
Select a desired value with , , , button, then save with button or press button
to escape without saving.
- Level Selection
0$67(5

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

6HF
22B9EL30
without saving.
7-62
7) ALARM & ALARM HISTORY
(1) How to check alarms
Normally, ALARM SCREEN pops up if any kind of a alarm happens, but service man can switch
between a MAIN SCREEN and ALARM SCREEN with , buttons as follows :
(Press more than 1 sec)
75,3
&2'( 1$0(
0 &RQWDFWRU2SHQ
6)% :DLWLQJIRU1RGH
22B9EL35
7-63
(2) Detail description of ALARM SCREEN

75,3
&2'(
6)% &RQWDFWRU2SHQ
0
①
ɂ

J ③
ɂ

②
ɂ

6)% :DLWLQJIRU1RGH
22B9EL36
① First yellow capital letter shows in which controller the alarm happens as below;
M : Traction-Master
S : Traction-Slave
P : Pump
V : Mhyrio CB
② Following two letters or digits show alarm code. Please refer to 7. ALARM CODE (Page 7-71).
③ This shows a name of ALARM. Please refer to 7. ALARM CODE (page 7-71).
(3) Alatm history

Alarm History can be looked up as follows ;
758&.0(18 $/$50+,6725<
6(77,1*
021,725,1* :DLWđ
$/$50+,6725<
Step 1 Step 2
0$67(5$/$50
0$67(5$/$50
$/$50+,6725<
&2'(
&2'( 1$0(
0$67(5 &RQWDFWRU2SHQ 1$0(
6WHHULQJ6HQVRU.2 &RQWDFWRU2SHQ
6/$9( RFFXUHQFHV
3803 7HPSȔ
.H\7LPHKU
Step 3 Step 4 Step 5-1
0$67(5$/$50
0$67(5$/$50
$5(<28685("
<(6(17(512(6&
Step 5-2
22B9EL37
7-64
① Step 1 : Service man can check the alarm history on ALARM HISTORY menu
② Step 2 : When service man enter the ALARM HISTORY menu, display read entire alarm records
of all controller. So it takes 9~15 seconds to read.
③ Step 3 : When display finish to read alarm records, service man can choose each controller to
read the alarm history.
④ Step 4 : When service man enters each controller’s alarm history, service man can check simply
up to 5 alarms and choose a specific alarm to read detail alarm information.
⑤ Step 5-1 : When service man press button at Step 4, operator can see a detail alarm
information of chosen alarm. Please refer to 6-7)-(4) DETAIL ALARM INFORMATION (page
7-65)
⑥ Step 5-2 : When service man press button at Step 4, service man can see a alarm clear
menu. If service man press button, Recorded alarms of selected controller will be erased.
(to verify cleaned alarm records, service man should be back to Step 1 & 2 to refresh.)
If operator press button, just escape to step 3 without clearing
(4) Detail
etail alarm information
①
0$67(5$/$50
&2'(
1$0( ③
② &RQWDFWRU2SHQ
RFFXUHQFHV ④
7HPSȔ
⑤
.H\7LPHKU
22B9EL38
① Code of alarm
② Name of alarm
③ Count of alarm
④ Temperature of controller as alarm occurs.
⑤ Hourmeter of controller as alarm occurs.
7-65
8) VASS SETUP USING DISPLAY MENU
This function searches and memorizes the minimum and maximum potentiometer wiper voltage of
the accelerator pedal, lift lever, and steering sensor which use potentiometer sensors. The belows
show how to use the VASS function of DISPLAY.
(All figures in belows are just example.)
※ While even a motor is running, VASS can not be configurated properly, so please be sure that all
motors are not running before entering configuration process & saving.
(1) ACCEL VASS setting method
9$66
$&&(/
Please make sure that all motors
0,1)25:$5'9
are not running & direction lever
0$;)25:$5'9
is in NEUTRAL position.
0,15(9(56(9
0$;5(9(56(9
9$66
$&&(/5($'< If “READY” appears beside
0,1)25:$5'9 ACCEL, you are in configuration
process.
0$;)25:$5'9
Set direction lever in FORWARD
0,15(9(56(9
position.
0$;5(9(56(9
9$66
$&&(/5($'< Now, you can see that voltage
0,1)25:$5'9 value of MIN FORWARD and
0$;)25:$5'9 MAX FORWARD are changed.
Step on accel pedal fully, then
0,15(9(56(9
Take foot off accel pedal.
0$;5(9(56(9
Now, you can see that voltage

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

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

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

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

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

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

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

voltage value will be changed.
67((5/()79
Please make sure that all traction motors
67((53269
are not running
9$66
67((5$1*/(5($'<
$5(<28685("
<(6(17(512(6&
22B9EL41
7-68
9) STRUCTURE OF TRUCK MENU
TRUCK MENU is in order to make configuration of truck easily, and consists of 3 major categorys :
SETTING, MONITORING, ALARM HISTORY.
[To know how to get in to TRUCK MENU, refer to 6-6)-(1) “ACCESS TO TRUCK MENU” page 7-61]
(1) Settings
758&.0(18 6(77,1*
6(77,1* 0$67(5
6/$9(
021,725,1*
$/$50+,6725< 3803
9$66
0$67(5
6(7237,216
$'-8670(176
3$5$0(7(5&+$1*(
22B9EL42
In SETTINGS, service man can choose a specific controller’s submenu or VASS menu.
① MASTER->SET OPTIONS
Refer to 5-4)-■“TRACTION-MASTER CONTROLLER”-(1) “SET OPTIONS” (page 7-28)
② MASTER->ADJUSTMENTS
Refer to 5-4)-■”TRACTION-MASTER CONTROLLER”-(2) “ADJUSTMENTS” (page 7-29)
③ MASTER->PARAMETER CHANGE
Refer to 5-4)-■”TRACTION-MASTER CONTROLLER”-(3) “PARAMETER CHANGE” (page 7-32)
④ SLAVE->SET OPTIONS
Not available
⑤ SLAVE->ADJUSTMENTS
Refer to 5-4)-■”TRACTION-SLAVE CONTROLLER”-(2) “ADJUSTMENTS” (page 7-34)
⑥ SLAVE->PARAMETER CHANGE
Refer to 5-4)-■”TRACTION-SLAVE CONTROLLER”-(3) “PARAMETER CHANGE” (page 7-34)
⑦ PUMP->SET OPTIONS
Refer to 5-4)-■“PUMP CONTROLLER”-(1) “SET OPTIONS” (page 7-34)
⑧ PUMP->ADJUSTMENTS
Refer to 5-4)-■”PUMP CONTROLLER”-(2) “ADJUSTMENTS” (page 7-35)
⑨ PUMP->PARAMETER CHANGE
Refer to 5-4)-■”PUMP CONTROLLER”-(3) “PARAMETER CHANGE” (page 7-36)
⑩ V.A.S.S
Refer to 6-8) “VASS SETUP USING DISPLAY MENU” (page 7-66)
7-69
(2) Monitoring
758&.0(18 021,725,1*
6(77,1* 0$67(5

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

① MASTER
Refer to 5-6)-(1) “Traction controller-master” (page 7-48)
② SLAVE
Refer to 5-6)-(2) “Traction controller-Slave” (page 7-49)
③ PUMP
Refer to 5-6)-(3) “Pump controller” (page 7-51)
(3) Alarm history

Refer to 6-7) “ALARM & ALARM HISTORY” (page 7-63)
7-70
7. ALARM CODE
1) TRACTION-MASTER CONTROLLER
Condition that has to occur to come out from
Code Alarm name Description
alarm status
08 WATCHDOG Alarm: the Watchdog circuit has - If the alarm is present in Init status, remove
been triggered the alarm condition
- If the alarm has occurred in stby or running
mode, it is necessary to remove alarm
condition and to activate a traction request
0D EEPROM KO Warning: Eeprom fault, controller To remove Warning cause
will use default parameters
11 LOGIC FAILURE #3 Alarm: failure in over-load - To remove alarm condition + activation of
protection hw circuit traction request
- Check the Controller
12 LOGIC FAILURE #2 Alarm: failure in U, V, W voltage To remove alarm condition + activation of
feedback circuit traction request
13 LOGIC FAILURE #1 A l a r m : a n o v e r v o l t a g e o r - To recycle the key switch
undervolt. condition has been - Sometimes if battery voltage is too low, it can
detected be happens
1E VMN LOW Alarm: wrong voltage on motor - If the alarm is present in Init status, remove
power outputs; failure in the the alarm condition
power section or in the mosfet - If the alarm has occurred in stby or running
driver circuit or in the motor mode, it is necessary to remove alarm
- Check the U,V,W cable and motor and if there
is any shorted circuit with frame or any other
parts of truck
1F VMN HIGH Alarm: wrong voltage on motor - If the alarm is present in Init status, remove
parts of truck
26 CONTACTOR OPEN Alarm: line contactor power - To remove alarm cause within a timeout; if the
contact does not pull-in timeout is elapsed, it is necessary to re-cycle
the key
- Check the contactor & cables attached to the
contactor
31 I = 0 EVER Alarm: While truck is running, - Check the Main contactor
current value is 0 for more than - Check the controller
1 Sec
35 STBY I HIGH Alarm: wrong voltage in the - If the alarm is present in Init status, remove
current sensor feedback circuit the alarm condition
7-71
alarm status
3C CAPACITOR Alarm: power capacitor voltage - To remove alarm condition
CHARGE does not increase when the key - Check the contactor resistance (300, 10W)
is turned ON; failure in the power - Check the controller
section, or in the Logic PCB, or in
the driver PCB, or in the motor
3D HIGH Warning: Master or Slave or both - To remove Warning cause
TEMPERATURE temperature higher than 75°C
41 MOTOR Warning: Master or Slave or both - To remove Warning cause
TEMPERA-TURE motors temperature high - Check the motor temp-sensor
42 BATTERY LOW Warning: battery charge level - To remove Warning cause
below 10%
4A DRIVER SHORTED Alarm: line contactor coil driver is - If the alarm is present in Init status, remove
shorted the alarm cause
mode, it is necessary to remove alarm cause
and to activate traction request
4B CONTACTOR Alarm: line contactor coil driver is - To remove alarm cause and to activate
DRIVER open (not able to drive the coil to traction request
the correct voltage)
4C COIL SHORTED Alarm: - If the alarm is present in Init status, remove
-Init: the LC and EB coil driver the alarm cause
protection circuit is damaged - If the alarm has occurred in stby or running
-Stby or running: short on LC coil mode, it is necessary to remove alarm cause
or EB coil" and to activate traction request
4E VACC NOT OK Warning: acc. signal (CPOT) - To remove Warning cause
voltage higher than VACC MIN - Re-configurate VASS ACCEL
+1V while the traction enable
switch is open
4F INCORRECT START Warning: wrong traction request - To remove Warning cause
sequence
50 FORWARD + Warning: forward and reverse - To remove Warning cause
BACKWARD inputs are both active
52 ENCODER ERROR Alarm: motor speed sensor - To recycle the key
(encoder) does not work properly - Check the motor encoder
54 STEER SENSOR Alarm: steering sensor signal out - To remove alarm cause
KO of range
56 PEDAL WIRE KO Alarm: fault in accelerator negative - To remove alarm cause and activate a
(NPOT) input circuit traction request
EE BRAKE OIL Lack of brake oil - Check the brake oil tank & sensor
EF DISPLAY ENABLE Warning: The display enable - To remove warning cause
signal has not been received to
operate the truck
F0 MOTOR STALL Warning: the encoder signal - To recycle the key
is constantly zero when the - Check the motor and encoder
maximum torque is applied to the
motor
7-72
alarm status
F3 SEQUENCE Warning: an incorrect start - To remove Warning cause
FAULT sequence has been detected
on the seat, pedal and levers
commands
F4 SAFETY Alarm : the controller detects - To recycle the key
malfunction on safety circuit - Check if any other alarms happen on
(MASTER CONTROLLER A12<- controllers.
> SLAVE CONTROLLER A28) - Check the safety circuit
F5 WRONG SET Alarm: the battery voltage does - To remove alarm cause
BATTERY not correspond to SET BATTERY
programming
F6 SLAVE KO Alarm: Master µC detects a Slave - To recycle the key
µC malfunctioning - Check if any other alarm happens
(Some alarms such as CHAT TIME or
PEDAL WIRE KO, alarms related to
CONTACTOR, DISPLAY ENABLE, alarms
related to CANBUS can make this alarm
sometimes.)
- Check the communication with all controllers
(display TRUCK MENU->MONITORING->
choose controller->H/W VER, S/W VER.
If CAN communication is not availabel, H/W
VER, S/W VER will be blank.)
F7 CAN BUS KO Alarm: CONTROLLER doesn't - Check the CAN wiring
receive any message from CAN - Check if any other alarm happens
line (Some alarms such as CHAT TIME or
CONTACTOR, DISPLAY ENABLE, alarms
related to CANBUS can make this alarm
sometimes.)
(display TRUCK MENU->MONITORING-
>choose controller->H/W VER, S/W VER. If
CAN communication is not availabel, H/W
- Check the controller's logic board
F9 THERMIC Warning: Master or slave temp. - To remove Warning cause
SENSOR KO sensor is out of range
FA HANDBRAKE Warning: handbrake microswitch - To remove Warning cause
is open and a travel request is
active
7-73
alarm status
FB WAITING FOR Warning: Master Controller - To remove Warning cause
NODE signals that other controllers are - C h e c k i f a n y o t h e r a l a r m h a p p e n s
in alarm status (Some alarms such as CHAT TIME or PEDAL
WIRE KO, alarms related to CONTACTOR,
DISPLAY ENABLE, alarms related to
CANBUS can make this alarm sometimes.)
(display TRUCK MENU-> MONITORING->
choose controller->H/W VER, S/W VER.
- Check other controllers
FC CHAT MODE Warning: the chat time has - To activate traction or pump request
expired
FD AUX OUTPUT KO Alarm: pump line contactor - If the alarm is present in Init status, remove
driver (A28-A29) shorted or the alarm cause
open - If the alarm has occurred in stby or running
FE CANBUS KO Alarm: master has lost can To remove warning cause
DISPL. communication with the display
7-74
2) TRACTION-SLAVE CONTROLLER

alarm status
0D EEPROM KO Warning: Eeprom fault, controller - To remove Warning cause
- Check the controller
12 LOGIC FAILURE #2 Alarm: failure in U, V, W voltage - To remove alarm condition + activation of
undervoltage condition has been - Sometimes if battery voltage is too low, it can
detected be happens
parts of truck
- Check the U, V, W cable and motor and if
there is any shorted circuit with frame or any
other parts of truck
31 I = 0 EVER Alarm: while truck is running, - Check the main contactor
current value is 0 for more than 1 - Check the controller
sec
is turned ON; failure in the power - Check the controller
section, or in the logic PCB, or in
3D HIGH Warning: Master or Slave or both - To remove warning cause
TEMPERATURE temperature higher than 75°C
7-75
alarm status
41 MOTOR Warning: Master or Slave or both - To remove Warning cause
TEMPERA-TURE motors temperature high - Check the motor temp-sensor
52 ENCODER Alarm: motor speed sensor - To recycle the key
ERROR ( e n c o d e r ) d o e s n o t w o r k - Check the motor encoder
properly
56 PEDAL WIRE KO Alarm: fault in accelerator To remove alarm cause and activate a traction
negative (NPOT) input circuit request
is constantly zero when the - Check the motor and encoder
maximum torque is applied to
the motor
F3 L O A D S E N S Alarm: Load weight sensor - To remove alarm cause
ERROR detects that loaded weight - Check the load weight sensor
exceeds the weight limitation,
or load weight sensor is not
working properly
F4 OVERLOAD Warning: Load weight sensor - To remove warning cause
detects that loaded weight
exceeds the weight limited
in OVERLOAD WEIGHT
programming.
F5 SAFETY Alarm: the controller detects - To recycle the key
(PUMP CONTROLLER controllers
A12-A34) - Check the safety circuit
F6 MASTER KO Alarm: Slave µC detects a - to recycle the key
Master µC malfunctioning or a - C h e c k I f a n y o t h e r a l a r m h a p p e n s
mismatch between inputs status (Some alarms such as CHAT TIME or PEDAL
and Master commands (via WIRE KO, alarms related to CONTACTOR,
Canbus) DISPLAY ENABLE, alarms related to
(display TRUCK MENU->MONITORING
->choose controller->H/W VER, S/W VER.
F7 CAN BUS KO Alarm: CONTROLLER doesn't - Check the CAN wiring
receive any message from CAN - Check if any other alarm happens
line (Some alarms such as CHAT TIME or PEDAL
WIRE KO, alarms related to CONTACTOR,
7-76
alarm status
F9 THERMIC Warning: Master or slave temp. - To remove Warning cause
SENSOR KO sensor is out of range
FB WAITING FOR MC Warning: SLAVE Controller - To remove Warning cause
detects that Master Controller is - C h e c k i f a n y o t h e r a l a r m h a p p e n s
malfunctioning or ALARM occurs (Some alarms such as CHAT TIME or PEDAL
on master controller WIRE KO, alarms related to CONTACTOR,
- Check other controllers
FD AUX OUTPUT KO Alarm: PWM AUX (A28-A29 - If the alarm is present in Init status, remove
: CURRENTLY NOT USED the alarm cause
PORT) driver shorted or open - If the alarm has occurred in stby or running
7-77
3) PUMP CONTROLLER

alarm status
0D EEPROM KO Warning: Eeprom fault, controller - To remove Warning cause
12 LOGIC FAILURE #2 Alarm: failure in U, V, W voltage - To remove alarm condition + activation of
undervolt. condition has been - Sometimes if battery voltage is too low, it can
detected be happens
31 I = 0 EVER Alarm: while truck is running, - Check the main contactor
current value is 0 for more than 1 - Check the controller
Sec
is turned ON; failure in the power
section, or in the Logic PCB, or in
7-78
alarm status
3D HIGH Warning: controller temperature - To remove warning cause
TEMPERATURE higher than 75°C
41 MOTOR W a r n i n g : P u m p m o t o r ’ s - To remove warning cause
TEMPERA-TURE temperature high - Check the motor temp-sensor
4A DRIVER Alarm: line contactor coil - If the alarm is present in Init status, remove
SHORTED driver(A27-A26 : CURRENTLY the alarm cause
NOT USED) or FAN RELAY - If the alarm has occurred in stby or running
(A29-A28) coil driver is shorted mode, it is necessary to remove alarm cause
4B CONTACTOR Alarm: line contactor coil driver - To remove alarm cause and to activate
DRIVER (A27-A26 : CURRENTLY NOT traction request
USED) is open (not able to drive
the coil to the correct voltage)
4C COIL SHORTED Alarm : - If the alarm is present in Init status, remove
- Init: the LC (A27-A26 : the alarm cause
CURRENTLY NOT USED) - If the alarm has occurred in stby or running
or FAN RELAY (A29-A28) mode, it is necessary to remove alarm cause
coil driver protection circuit is and to activate traction request
damaged
- Stby or running: short on LC
(A27-A26 : CURRENTLY
NOT USED) or FAN RELAY
(A29-A28)
4E VACC NOT OK Warning: acc/lift signal (CPOT) - To remove warning cause
voltage higher than VACC MIN - Re-configurate VASS LIFT
+1V while the traction/lift enable
switch is open
4F INCORRECT Warning: wrong traction/pump - To remove warning cause
START request sequence
52 ENCODER Alarm: motor speed sensor - To recycle the key
ERROR ( e n c o d e r ) d o e s n o t w o r k - Check the motor encoder
properly
56 PEDAL WIRE KO Alarm: fault in accelerator/Lift - To remove alarm cause and activate a
negative (NPOT) input circuit traction/pump request
DF S B R S W I T C H Warning: SIDE BATTERY - To remove warning cause
OPEN REMOVAL sensor is open - Check the sensor
E0 ACQUIRE AUX Controller is configurating “AUX” - Finish the configuration process.
lever function
E1 ACQUIRE SHIFT Controller is configurating - Finish the configuration process.
“SHIFT” lever function
E2 ACQUIRE TILT Controller is configurating “TILT” - Finish the configuration process.
lever function
E3 TILT SENS OUT Value of tilt sensor (AUTO TILT - Check the Tilt Sensor of AUTO TILT
RNG LEVELING) is out of range LEVELING Option
- Re-configurate Tilt Sensor of AUTO TILT
LEVELING Option
7-79
alarm status
E4 T I L T S E N S Value of tilt sensor (AUTO TILT - Check the Tilt Sensor of AUTO TILT
LOCKED LEVELING) is fixed even tilt LEVELING Option
request is activated - Re-configurate Tilt Sensor of AUTO TILT
LEVELING Option
E5 AUX FUNCT KO Fingertip aux function is not - Check the MCV valve
working properly - Re-configurate lever
- Check the fingertip controller
E6 SHIFT FUNCT KO Fingertip shift function is not - Check the MCV valve
working properly - Re-configurate lever
E7 TILT FUNCT KO Fingertip tilt function is not working - Check the MCV valve
properly - Re-configurate lever
E8 LIFT FUNCT KO Fingertip lift function is not working - Check the MCV valve
properly - Re-configurate lever
E9 AUX OUT OF RNG Voltage value of AUX sensor is - Re-configurate the AUX lever
out of range - Check the AUX lever
EA SHIFT OUT OF Voltage value of SHIFT sensor is - Re-configurate the SHIFT lever
RNG out of range - Check the SHIFT lever
EB FORK WRONG DIR D i r e c t i o n o f “ A U T O T I L T - Check if operator operates truck correctly

LEVELING” movement is not - Check the Tilt Sensor of fork leveling option
correct - Re-configurate Tilt Sensor of Fork leveling
Option
EC TILT SENS OUT Value of tilt sensor (AUTO TILT - Check the Tilt Sensor of AUTO TILT
RNG LEVELING) is out of range LEVELING option
- Re-configurate Tilt Sensor of AUTO TILT
LEVELING option
ED TILT SENS Value of tilt sensor (AUTO TILT - Check the Tilt Sensor of AUTO TILT
LOCKED LEVELING) is fixed even tilt LEVELING option
request is activated - Re-configurate Tilt Sensor of AUTO TILT
LEVELING option
is constantly zero when the - Check the motor and encoder"
maximum torque is applied to the
motor
F2 ACQUIRE LIFT Controller is configurating “LIFT” - Finish the configuration process
lever function
F4 SAFETY Alarm : the controller detects - To recycle the key
(Pump controller A12-A34) controllers
- Check the safety circuit
F5 WRONG SET Alarm: the battery voltage does - To remove alarm cause
BATTERY not correspond to SET BATTERY
TYPE programming
7-80
alarm status
F7 CAN BUS KO Alarm: controller doesn't receive - Check the CAN wiring
any message from CAN line - Check if any other alarm happens
(Some alarms such as CHAT TIME or
contactor, display enable, alarms related to
(display TRUCK MENU->MONITORING-
>choose controller->H/W VER, S/W VER. If
F9 THERMIC SENSOR Warning: Master or slave temp. - To remove Warning cause
KO sensor is out of range
FB WAITING FOR Warning: controller signals that - To remove Warning cause
NODE other controllers are in alarm - C h e c k i f a n y o t h e r a l a r m h a p p e n s
status (Some alarms such as CHAT TIME or
contactor, display enable, alarms related to
(display TRUCK MENU->MONITORING->
choose controller->H/W VER, S/W VER. If
- Check other controllers.
FD AUX OUTPUT KO Alarm: fan relay (A28-A29) driver - If the alarm is present in Init status, remove
shorted or open the alarm cause
and to activate traction request"
7-81
8. BATTERY CHARGER
This explains basic information related to charger to help you easily understand and use it. This
includes the contents from the way to install a charger to tips for emergency situations. This is
focused on practices aiming to be usefully utilized in the field.
1) BASIC INFORMATION
(1) What is charger
Charger is a device which makes a battery accept D.C electricity under optimal condition as it
transforms A.C provided from external source of electricity.
The charger is a constant-current and constant-voltage way, SCR type charger that it has
advantages as follows
① Even though A.C input voltage fluctuates within 10% of rated voltage (220/380/410/440V), the
current and voltage provided to the battery are stable.
② As minimizing the increase of temperature while charging a battery, it minimizes the stress on
the battery.
③ The noisy of charger is minimal but the charging efficiency is very high.
④ It prevents from under charging and overcharging.
Therefore, it helps the battery to maintain its performance for longer time and to prolong the life
of the battery.
(2) Notice on caring chargers

① If any abnormal status is found while using a charger, immediately stop using and check the
charger. If it is impossible to take an appropriate measure for yourself, please apply for A/S.
② While charging, hydrogen and oxygen gas is produced. Use or approach of fire should be strictly
prohibited.
③ Keep clean to prevent from sneak current and attack on the interface and surroundings of the
battery.
④ Check the electrolyte of the battery every week and provide distilled water immediately if it is
required. (Electrolyte has to be provided between 10~12 mm level on the positive plate inside
storage battery)
⑤ If battery liquid temperature becomes over 55°C, charging should be stopped.
If it is continued,
- the appearance is transformed
- and metal area can be attacked as electrolyte overflows
⑥ Electric forklift truck using battery should be charged as soon as the charging lamp is on while
driving. As batteries are internally discharged naturally if they are deposed for a long time,
charge them once or twice a month to prevent from reducing the lives of batteries.
⑦ When a green sign is on among charging status indication lamps, please notify that it is not
converted as equalized charge for stabilization of charging status.
7-82
(3) Names of each part (independent items)
1 2 3
4 5
6 7 8 9 10
22B9BAT30
1 Main PCB board 5 Monitor PCB 9 Resistance (RD)

2 Main trans (Class H) 6 Overload 10 Resistance (DR)
3 Cooling fan 7 MG S/W
4 SCR module 8 Assistant trans
7-83
2) Charger installation method
(1) Location for charger installation
① Dry and well ventilated place.
② No inflammable and B7 fire are near by.
③ Safe place where no collision possibility
with people or equipment is.
(2) Check points before installing charger
① Enough capacity of AC input power
source to operate charger.
② Standard electric wire for power source
by capacity.
(3) Table for capacity of charger input cable
Capacity of Input
48 V battery Remarks
cable voltage
200-365 AH 4P - 2.5 mm2
400-580 AH 4P - 4 mm2
For 3Ø220V,
600-800 AH 4P - 6 mm2
one step
850-1000 AH 4P - 10 mm2 Based on higher
24 V battery - 3Ø380 V capacity
200-600 AH 4P - 2.5 mm 3Ø440 V cable should
2
700-1000 AH 4P - 4 mm2 be used.
80V battery - (2.5 mm2 →

4mm2)
500-600 AH 4P - 6 mm2
700-800 AH 4P - 10 mm2
7-84
3) HOW TO USE A CHARGER
(1) General charging method (Floating
charging)
① Charging by this method supplies electric
power to the charger as operating
external AC power switch of the charger.
② Connect battery connecter and charger
connecter.
·According
According to charging condition
① If there is no abnormality found when the
22B9BAT01
charger checks itself for 3-4 seconds
after inputting AC input power source, the
charger slowly increases the electric flow
for charging and the charging condition
lamp in the lower part of the front panel Display
for floating charging of "input" is on. 85%
② A charging voltage, current, amount and 2
1
time are displayed in order on a monitor
80%
display window. 3 2
③ When charging is processed about 80%,
yellow lamp in the middle of the front 1
panel, which shows that the charging
condition is in the middle, is on and then BOP7BAT02
green lamp is on when charging is

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

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

function (Refer to the monitor)
① Plug it into a manual connector and input
①
after 5 sec., a floating charge, charging ③
status red LED lights up. ②
② After 15 sec., charging status yellow LED
lights up.
③ After a green LED lights up, if measured
voltage comes out as IuIa105V by BOP7BAT10
measuring output voltage of battery
connector side with multi-meter, then it is
normal.
④ After 30 sec. of switching to a manual
connector, if a buzzer sound rings
continuously for 10 sec. and completion
LED lights up, then it is normal.
⑤ If you confirm that the charger operates in
normal after checking manual switching of
the charger, make sure that the charger is
switched to automatic.
7-86
⑥ If charger's out voltage is under 100 V, it is
abnormal.
Please refer to the error sheet.
⑦ When the charging voltage is indicated as
normal condition (105 V), convert
automatic / manual switch to automatic
and start charging.
※ Display error code on the front cover as
22B9BAT11
following table.
No Code Description of error
1 E.F EPROM fail

2 O.V Over voltage - Refer to page 7-92
3 O.C Over current - Refer to page 7-91, 7-93.
4 F.B Battery error (After starting charging, the voltage doesn't go over 52V for 2 hours.)
Check the battery.
5 O.T Transformer over heat (Stop charging when it is over 160°C).
- If input voltage is high, output current is over normal value and there is heat in the
trans because of SCR control part fault.
- Check the output current and PCB control board
6 O.H Heatsink over heat (Stop charging when it is over 100°C).
- Check the cooling fan, SCR connection cable contact point and control part.
7 A.O Power supply error (input power 220/380V wrong wiring). - Refer to page 7-90.
8 A.F Power supply error (absent phase) - Check if input cable is open.
9 A.C AC fail (black out) - Check if input voltage is right.
10 L.C Low current (If this sign is on for setting value (60 sec), charging is over).
11 F Manual stop.
7-87
4) CHECK POINTS BEFORE APPLYING A/S
(1) AC input power source switch is input.
(2) Check if the battery connector of the order
picker truck and charger's connector are
connected.
(3) Check points when "Error" lamp is on in
the front monitor of the charger.
(4) Check the front cover indicator.
① A.F : Input three phase power source
continuity check = Check if input three Error indication BOP7BAT12
phase power source is normal with AC

voltage meter.
② A.O : Error on selection of input power
source of 220V or 380V - Check it
appropriately with full three phases.
③ A.C : Check if the input power source
(220V or 380V) is normal.
④ O.C : Check the electric current, as
charging current of the battery is over-
standards condition.
⑤ O.V : Check the voltage, as charging
voltage of the battery is over-voltage
condition (108V).
Normally it is 105V±1.0V.
(5) Check other abnormalities as well. Then
apply for A/S when on-site
measurements are not applicable.
7-88
5) ERROR DETECTION
(1) Error list
① Only floating charge lamp is on in the
monitor but it is not charged.
② ON and OFF is repeated with a few
minutes intervals even after starting
charging.
③ Charger TRIP is occurred after
abnormality lamp is on.
In case error code is "O.V"
④ Charger TRIP is occurred after
abnormality lamp is on.
In case error code is "O.C"
⑤ Charger TRIP is occurred after it started
charging and charging completion lamp
is on.
⑥ Charger has no response even the
battery connector is connected.
⑦ SCR module checking method
7-89
(2) Troubleshooting
① Only floating charge lamp is on after indicating "A.O", It's not charged.
· 220/380V Model : Measure the TB.4 (380V) TB.8(220V)

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

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

Input power supply is not 220V
PCB RELAY fault
supplied.
YES TH manual
· Check external lead cable.
restoration release
· Check the connection of MS COIL fault
external input connecter Relay Relay
contact
· Check external NFB TRIP point
7-90
② ON and OFF is repeated with a few minutes intervals after starting charging.
Indicate "O.C" on the monitor.
- TH is operated (AC input over-current TRIP).
OUTPUT
CURRENT
DE- IN-
CREASE CREASE
Trans
noise is Measure output Current Exceed Adjust output current
NO NO
severe at current using DC value : 10~16A Standard AMP, VR within PCB
MS ON current measure /100AH current Re-adjust to VR
status
YES
· TH Setting fault
YES
· Re-adjust TH TH. TRIP Change TH
setting value
NO
* Refer to SCR Rated
Complete Current
YES Module checking
method SETTING
YES NO
Complete Change PCB
NO Change
SCR MODULE
Separate the battery Check
connector and tune SCR
the charger off Module
YES Check
Check the normal
MAIN NO Change
operating condition
TRANS PCB
of the charger
VOLT
YES
7-91
③ Charger TRIP is occurred after abnormality lamp is on.
In case error code is "O.V" → Over-voltage output / Set at 66V (In case of BATT 48V)
34V (In case of BATT 24V)
108V (In case of BATT 80V)
After separating battery connector, Rotate charging voltage volume,

Check
insert automatic/manual selection located in the middle of PCB, to
the voltage of the NO
connector(J2) at the left side of PCB counterclockwise.
output connecter
to manual and then, MS will be turned Adjust a real output voltage
105V? identical to displayed voltage
“ON”
Reset voltage as turning

YES De- In-
volume volt for setting voltage crease crease
on the center of PCB
Measure
YES the voltage of the VOLT
Adjust voltage so as
output connecter
to have same output
105V?
between actual output
Check contact error
voltage and indication
or breaking of wiring NO Change
of display
De- In- OK NO of the detect cable PCB
crease crease
connecter pin
Check Check
whether the charger
the detect
is normal condition after
YES voltage of the J3 NO
connecting the
battery connector
105V?
NO
YES
Change PCB
OK
7-92
④ Charger TRIP is occurred after abnormality lamp is on.
After opening the cover which is located on the front bottom side of the charger.
In case error code is "O.C" → Output over current, established as 110~120% of the rated
current.
Measure
Check poor contact of current
the output current
Restart the charger as pushing NO connector (J1), located right side of
by DC current measure
reset switch in the monitor. PCB; check if there is disconnection
10~16A/
(cleaning and wiring )
100AH
YES
Re-establish charge current Measure

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

OK
persists after adjustment PCB
De- In-
crease crease
7-93
⑤ Charger TRIP is occurred after it started charging and charging completion lamp is on.
(In case input voltage is normal - Refer to the error detection No. 1)
Restore the charger as pushing reset switch.
If charging
current measurement After separating battery
NO Measure the output
is normal when it is measured connector, put the automatic/
voltage 64V
with DC ammeter manual S/W (J2) to manual
YES
YES
Change PCB or NO
J2
Request After-Service Contact fault between
Check
the battery connector
SCR Module
and charger connector
Normal Battery is over-
discharged
NO YES
Change Change
SCR Module PCB
7-94
⑥ Charger has no response even if the battery connector is connected.
- In case only floating LED is on, charger input power is cut off or doesn't connect. (In case
the input voltage is normal - Refer to the error detection No. ① )
NO Charger BATTERY
Connector contact fault
Battery
Measure Measure the
NO voltage
the battery voltage voltage within the is normal
Is it under RD of the charger (Over
48V? BATT(+) SHUNT 35V)
J.3
YES RD PCB(+)
YES
PCB(-)
BATT(-)
PCB
(+)(-) Voltage Check the cable and contact
is over YES point status at PCB connector(J3)
12V
On the
Put the auto/manual S/W to manual, after 30
left side of PCB
min. ~1 hr, put the S/W to auto and let it be
Is LP LED
charged normally. NO NO
ON?
If battery voltage doesn’t increase after 1 hr of
starting auto charge, then battery check in YES Change
needed. PCB
Refer to the error detection No.①

Change Check the input power wire line
RD 340/50W in the charger
RD
BATT(+)
70 12V or higher LP, LED
BATT(-)
( based on 48V)
7-95
7) HOW TO CHECK THE SCR MODULE
Circuit Real diagram
K2 K2
G1
K1 G1
3 2 1 K1
* Before checking SCR MODULE, be sure to disconnect bus bar and wire on the terminal.
Measuring point Measure value
No. SURGE PCB
(Real diagram) (Measurement of digital tester)
1 No.1 ~ No.3 Forward : Under 100 k ohm

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

3 G1 ~ K1 Forward : Under 100 ohm

Reverse : Under 100 ohm
But It depends on the module.
If it is not 0 ohm, It is Ok.
4 G1 ~ K2 Forward : Infinity ( ∞ )
7-96
8) PCB MAJOR PARTS (NAME AND LOCATION)
②Lp lamp
Auto ⑬Auto/manual
Manual switch TAP ④SHUNT
detect current J2
J2 ⑫Auxiliary ③Detect
connector power supply voltage J3
⑥Correct ⑤Correct ⑦Correct

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

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

2 Lp lamp 7 Correct CPU voltage 12 Auxiliary power supply
3 Detect voltage 8 Monitor display output 13 Auto/manual switch TAP
4 SHUNT detect current 9 Temperature sensor 14 SCR control connector
5 Correct output current 10 SCR control
7-97
22B9BAT27
7-98
CHARGER INTERIOR PARTS
12 5 9 1 3
6 7
2
13
10
14
8
11
22B9BAT28
No Part name Remarks

1 AC fan
2 Over load
3 Resister RD
4 Trans-aux
5 Magnet switch
6 SCR module
7 Monitor
8 DC out cable
9 Resister DR
10 Main transformer
11 AC input cable
12 Main control board
13 Filter
14 Fuse
7-99

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SECTION 7 ELECTRICAL SYSTEM

Group 1 Component location --------------------------------------------------------------------------------------- 7-1

1 Combination switch 10 Pump controller 19 Beacon lamp (opt)

F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

20 23 24 27 26 26A 25 55 52 52A FAN 28

M V FWD S/W V M LIFT S/W V M

ACCEL S/W AUX1 S/W

121 92A ELECTRIC FORKLIFT DISPLAY 222E 65

06 125 A19 CAN L 125B 04

F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

20 23 24 27 26 26A 25 55 52 52A FAN 28

M V FWD S/W V M LIFT S/W V M

ACCEL S/W AUX1 S/W

121 92A ELECTRIC FORKLIFT DISPLAY 222E 65

06 125 A19 CAN L 125B 04

F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

M V FWD S/W V M LIFT S/W V M

06 125 A19 CAN L 125D 04

F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

20 23 24 27 26 26A 25 55 52 52A FAN 28

M V FWD S/W V M LIFT S/W V M

ACCEL S/W AUX1 S/W

121 92A 222E A10 INVERTER 65

06 125 A19 CAN L 125D 04

F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

06 125 A19 CAN L 125D 04

F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

20 23 24 27 TRF 26 26A 25 55 52 52A 28

06 125 A19 CAN L 125D 04

F3 F5 F6 F9 F8 F10 F11 F12 F4 F13 F14

20 23 24 27 TRF 26 26A 25 55 52 52A FAN 28

06 125 A19 CAN L 125D 04

F3 F5 F6 F9 F8 F10 F11 F12 F4

20 23 24 27 26 26A 25 55 52 52A FAN 28

M V FWD S/W V M LIFT S/W V M

06 125 A19 CAN L 125B 04

F3 F5 F6 F9 F8 F10 F11 F12 F4

20 23 24 27 26 26A 25 55 52 52A FAN 28

M V FWD S/W V M LIFT S/W V M

06 125 A19 CAN L 125D 04

F3 F5 F6 F9 F8 F10 F11 F12 F28 F29 F4

M V FWD S/W V M LIFT S/W V M

06 125 A19 CAN L 125D 04

F3 F5 F6 F9 F8 F10 F11 F12 F28 F29 F4

20 23 24 27 TRF 26 26A 25 55 52 8182B 82 28

06 125 A19 CAN L 125D 04

F3 F5 F6 F9 F8 F10 F11 F12 F28 F29 F4

06 125 A19 CAN L 125D 04

F3 F5 F6 F9 F8 F10 F11 F12 F28 F29 F4

06 125 A19 CAN L 125D 04

560 00A 324A

125A 567 326A

1. FUNCTIONS OF BATTERY FORKLIFT TRUCK AND ELECTRIC COMPONENTS

1 Cells 6 Cable connector

3) SPECIFICATION AND SERVICE DATA

Item Unit 40/45/50B-9

Fully charged specific gravity 1.280 (25°C)

Minimum Level Maximum Level

1 Rotor 5 Block-Terminal A 9 Bearing