ES16-16RAS

ES16-16RAS
Electric Stacker
Service Manual
MANUAL NO. SM2214 05.15
WARNING
Do not operate this truck unless you have been Do not overload truck. Check nameplate for capacity
authorized and trained to do so, and have read all and load center information.
warnings and instructions in Operator’s Manual and
on this truck. When using forks, space forks as far apart as load
will permit. Before lifting, be sure load is centered,
Do not operate this truck until you have checked forks are completely under load, and load is as far
its condition. Give special attention to tires, horn, back as possible against load backrest.
battery,controller, lift system (including forks or
attachments,chains, cables and limit switches), Do not handle unstable or loosely stacked loads.
brakes, steering mechanism, guards and safety Use special care when handling long, high or wide
devices. loads, to avoid losing the load, striking bystanders,
or tipping the truck.
Operate truck only from designated operating
position.Never place any part of your body into the Do not handle loads which are higher than the load
mast structure or between the mast and the truck. backrest or load backrest extension unless load is
Do not carry passengers. Keep feet clear of truck secured so that no part of it could fall backward.
and wear foot protection. Elevate forks or other lifting mechanism only to
Observe applicable traffic regulations. Yield right of pick up or stack a load. Watch out for obstructions,
way to pedestrians. Slow down and sound horn at especially overhead.
cross aisles and wherever vision is obstructed. Do not lift personnel except on a securely attached
Start, stop, travel, steer and brake smoothly. Slow specially designed work platform. USE EXTREME
down for turns and on uneven or slippery surfaces CARE WHEN LIFTING PERSONNEL. Make sure
that could cause truck to slide or overturn. Use mast is vertical, place truck controls in neutral and
special care when traveling without load as the risk apply brakes. Lift and lower smoothly. Remain in
of overturn may be greater. operating position or immediate vicinity as long as
personnel are on the work platform. Never transport
Travel with lifting mechanism as low as possible. personnel on forks or work platform.
Always look in direction of travel. Keep a clear view,
and when load interferes with visibility, travel with Do not allow anyone to stand or pass under load or
load trailing. lifting mechanism.
Use special care when operating on ramps travel When leaving truck, neutralize travel control, full
slowly, and do not angle or turn. Travel with load lower lifting mechanism and set brake. When leaving
downhill. truck unattended, also shut off power.
SM2214 05.15
TABLE OF CONTENTS
Section Page Section Page

1 DESCRIPTION ......................................................1 5-2. COMPARTMENT COVERS .........................48
1-1. INTRODUCTION ............................................1 5-2.1. Removal .................................................48
1-2. GENERAL DESCRIPTION .............................1 5-3. STEERING ARM ..........................................48
1-3. SAFETY FEATURES .....................................1 5-3.1. Return Spring Replacement ...................48
5-3.2. Steering Arm Removal ...........................48
2 OPERATION..........................................................3 5-3.3. Steering Arm Installation ........................48
2-1. GENERAL ......................................................3
2-2. OPERATING PRECAUTIONS .......................3 6 BRAKE SERVICING............................................51
2-3. BEFORE OPERATION...................................4 6-1. BRAKES .......................................................51
2-4. GENERAL CONTROL OPERATION ..............6 6-1.1. Brake Assembly Replacement ...............51
2-5. DRIVING AND STOPPING
PROCEDURES ..............................................6 7 DRIVING SYSTEM ..............................................53
2-5.1. Stopping ...................................................6 7-1. DRIVE WHEEL.............................................53
2-6.BELLY-BUTTON SWITCH...............................7 7-2. TRANSMISSION ..........................................53
2-7.STEERING ARM GAS SPRING ......................7 7-3. STEERING MOTOR.....................................53
2-8. LIFT AND LOWER CONTROLS ....................7 7-4. LOAD WHEEL ..............................................55
2-9. LOADING AND UNLOADING ........................7 7-4.1. Removal .................................................55
2-10.PARKING ......................................................7 7-4.2. Repair .....................................................55
7-4.3. Load Wheel Installation ..........................55
3 PLANNED MAINTENANCE ..................................9
3-1. GENERAL ......................................................9 8 ELEVATION SYSTEM SERVICING ....................57
3-2. MONTHLY AND QUARTERLY CHECKS .......9 8-1. GENERAL ....................................................57
3-3. BATTERY CARE ............................................9 8-2. LIFT CHAIN LENGTH ADJUSTMENT .........57
3-3.1. General.....................................................9 8-3. LIFT CHAIN WEAR INSPECTION ...............58
3-3.2. Safety Rules ...........................................10 8-4. LIFT CHAIN REPLACEMENT ......................58
3-3.3. Battery Care and Charging.....................10 8-4.1. Telescopic...............................................58
3-3.4. Battery Cleaning .....................................10 8-4.2. TRIMAST Free Lift Chain .......................60
3-4. CHARGING BATTERIES ............................. 11 8-4.3. TRIMAST Secondary Lift Chain .............60
3-5. LUBRICATION ............................................. 11 8-5. LIFT CYLINDERS ........................................60
3-6. LIFT CHAIN MAINTENANCE....................... 11
9 HYDRAULIC SYSTEM ........................................63
4 TROUBLESHOOTING ........................................13 9-1. LINES AND FITTINGS .................................63
4-1. GENERAL ....................................................13 9-2. HYDRAULIC PUMP, MOTOR, AND
4-2. CONTROLLER TROUBLESHOOTING........16 RESERVOIR ASSY ......................................63
4-2.1. Zapi Handset ..........................................16 9-2.1. Removal .................................................63
4-2.2. Fault Detection .......................................16 9-2.2. Disassembly and Reassembly ...............66
4-2.2.1. General..............................................16 9-2.3. Installation ..............................................66
4-2.2.2. Logbook Access ................................16 9-2.4. Lift Cylinder (Telescopic) ........................68
4-2.3. Testing Truck Operation .........................16 9-2.4.1. Removal ............................................68
4-2.4. Settings and Adjustments .......................17 9-2.4.2. Repair ................................................68
4-2.4.1. Set Options........................................17 9-2.4.3. Installation .........................................68
4-2.4.2. Adjustments .......................................21 9-2.5. Lift Cylinder (TRIMAST Free Lift) ...........69
4-2.4.3. Parameter Change ............................23 9-2.5.1. Removal ............................................69
4-2.5. Troubleshooting.27 ..................................... 9-2.5.2. Repair ................................................69
9-2.5.3. Installation .........................................69
5 OPERATING CONTROL SYSTEM .....................43 9-2.6. Lift Cylinder (TRIMAST Secondary) .......70
5-1. CONTROL HEAD .........................................43 9-2.6.1. Removal ............................................70
5-1.1. Cap Assembly Removal .........................43 9-2.6.2. Repair ................................................70
5-1.2. Cap Assembly Installation ......................44 9-2.6.3. Installation .........................................70
5-1.3. Control Head Removal ...........................45
5-1.4. Control Head Installation ........................45 10 ELECTRICAL COMPONENTS ..........................71
5-1.5. Potentiometer Replacement ...................45 10-1. ELECTRICAL CONTROL PANEL ..............71
5-1.6. Belly-Button Switch Replacement ..........45 10-1.1. Maintenance .........................................71
SM2214 05.15
Section Page
10-1.2. Cleaning ...............................................71
10-1.3. Panel Removal .....................................71
10-1.4. Panel Disassembly ...............................71
10-1.5. Panel Installation ..................................71
10-2. HORN REPLACEMENT .............................71
10-3. PUMP MOTOR ...........................................76
10-4. DRIVE MOTOR ..........................................76
10-5. DEADMAN SWITCH ..................................76
11 OPTIONAL EQUIPMENT ..................................77
12 ILLUSTRATED PARTS BREAKDOWN .............79
SM2214 05.15
SECTION 1
DESCRIPTION
1-1. INTRODUCTION
This publication describes the 24 volt lift truck
distributed by EP Included are operating instructions,
planned maintenance instructions, lubrication Model:
procedures, corrective maintenance procedures and Capacity: kg Lifting height: mm
a complete parts list with part location illustrations. Load center: mm Battery capacity: Ah
Fork width: mm Selfweight with battery: kg
By following these requirements and the recomm-

Fork length: mm Series number:
endations contained in this manual, you will receive

many years of dependable service from your lift
truck.
Figure 1-1 Name Plate
1-2. GENERAL DESCRIPTION • Emergency brake switch to apply the brake and cut
off drive power when depressed.
The self-propelled truck, Figure 1-2, lifts and transp-
orts payloads up to 3500 pounds on rigid forks. • Belly-button switch to reverse truck should the ope-
rator accidentally pin himself against a wall or obst-
The forward and reverse motion is controlled by ruction when backing up in slow speed.
either of two controller levers mounted on the
• High speed limit switch to restrict speed when lift
control head.Stopping and turning is controlled
carriage is raised above the preset limit.
by the steering arm.Lift and Lower is controlled
by pushbuttons on the control head. The battery • All control functions automatically return to “OFF”
powered lift truck is quiet and without exhaust fumes. when released.
• Externally accessible battery disconnect within
The reversible AC motor propels the lift truck in
operator's reach.
forward or reverse direction throughout the available
speed range. The lift truck can be driven with forks • Separately fused control circuits and power circuits.
raised or lowered; however, the speed is restri-cted • Readily accessible horn button.
when the platform is raised above a preset limit.
• Lift carriage backrest to help stabilize the load.
The model number will be found on the name • Handle to provide a firm hand hold for operator.
plate (Figure 1-1) along with the serial number,
• Flow control valve regulates maximum lowering
lifting capacity, and load center. Figure 1-2 shows
speed within prescribed limits.
the locations of the truck’s main components and
controls. • Relief valve maintains hydraulic pressure within
prescribed limits.
1-3. SAFETY FEATURES • High visibility color scheme of truck provides visual
The truck is designed engineered to provide alert of truck’s presence.
maximum safety for operator and payload. Some of • Battery Indicator
the safety features incorporated into the design are:
• Casters
• Dead-man brake to apply the brake and cut off
drive power when the steering arm is released.
SECTION DESCRIPTION SECTION DESCRIPTION

1 DESCRIPTION 7 DRIVING SYSTEM
2 OPERATION 8 ELEVATION SYSTEM SERVICING
3 PLANNED MAINTENANCE 9 HYDRAULIC SYSTEM
4 TROUBLESHOOTING 10 ELECTRICAL COMPONENTS
5 OPERATING CONTROL SYSTEM 11 OPTIONAL EQUIPMENT
6 BRAKE SERVICING 12 ILLUSTRATED PARTS BREAKDOWN
SM2214 05.15
1
Figure 1-2 Lift Truck
ITEM COMPONENT ITEM COMPONENT

1 Control handle 7 Chassis
2 Key switch 8 Caster
3 Battery indicator 9 Drive wheel
4 Windshield 10 Platform
5 Emergency stop switch 11 Handrails
6 Forks
SM2214 05.15
2
SECTION 2
OPERATION
2-1. GENERAL • Be certain that the lifting mechanism is operating
smoothly throughout its entire height, both empty
This section gives detailed operating instructions
and loaded.
for the lift truck. The instructions are divided into the
various phases of operations, such as operating • Be sure that mast is vertical - do not operate on a
lift, driving, and stopping. Routine precautions are side slope.
included for safe operation. • Be sure the truck has a firm and level footing.
• Avoid overhead wires and obstructions.
2-2. OPERATING PRECAUTIONS
• Check for obstructions when raising or lowering the
WARNING:Improper operation of the lift truck may lift carriage.
result in operator injury, or load and/or lift • Do not handle unstable or loosely stacked loads.
truck damage. Observe the following Use special care when handling long, high, or wide
precautions when operating the lift truck. loads to avoid tipping, loss of load, or striking bysta-
nders.
The following safety precautions must be adhered to
at all times. • Center and carry the load as far back as possible
toward the lift carriage back rest. The center-of-
• Do not operate this truck unless you have been
gravity of the load must not exceed the load center
trained and authorized to do so.
listed on the nameplate. See Figure 2-1 for load
• All warnings and instructions must be read and center limitations.
understood before using the equipment.
• Pick up loads on both forks. Do not pick up on only
• Equipment must not be altered in any way. one fork.
• Equipment must be inspected by a qualified person • When traveling, always lower the load as far as
on a regular basis. possible.
• Do not exceed the rated capacity. Overloading may
result in damage to the hydraulic system and struct-
ural components.
Figure 2-1 Load Center
SM2214 05.15
3
• When stacking pallets in racks and it is necessary Figure 2-2 shows a sample format for an Operator
to move the load in a raised position, use caution. Checklist, which can be modified as necessary to fit
Operate truck smoothly. your operation.
• Observe applicable traffic regulations. Yield right of WARNING: Periodic maintenance of this truck by a
way to pedestrians. Slow down and sound horn at QUALIFIED TECHNICIAN is required.
cross aisles and wherever vision is obstructed.
• Operate truck only from designated operation
position.Never place any part of your body between CAUTION: A QUALIFIED SERVICE TECHNICIAN
the mast uprights. Do not carry passengers. should check the truck monthly for
• Do not allow anyone to stand or pass under load or proper lubrication, proper fluid levels,
lifting mechanism. brake maintenance, motor maintenance
and other areas specified in the SEC-
• When leaving truck, neutralize travel control. Fully TION 3.
lower lifting mechanism and set brake. When leavi-
ng truck unattended, turn off key switch, remove WARNING: If the truck is found to be unsafe and in
key and disengage the emergency stop switch. need of repair, or contributes to an
unsafe condition, report it immediately to
2-3. BEFORE OPERATION the designated authority. Do not operate
it until it has been restored to a safe
Table 2-1 covers important inspection points on the operating condition. Do not make any
lift truck which should be checked prior to operation. unauthorized repairs or adjustments. All
Depending on use, some trucks may require service must be performed by a qualified
additional checks. maintenance technician.
Table 2-1 Operator Checks

ITEM PROCEDURE ITEM PROCEDURE
Transmission Check for signs of fluid leakage. Wheels Check drive wheel for cracks or
and hydraulic damage. Move truck to check
systems. load for freedom of rotation.
Forks Check for cracks and damage; Hydraulic Check operation of lift and lower
and, that they are properly controls to their maximum positions.
secured. Brakes Check that brakes actuate when
Chains, cables Check that they are in place, steering arm is raised to upright
and hoses secured correctly, functioning position, and when lowered to
properly and free of binding or horizontal position.
damage. Deadman/ Check that steering arm raises to
Guards and load Check that safety guards are in Parking brake upright position when released
backrest place, properly secured and not and brake applies.
damaged. Emergency Stop Check that emergency stop
Safety signs Check that warning labels, Switch switch can be disengaged and
nameplate, etc., are in good reengaged.
condition and legible. Battery charge Check the battery indicator.
Horn Check that horn sounds when High speed limit Allow for enough space to
operated. switch operate truck in high speed.
Steering Check for binding or looseness in Elevate forks approximately
steering arm when steering. two feet, then test drive truck to
check if high speed is cut out.
Travel controls Check that speed controls on
control head operate in all
speed ranges in forward and
reverse and that belly button
switch functions.
SM2214 05.15
4
Electric Truck
Daily Operator Check-Off List
Date Operator
Truck No. Model No.
Dept. Shift
Hour Meter
Reading-Drive Hoist
Check O.K.(√) Need maintenance

Tires
Load Wheels
Horn
Lift-Lower Controls
Attachment Operation
Forward & Reverse Controls
Steering
Brakes
Hydraulic Leaks,cylinders,
Valves, Hoses, Etc.
Figure 2-2 Sample of Operator Check List
SM2214 05.15
5
2-4. GENERAL CONTROL OPERATION 2. Lower the steering arm to a comfortable position
above horizontal to disengage the brake and to
The speed control (See Figure 2-3) located on each energize the electrical circuits. If the truck is not
side of the control head provides fingertip control for moved, the electrical circuits will time out and will
driving the truck. Rotate the control in the direction deenergize. See Figure 2-5.
you want to travel. The farther you rotate the control
3. To move forward (with load in back), slowly press
from the neutral position, the faster the truck will
the speed control forward. See Figure 2-3. Press
travel.
the forward speed control farther to increase
speed.
4. To slow down or stop, release the speed control
and lower or raise the steering arm to the horizo-
ntal or vertical position. See Figure 2-5. In those
positions, the brake engages, slowing or stopping
the truck.
5. Procedures for movement in reverse are the same
as in the forward direction except slowly press the
speed control backward. See Figure 2-3.
2-5.1. Stopping
The stopping distance of the truck depends on the
ground conditions. The driver must take this into
account when operating the truck.
Figure 2-3 Forward/Reverse Control The driver must be looking ahead when traveling.
If there is no hazard, brake moderately to avoid
The pushbutton switches (See Figure 2-4), located moving the load.
on the front of the control head activate the lift-lower There are four different ways to stop the truck:
controls and the horn.
1. Plugging: This electrical braking function consists
of rotating the speed control lever in the opposite
direction of travel and then releasing it when the
truck stops. Plugging is a convenient way to slow
down the truck during normal operation. If the
control is not released, the truck will accelerate in
the opposite direction.
2. Steering arm (See Figure 2-5): The brake is fully
applied by lowering or raising the steering arm.
(See Figure 2-4) All traction control power is shut
off when the brake is engaged. When the steering
arm is in the upright position, the brake acts as a
parking brake. Deadman braking occurs when the
handle is released and spring action raises steer-
ing arm to the upright position.
3. Emergency braking: Press the emergency brake
Figure 2-4 Pushbutton Switches switch, all electrical functions are cut out and the
truck automatically brakes.
2-5.DRIVING AND STOPPING PROCEDURES 4. Regenerative braking: If the speed control lever
is released, the truck automatically brakes regene-
1. Connect the battery and turn on the key switch. ratively.When the speed is below.5 MPH, the bra-
Grasp the grips of the steering head so that the ke applies.
speed control can be comfortably operated by
either thumb.
SM2214 05.15
6
2-7.STEERING ARM GAS SPRING
The steering arm gas spring automatically raises the
steering arm to the upright position when the
steering arm is released. If the steering arm does
not return fully, the steering arm gas spring requires
replacement.Return truck to maintenance for repair.
2-8. LIFT AND LOWER CONTROLS

Lift/Lower Control buttons are located on the steering
control head. (Figure 2-4)
To lift forks, push in either LIFT button and hold until
forks reach desired height. To lower forks, push in
either LOWER button and hold until forks descend to
desired height.
2-9. LOADING AND UNLOADING

1. Move truck to location where load is to be picked
up.
2. Move the truck into position so forks are within
pallet or skid, and the load is centered over the
forks and as far back as possible.
3. Raise forks to lift load.
4. Drive to area where load is to be placed.
Figure 2-5 Brake Actuation
5. Move truck to align load with its new position.
2-6.BELLY-BUTTON SWITCH 6. Lower the load until it rests squarely in place and
the forks are free.
The belly-button switch (Figure 2-6) minimizes the
7. Slowly move the truck out from under the load.
possibility of the driver being pinned by the steering
arm while driving the lift truck in slow speed. If the
switch presses against the operator while the lift 2-10.PARKING
truck is being driven toward the operator, the switch When finished with moving loads, return the truck
changes the direction of the lift truck. to its maintenance or storage area. Turn off the key
switch and disconnect the battery. Charge battery
as necessary. Refer to battery care instructions,
SECTION 3.
Figure 2-6 Belly-Button Switch
SM2214 05.15
7
NOTES
SM2214 05.15
8
SECTION 3
PLANNED MAINTENANCE
3-1. GENERAL CAUTION: Gases produced by a battery can be
explosive. Do not smoke, use an open
Planned maintenance consists of periodic visual and
flame, create an arc or sparks in the
operational checks, parts inspection, lubrication, and
vicinity of the battery. Ventilate an
scheduled maintenance designed to prevent or
enclosed area well when charging.
discover malfunctions and defective parts. The
CAUTION: Batteries contain sulfuric acid which may
operator performs the checks in SECTION 2,
cause severe burns. Avoid contact with
and refers any required servicing to a qualified
eyes, skin or clothing. In case of contact,
maintenance technician who performs the scheduled
flush immediately and thoroughly with
maintenance and any required servicing.
clean water. Obtain medical attention
when eyes are affected. A baking soda
3-2. MONTHLY AND QUARTERLY CHECKS solution (one pound to one gallon of wat-
er) applied to spilled acid until bubbling
Table 3-1 is a monthly and quarterly inspection and
stops, neutralizes the acid for safe hand-
service chart based on normal usage of equipment
ing and disposal.
eight hours per day, five days per week. If the lift
truck is used in excess of forty hours per week, Leakage voltage from battery terminals to battery
the frequency of inspection and service should be case can cause misleading trouble symptoms with
increased accordingly. These procedures must be the truck electrical system. Since components of
performed by a qualified service technician or your the truck electrical system are insulated from truck
EP Service Representative. frame, leakage voltage will not normally affect truck
operation unless a short circuit or breakdown of
3-3. BATTERY CARE circuit wire insulation to truck frame occurs.
3-3.1. General A voltage check from battery connector terminal

to battery case should indicate near zero volts.
The truck may be equipped with maintenance free Typically, however, the sum of the voltages at both
batteries. terminals will equal battery volts. This leakage
The care and maintenance of the battery is very voltage will discharge the battery. As battery
important to obtain efficient truck operation and cleanliness deteriorates, the usable charge of the
maximum battery life. battery decreases due to this self discharge.
Table 3-1 Monthly and Quarterly Inspection and Service Chart

VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check electrical brake for proper operation.
Monthly Check load wheels for wear. A poly load wheel must be replaced if worn to within 1/16
inch of hub. Check for separation from hub.
Monthly Check drive wheel for wear. A poly drive wheel must be replaced if worn to within 3/4
inch of hub. Check for separation from hub.
Monthly Inspect wiring for loose connections and damaged insulation.
Monthly Inspect contactors for proper operation.
Monthly Check deadman brake switch for proper operation.
Monthly Check lift chain tension, lubrication & operation (see paragraph 3-6.)
Quarterly Check lift cylinder for leakage.
Quarterly Check for excessive jerking of steering arm when stopping or starting.
Semi-annually nspect for chain wear (See SECTION 8)
SM2214 05.15
9
Although a leakage voltage reading of zero volts 1. Charge the battery only in areas designated for
may not be possible, a cleaner battery will have that use.
more usable charge for truck operation and not affect 2. Make certain the charger being used matches the
operation of electronic devices on the unit. voltage and amperage of the truck battery.
3. Before disconnecting or connecting batteries to a
3-3.2. Safety Rules charger, make sure the charger is “OFF”. If an
• Wear protective clothing, such as rubber apron, attempt is made to do this while the charger is
gloves, boots and goggles when performing any “ON”, serious injury to you, the battery and the
maintenance on batteries. Do not allow electrolyte charger could result.
to come in contact with eyes, skin, clothing or floor. 4. Before connecting the battery cable to the trucks
If electrolyte comes in contact with eyes, flush receptacle, make sure the key switch is off. The
immediately and thoroughly with clean water. battery cable must be fully connected before the
Obtain medical attention immediately. Should truck is used. If the plug is not making good con-
electrolyte be spilled on skin, rinse promptly with tact, heat will weld the two parts of the battery
clean water and wash with soap. A baking soda connector together, making it difficult to remove
solution (one pound to one gallon of water) will and necessary to replace.
neutralize acid spilled on clothing, floor or any 5. Battery terminals should be checked and cleaned
other surface. Apply solution until bubbing stops of corrosion regularly. Good battery terminal con-
and rinse with clean water. tact is essential not only for operation, but also for
• If truck is equipped with wet cell batteries, keep vent proper charging of the battery.
plugs firmly in place at all times except when adding 6. The charging requirements will vary depending on
water or taking hydrometer readings. Do not allow the use of the truck. The battery should be given
dirt, cleaning solution or other foreign material to as equalizing charge on a weekly basis. This
enter cells. Impurities in electrolyte has a neutraliz- charge should normally be an additional three
ing effect reducing available charge. hours at the finish rate.
• Do not bring any type of flame, spark, etc., near the 7. Make certain battery used meets weight and size
battery. Gas formed while the battery is charging, is requirements of truck. NEVER operate truck with
highly explosive. This gas remains in cell long after an undersized battery.
charging has stopped.
• Do not lay metallic or conductive objects on battery. 3-3.4. Battery Cleaning
Arcing will result.
Always keep vent plugs tightly in place when
• Do not touch non-insulated parts of DC output
cleaning battery. When properly watered and
connector or battery terminals to avoid possible
charged, the battery will remain clean and dry. All
electrical shock.
that is necessary is to brush or blow off any dust
• De-energize all AC and DC power connections or dirt that may accumulate on them. However,
before servicing battery. if electrolyte is spilled or overflows from a cell, it
• Do not charge a frozen battery. should be neutralized with a solution of baking soda
and water, brushing the soda solution beneath the
• Do not use charger if it has been dropped or oth-
connectors and removing grime from the covers.
erwise damaged.
Then rinse the battery with cool water from a low
pressure supply to remove the soda and loosen dirt.
3-3.3. Battery Care and Charging If batteries stay wet consistently, they may be either
CAUTION: Never smoke or bring open flame near overcharged or over filled. This condition should be
the battery. Gas formed during charging investigated and corrected.
is highly explosive and can cause seri-
ous injury.
SM2214 05.15
10
3-4. CHARGING BATTERIES
Table 3-2 Recommended Lubricants
Charging requirements will vary depending on depth
(See Table 3-3 for Application)
of discharge and temperature. Follow safety rules
when placing a battery on charge.
No. 1 Transmission oil— 85W-90
Proceed as follows: Transmission oil—10W-30 (Note)
1. Park truck at charging station with carriage low-
ered and turn the key switch off. No. 2 Grease—Lithium base, general
2. Check the condition of the AC cord and battery purpose.
cables. If there are any cuts in the cable, any
exposed wires, loose plugs or connectors, DO No. 3 Hydraulic oil-Heavy duty with a viscosity
NOT attempt to charge the batteries. Contact of 150 SUS foam suppressing agent
appropriate personnel for repairs to be made. and rust and oxidation inhibitors
Hydraulic oil-Heavy duty with a viscosity
3. Disconnect the batteries from the truck and con-
of 100 SUS foam suppressing agent
nect the batteries to the charger. Make sure
and rust and oxidation inhibitors (Note)
connectors are mated properly.
4. Connect the charger to the appropriate power No. 4 SAE 30 or 40 Engine lubricating oil.
supply.
5. Follow the instructions for the charger being used. NOTE: USED ON COLD CONDITIONED TRUCKS
3-5. LUBRICATION
Refer to Table 3-2 for the recommended types of
grease and oil. Table 3-3 in conjunction with
Figure 3-1 identifies the items requiring lubrication.
3-6. LIFT CHAIN MAINTENANCE

Fully raise and lower lift carriage while observing
chains as they move over chain sheaves. Ensure
chain is aligned and tracking properly and all links
are pivoting freely. With lift carriage fully lowered,
spray or brush on a film of SAE 30 or 40 engine oil.
SM2214 05.15
11
Figure 3-1 Lubrication Diagram
Table 3-3 Lubrication Chart

INDEX APPLICATION
METHOD OF TYPE
NO. LOCATION OF
APPLICATION (Table3-2)
(FIG 3-4) LUBRICANT
1 Transmission Can No. 1 Fill to level plug opening.
Capacity 2 pints
2 Inner & Outer Mast Brush No. 2 Full length of channel where
rollers operate.
3 Hydraulic Reservoir Can No. 3 With lift carriage fully lowered,
Capacity-1 quarts fill reservoir with hydraulic oil
to 1 inch below opening.
4 Lift Chain Brush or Spray No. 4 See Paragraph 3-6.
SM2214 05.15
12
SECTION 4
TROUBLESHOOTING
4-1. GENERAL Operate:
Truck Does Not Operate Forward or Reverse:
Use Table 4-1 as a guide to determine possible
Trouble With Braking: Trouble With Lifting Or Lower-
causes of trouble. The table is divided into five main
ing, and Miscellaneous malfunctions.
categories: Truck and Hydraulic System Will Not
Table 4-1 Troubleshooting Chart

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TRUCK AND HYDRAULIC
SYSTEM WILL NOT OPERATE
Truck will not travel not will lift sys- a. Fuse (5, Figure 10-1) blown. Check fuse and replace if
tem operate. necessary.
b. Fuse (12, Figure 10-2) blown. Check fuse and replace if

necessary.
c. Battery dead or disconnected. Check battery connections and

check battery voltage.
d. Key switch (15, Figure 10-1) Bypass key switch to determine if it

defective. is malfunctioning.
e. Emergency stop switch (12, Bypass the switch to determine if it

Figure 10-1) defective. is malfunctioning.
f. Defective wiring. Check for open circuit. Repair as

required.
TRUCK DOES NOT OPERATE
FORWARD OR REVERSE
Truck does not travel forward or a. Check all wiring. A loose con- Tighten all loose connections
reverse. All other functions oper- nection may be the cause of before further troubleshooting.
ate normally. malfunction.
b. Defective deadman switch (22, Check and replace switch if

Figure 5-2). defective.
c. Defective main controller (3, Check for proper operation and
Figure 10-2). replace if necessary.
d. Defective potentiometer (21, Check and replace potentiometer
Figure 5-1). if defective.
Truck travels forward but not in Defective potentiometer (21, Fig- Check and replace potentiometer
reverse. ure 5-1) in control head. if defective.
Truck travels reverse but not in Defective potentiometer (21, Fig- Check and replace potentiometer
forward. ure 5-1) in control head. if defective.
Truck travels forward and in Defective potentiometer (21, Fig- Check and replace potentiometer
reverse at lower speeds; will not ure 5-1) in control head. if defective.
travel at high speed.
SM2214 05.15
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Table 4-1 Troubleshooting Chart- Continued
TROUBLE WITH BRAKING
Truck does not slow with brake, or a. Defective deadman switch (22, Check deadman switch for
brake does not engage. Figure 5-2). continuity. If none found when
the control arm is in the brake
position, replace switch.
b. Defective electric brake (3, Fig- Adjust or replace brake.
ure 7-1).
Brake will not release. a. Defective electric brake (3, Fig- Replace.
ure 7-1).
b. Brake temperature above Allow to cool and check air gap.
281° F (140° C).
c. Open brake circuitry or wiring. Make voltage checks.
Brake drags. Defective electric brake (3, Figure Replace.
7-1).
Brake grabs. a. Incorrect stopping distance Adjust.
adjustment.
b. Defective electric brake (3, Fig- Replace.
ure 7-1).
Abnormal noise and chatter when Defective electric brake (3, Figure Replace.
brake is applied. 7-1).
TROUBLE WITH LIFTING OR

LOWERING
Oil sprays or flows from the top of Defective packing in lift cylinder. Repair lift cylinder.
the lift cylinder.
Squealing sounds when lifting a. Oil level too low. Identify oil leak and fill reservoir.
forks. b. Lift linkage binding. Apply grease.
Forks do not lift to top. a. Oil level too low. Add oil to reservoir.
b. Load larger than capacity. Refer to I.D.plate for capacity.
Weak, slow or uneven action of a. Defective pump or relief valve. Check pressure. Adjust as
hydraulic system. necessary.
b. Worn lift cylinder. Replace cylinder.
c. Load larger than capacity. Refer to I.D.platefor capacity.
d. Defective lift motor solenoid. Replace solenoid on pump motor.
e. Battery charge low. Charge battery.
Forks do not lift, pump motor does a. Battery is dead or disconnect- Check and recharge if required.
not run. ed.
b. Defective wiring. Check and repair as required.
c. Defect in electrical system for Check lift switch in control head,
operating pump motor. as well as the solenoid .
SM2214 05.15
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Table 4-1 Troubleshooting Chart- Continued
TROUBLE WITH LIFTING OR
LOWERING - Continued
Forks do not lift, motor runs. Defect in hydraulic system. Check the oil level in the reservoir
and the oil lines to the lift cylin-
der, and repair as required. If
normal, check the hydraulic
pump, and relief valve. Repair, or
adjust.
Forks lift, but will not go down. Defect in hydraulic system Check lowering control switch in
control head and lowering sole-
noid on valve assembly.
Replaceas required.
Load will not hold. a. Oil bypassing internally in con- Replace valve assembly.
trol valve.
b. Worn lift cylinder or packing. Repack cylinder.
Forks does not lift to top. Pump a. Oil level too low. Add oil to reservoir.
motor runs. b. Load larger than capacity. Refer to nameplate on side of
mast for maximum load capacity.
c. Incorrect stopping distance Change batteries.
adjustment.
Forks creep downward under load Leak in hydraulic system, lift cylin- Check for leaking fitting in hydrau-
when in a raised position. der or lowering valve. lic line and repair as required.
Repack lift cylinder or replace
valve assembly .
MISCELLANEOUS
Steering arm does not return to a. Week return spring. Replace spring.
the upright position. b. Binding. Check and free the binding item.
Verify that the cable has not
been damaged. Repair or
replace as needed.
Truck moves forward when arm is a. Belly-button switch defective. Check for short, and repair or
pulled down. replace as necessary.
b. Short in control head. Check wiring and repair as
required.
Steering arm jerks excessively Drive wheel worn. Replace drive wheel if worn to
starting or stopping the truck. within 3/4 inch of hub.
Drive motor is jerky. Motor internally damaged or worn. Replace motor.
SM2214 05.15
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4-2. CONTROLLER TROUBLESHOOTING • The number of times that each alarm occurs con-
secutively.
4-2.1. Zapi Handset
• The Hour Meter reading (value) when the latest
A Zapi Handset is available that is designed specifi- event of every alarm occurred.
cally for use with the Zapi controller. It serves multiple • The invert temperature when the latest event of
functions of reading diagnostic data, testing truck every alarm occurred.
operation,setting options,adjustments and parameter
changes of the controller. The Zapi Handset is avail- This function permits a deeper diagnosis of problems
able through your EP dealer. If you require dealer as the recent history can be revisited.
location information, contact EP.
4-2.2.2. Logbook Access
Remove the rubber plug from the CNC connector of
the controller and plug in the Zapi Handset connector To view the alarm logbook proceed as follows:
as shown in Figure 4-1.
1. Connect the Zapi Handset, refer to paragraph 4-
2.1.
2. Press the ROLL down button (1, Figure 4-2) and
the ENTER button (3) at the same time to enter
the MAIN MENU.
-B +B FU 3. Press the ROLL down button (2) or the ROLL up
FW button (1) to find the ALARMS display.
AC-0 4. Press the ENTER button (3) to view the alarms.

FV
INVERTER 5. Press the OUT button (6) to exit the alarms.
NOTE: Refer to bigjoesupport.com for the Zapi sup-

plement containing detailed information of
alarm codes. There are two versions shown.
The PDS uses the Standard version which
lists the error by: Alarm Name, Repetitions,
Temperature and Hour Meter reading.
4-2.3. Testing Truck Operation

The Zapi Handset can be used to test certain truck
operations as follows:
1. Connect the Zapi Handset, refer to paragraph 4-
2.1.
CNC CNB CNA 2. Press the ROLL down button (1,Figure 4-2) and
Figure 4-1 Controller Terminals the ENTER button (3) at the same time to enter
the MAIN MENU.
4-2.2. Fault Detection 3. Press the ROLL down button (2) or the ROLL up
button (1) to find the TESTER display.
4-2.2.1. General
4. Press the ENTER button (3) to view the tests.
The controller provides diagnostics information to
5. To verify various switch functions, locate the
assist technicians in troubleshooting problems. When
switch on the display and then operate that funct-
a fault is detected, an alarm is recorded in the log-
ion to verify operation.
book.It has a FIFO (First Input First Output) structure
that means the oldest alarm is lost when the database 6. Press the OUT button (6) to exit the tests.
is full and a new alarm occurs.The logbook is com-
posed of alarms with the following information:
• The alarm code.
SM2214 05.15
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4-2.4. Settings and Adjustments
4-2.4.1. Set Options
To set options proceed as follows and refer to Table 4-
2:
1. Connect the Zapi Handset, refer to paragraph
4-2.1.
2. Press the ROLL up button (1, Figure 4-2) and the
SET up button (5) at the same time to enter the
CONFIG MENU.
3. Press the ROLL down button (1) or the ROLL up
button (2) to find the SET OPTIONS display.
4. Press the ENTER button (3) to view the options.
5. Press the ROLL down (2) or the ROLL up button
(1) to find the option to be changed.
6. Press the SET up button (5) or the SET down but-
ton (6) until the desired value setting is reached.
The option is now set at the desired value.
7. Press the OUT button (4) to exit the options.
Figure 4-2 Hand Held Programmer
Table 4-2 Set Options

Parameter Factory Setting Description
TILLER switch HANDLE This option handles the input CNB#3 (Table 4-5). This input opens
when the operator leaves the truck (released). It is connected to a
Keyswitch controlled voltage when the operator is present.
SET INPUT #1 OPTION #1 (Standard Version only). This option handles the digital input
CNA#15. It can be can be set as:
• OPTION #1: CNA is managed as a cutback speed input (SR#1).
• OPTION #2: CNA is managed as a digital handbrake input.
• OPTION #3: CNA is managed as an inching backward.
The input CNA#15 (Table 4-5) can only be used as Aux Lowering
request when the MDIPRC is PRESENT.
This input must be connected to a Keyswitch controlled voltage.
The SR#1 becomes active when CNA#15 (Table 4-5) is open.
The inching backward becomes active when the CNA#15 (Table 4-
5) is closed to a Keyswitch controlled voltage.
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Table 4-2 Set Options-Continued
SET INPUT #2 PRESENT It can be can be set as:
• PRESENT: CNA#14 (Table 4-5) is managed as a cutback speed
input (SR#2).
• OPTION #1: CNA#14 (Table 4-5) is managed as an inching back-
ward.
The input CNA#14 (Table 4-5) can only be used as Aux Lifting
request when the MDIPRC is PRESENT.
The SR#2 becomes active when CNA#14 (Table 4-5) is open.
The inching backward becomes active when the CNA#14 (Table 4-
5) is closed to a Keyswitch controlled voltage.
SET INPUT #4 OPTION #1 This option handles the digital input CNB#7 (Table 4-5). It can be
can be set as:
• BELLY CNB#7 (Table 4-5) is managed as a Belly Switch input.
• BRAKE CNB#7 (Table 4-5) is managed as service brake input.
This information can be used also to recognize when the operator
is driving with a pressed pedal braking.
• EX.HYDRO: CNB#7 (Table 4-5) is managed as Exclusive Hydro.
The Belly switch active level is specified on the QUICK INV LOGIC
below.
The service brake of the exclusive hydro becomes active when
CNB#7 is opened.
HOUR COUNTER RUNNING This option specifies the hour counter mode. It can be set as:
• RUNNING: The counter registers travel time only.
• key on: The counter registers when the keyswitch is closed.
BATTERY CHECK Level = 1 This option specifies the handling of the low battery charge detec-
tion. It can be set as:
• Level 0: Nothing happens, the battery charge level is ignored.
• Level 1: A BATTERY LOW alarm is raised when the battery level
is calculated being less than 10% of the full charge. A BATTERY
LOW alarm inhibits the Lifting function.
• Level 2: A BATTERY LOW alarm is raised when the battery level
is calculated being less than 10% of the full charge. A BATTERY
LOW alarm reduces the maximum truck speed down to 24% of
the full truck speed then, if the MDI-PRC is absent, inhibits the Lift-
ing function.
• Level 3 Equivalent to Level 1; a BATTERY LOW alarm is raised
when the battery level is calculated being less than 10% of the full
charge. A BATTERY LOW alarm inhibits the Lifting function.
HYDRO KEY ON OFF ON/OFF: If this options is programmed ON the traction Inverter
manages a hydraulic steering function when the keyswitch is
switched ON (only if the AUX OUTPUT #1 option is programmed
as HYDRO CONTACT or as WXCLUSIVE HYDRO).
STOP ON RAMP OFF Not used.
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AUX OUTPUT #1 BRAKE This option handles output CNA#3 (Table 4-5). It can be used as:
• BRAKE: CNA#3 (Table 4-5) drives an electromechanical Brake.
• HYDROCOMNT: CNA#3 (Table 4-5) drives the contractor for a
hydraulic steering function when the direction input or brake pedal
input are active or a movement of the truck is detected.
• EX.HYDRO: CNA#3 (Table 4-5) drives the contractor for a hydrau-
lic steering function when the exclusive hydro input is active.
• FREE: CNA#3 (Table 4-5) is not used.
The current this output can sink is up to 3Adc.
PEDAL BRAKING NONE The analog input CNA#18 (Table 4-5) has one of two functions:
• Pedal Braking input.
• Command input for lifting/lowering proportional valves in MDIPRC
version.
To turn from the first to the second function is just enough to set
PEDAL BRAKING to HNONE.
This option handles the analog input CNA#18 (Table 4-5) when
used as pedal braking input:
• ANALOG: With this setting it is possible to modulate the strength
of the braking when the accelerator is released. The strength of
the braking is proportional to the brake pedal potentiometer con-
nected to this input. When the pedal potentiometer voltage is
equal/less than the SET POT BRK MIN, the minimum release
braking strength is applied (following the RELEASE BRAKING
setting).
When the pedal potentiometer voltage is equal/higher than the
SET POT BRK MAX, the maximum release braking strength is
applied (following the PEDAL BRAKING setting). In the intermedi-
ate position, the electrical braking strength is a linear function
between the minimum (RELEASED BRAKING) and maximum
(PEDAL BRAKING) intensity. When there is also a switch con-
nected to the pedal braking (i.e. SET INPUT #4 to level BRAKE), it
must be closed, otherwise the release braking is stuck to the mini-
mum strength disregarding the pedal potentiometer position.
• DIGITAL: No pedal potentiometer is expected. Only when both the
SET INPUT #4 is Level BRAKE and the brake switch connected to
CNB#4 (Table 4-5) is closed, the release electrical braking follows
the PEDAL BRAKING setting (maximum strength); in all of the
other conditions the release electrical braking follows the
RELEASE BRAKING setting (minimum strength).
• NONE: The analog input CNA#18 (Table 4-5) is not used for the
release braking modulation.
QUICK INVERSION BELLY This option specifies the quick inversion mode when the SET
INPUT #4 is set BELLY. It can be set as:
• NONE: The quick inversion function is not managed (no effect
when CNB#7 (Table 4-5) switches over).
• TIMED: The quick inversion function is timed.
• BELLY: The quick inversion function is managed but not timed.
SM2214 05.15
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AUX VOLTAGE #1 100% This option specifies the percentage of the keyswitch controlled
voltage to be applied to the loads on CNA#1 (Table 4-5) (main
contactor coil) and CNA#3 (Table 4-5) (electromechanical brake).
The voltage modulation is set with a PWM at 1 kHz frequency.
After an initial delay of about 1 sec in which the entire keyswitch
controlled voltage is applied to the loads, the PWM reduces the
voltage at the loads down to the specified percentage.
PERFORMANCE OPTION #1 This option can be set

• OPTION#1
• OPTION#2
QUICK INV. LOGIC OPTION #1 This option specifies the active level for the Belly switch input
(CNB#7)
• OPTION#1: The quick inversion is executed when CNB#7 (Table
4-5) is closed to a Keyswitch controlled voltage.
• OPTION#2: The quick inversion is executed when CNB#7 (Table
4-5) is opened from a Keyswitch controlled voltage.
MDI-PRC ABSENT This option specifies:
• PRESENT: The MDI-PRC is connected to the ACO via the CAN
Bus: the handling of the Hydraulics is specified on the TRUCK
TYPE setting.
• ABSENT: The MDI-PRC is not connected to the ACO: the TRUCK
TYPE disappears from the SET OPTIONS function list.
MOT SET-UP LOCK OFF Not used.
SM2214 05.15
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4-2.4.2. Adjustments
To change an adjustment proceed as follows and
refer to Table 4-3:
4-2.1.
2. Press the ROLL up button (1, Figure 4-3) and the
SET up button (5) at the same time to enter the
CONFIG MENU.
button (2) to find the ADJUSTMENTS display.
4. Press the ENTER button (3) to view the adjust-
ments.
(1) to find the adjustment to be changed.
The adjustment is now set at the desired value.
7. Press the OUT button (4) to exit the adjustments.
Table 4-3 Adjustments

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

TYPE
ADJUST BATTERY XX V Do not modify - Factory adjusted (Fine adjustment of the battery
voltage measured by the controller.)
THROTTLE 0 ZONE 9% Establishes a deadband in the accelerator input curve.
SM2214 05.15
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Table 4-3 Adjustments-Continued
THROTTLE X 45% This parameter together with the THROTTLE Y POINT, changes
POINT the characteristic of the accelerator input curve: when the acceler-
ator is de-pressed to X point percent, the corresponding truck
speed is Y point percent of the Maximum truck speed. The rela-
tionship between the accelerator position and the truck speed is
linear between the THROTTLE 0 ZONE and the X point and also
between the X point and the maximum accelerator position but
with two different slopes (Figure 4-4).
THROTTLE Y 68% This parameter together with the THROTTLE X POINT, changes
POINT the characteristic of the accelerator input curve: when the acceler-
ator is de-pressed to X point percent, the corresponding truck
speed is Y point percent of the Maximum truck speed. The rela-
tionship between the accelerator position and the truck speed is
linear between the THROTTLE 0 ZONE and the X point and also
between the X point and the maximum accelerator position but
with two different slopes (Figure 4-4).
ADJUSTMENT #01 LEVEL = 5 Adjust the upper level of the battery charge table (Level 0 to 9).
ADJUSTMENT #02 LEVEL = 5 Adjust the lower level of the battery charge table (Level 0 to 9).
LOAD HM FROM OFF When set On, the Hourmeter of the Controller is transferred and
MDI recorded on the Hourmeter of the Standard MDI (connected on
the Serial Link).
CHECK UP DONE OFF Turn it On when asked Maintenance service has been executed to
cancel the CHECK UP NEEDED warning.
CHECK UP TYPE NONE It specifies the handling of the CHECK UP NEEDED warning:
• NONE: No CHECK UP NEEDED warning.
• OPTION#1: CHECK UP NEEDED warning on the handset and
MDIPRC after 300 hours.
• OPTION#2: Equal to OPTION#1 but Speed reduction after 340
hours.
• OPTION#3: Equal to OPTION#2 but the truck definitively stops
after 380 hours.
Figure 4-4 Throttle Regulation
SM2214 05.15
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4-2.4.3. Parameter Change
To change a parameter proceed as follows and refer
to Table 4-4:
4-2.1.
2. Press the ROLL down button (1, Figure 4-5) and
the ENTER button (3) at the same time to enter
the MAIN MENU.
button (2) to find the PARAMETER CHANGE dis-
play.
4. Press the ENTER button (3) to view the parame-
ters.
(1) to find the parameter to be changed.
The parameter is now set at the desired value.
7. Press the OUT button (4) to exit the parameters.
Table 4-4 Parameter Adjustments

ACCELER. DELAY LEVEL = 8 Level 0 to 9. It determines the acceleration ramp. At Level 9 the
truck takes a long time to accelerate.
RELEASE LEVEL = 5 Level 0 to 9. It controls the deceleration ramp when the travel
BRAKING request is released. At Level 9 the truck brakes abruptly.
INVERS. BRAKING LEVEL = 4 Level 0 to 9. It controls the deceleration ramp when the direction
switch is inverted during travel. At Level 9 the truck brakes
abruptly.
PEDAL BRAKING LEVEL = 9 Level 0 to 9. It controls the deceleration ramp when the travel
request is released and the brake pedal switch is pressed to its
maximum. At Level 9 the truck brakes abruptly.
SPEED LIMIT BRK LEVEL = 1 Level 0 to 9. It controls the deceleration ramp when the accelerator
has turned down but not completely released. At Level 9 the truck
decelerates abruptly.
BRAKE CUTBACK LEVEL = 5 Level 0 to 9. It controls the deceleration ramp when the a speed
reduction input becomes active and the motor slows down. At
Level 9 the truck decelerates abruptly.
MAX SPEED FORW 100 Hz Typically from 90 Hz to 160 Hz. It determines the maximum speed
in forward direction.
MAX SPEED BACK 100 Hz Typically from 90 Hz to 160 Hz. It determines the maximum speed
in backward direction.
SM2214 05.15
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Table 4-4 Parameter Adjustments-Continued
CUTBACK SPEED 100% Typically from 10% to 100%. It determines the percentage of the
max speed applied when the cutback switch 1 (SR#1 on CNA#15
(Table 4-5) is active. When set to 100% the speed reduction is
ineffective.
CUTBACK SPEED 2 68% Typically from 10% to 100%. It determines the percentage of the
max speed applied when the cutback switch 2 (SR#2 on CNA#14
(Table 4-5) is active. When set to 100% the speed reduction is
ineffective.
HS CUTBACK 100% Typically from 10% to 100%. It determine the percentage of the max
speed applied when the Hard & Soft function (H&S switch on
CNB#4 (Table 4-5) is active. When set to 100% the speed reduc-
tion is ineffective.
FREQUENCY 5.00 Hz Hz value. This is the minimum speed applied when the forward or
CREEP reverse switch is closed, but the accelerator at its minimum. In the
ACO sense Coils this setting is higher equal than 5 Hz.
RPM CREEP 100% A Percentage value. Set to 100% and not Used.
MAXIMUM 96% It specifies the percentage of the absolute current at which

CURRENT the current will be limited. Normally MAXIMUM CURRENT is
100%. DO NOT CHANGE.
INCHING SPEED 0 Hz Hz value. It determines the speed when the “Inching function” is
active.
INCHING TIME LEVEL = 0 Level 0 to 9. It determines the duration time when the “Inching func-
tion” is active.
AUXILIARY TIME 1 Time units value (seconds). For the encoder version, it determines
the time duration (in seconds) in which the frequency was arrived
to zero.
ANTIROLLBACK 80% A Percentage of the Maximum Current. This setting increases the
phase current when low frequency during starting operation. It is
used to push up, in feedforward way, the torque when it is not
possible to control the flux, in feedback way, because of the low
frequency.
SM2214 05.15
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Table 4-5 Zapi Controller Connector Pins
CNA Connector
PIN ABBREVATION Description
CNA#1 NMC Negative of main contactor coil.
CNA#2 PMC Positive of main contactor coil.
CNA#3 NEB Output for driving the electromechanical brake coil; drives the load
to -Batt. Maximum current: 3 A.
CNA#4 NPC Negative of pump contactor soil.
CNA#5 PPC/PEV Positive of pump contactor coil and lowering electrovalve coil.
CNA#6 NEV Negative of the lowering electrovalve coil.
CNA#7 CAN LOW Low level CAN-BUS voltage I/O.
CNA#8 -BAT -Bat.
CNA#9 ENC+ Encoder Positive Supply (+5 or +12 Vdc)
CNA#10 ENC- Encoder Negative Supply (GND to minus battery)
CNA#11 HM(+B) Output for driving an hourmeter; when the hourmeter is active this
output provides a +Batt signal; 3 maximum current.
CNA#12 -BATT -Batt.
CNA#13 MOT TH Motor thermal sensor input. The internal pull-up is a fixed 2mA
(Max 5V) source current.
CNA#14 SR2 Speed reduction 2 input. Active low (switch opened).
CNA#15 SR1 Speed reduction 1 input. Active low (switch opened).
CNA#16 +12V This output provides a +12V signal for the MDI PRC, it present; mA
maximum current.
CNA#17 CAN HIGH High level CAN-BUS voltage I/O.
CNA#18 CPOTB Brake potentiometer wiper.
CNA#19 ENC A Encoder Channel A.
CNA#20 ENC B Encoder Channel B.
CNB Connector
CNB#1 KEY SW Connected to the power supply through a microswitch (KEY) with a
6.3-10 A fuse in series (this could be mounted on the AC-0 cover).
CNB#2 CM Common for FW/BW/SR1/SR2/TILLER/H&S/BELLY/LIFTING/
LOWERING microswitches. This connection supplies a keyswitch
voltage level.
CNB#3 TILLER SW Tiller request input. Must be connected to the tiller microswitch,
active high.
SM2214 05.15
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Table 4-5 Zapi Controller Connector Pins-Continued
CNB Connector-Continued
CNB#4 H&S SW Hard & Soft request input. Must be connected to the Hard & Soft
microswitch, active high.
CNB#5 BACKWARD SW Backward direction request input. Must be connected to the back-
ward direction microswitch, active high.
CNB#6 FORWARD SW Forward direction request input. Must be connected to the forward
direction microswitch, active high.
CNB#7 BELLY SW Quick inversion function input; must be connected to the Belly
microswitch; it is active high.
CNB#8 LOWERING SW Lowering request input, active high.
CNB#9 LIFTING SW Lifting request input, active high.
CNB#10 CPOT Lifting request input, active high.
CNB#11 NPOT Negative of accelerator unit, tested for wire disconnection
diagnosis.
CNB#12 PPOT Potentiometer positive: 10V output; keep load >1kΩ.
CNC Connector
CNC#1 PCLRXD Positive serial reception.
CNC#2 NCLRXD Negative serial reception.
CNC#3 PCLTXD Positive serial transmission.
CNC#4 NCLTXD Negative serial transmission.
CNC#5 GND Negative console power supply.
CNC#6 +12V Positive console power supply.
CNC#7 FLASH Must be connected to C8 for the Flash memory programming (if
used).
CNC#8 FLASH Must be connected to C7 for the Flash memory programming (If
used).
SM2214 05.15
26
4-2.5. Troubleshooting to Table 4-6 for the traction controller error messages.
Refer to Table 4-7 for the steering controller error
The controllers provide diagnostics information to messages.
assist technicians in troubleshooting problems. Refer
Table 4-6 TRACTION CONTROLLER

Error Message
Possible Cause Fault Elimination
Code Error Text
1 WRONG CONFIG It occurs the first time a controller So ask for the assistance of a Zapi techni-
is switched on when the non cians when this alarm
volatile EEPROM memory is not
initialized yet.
8 WATCH DOG It occurs when the embedded Verify the motor is connected and the con-
WATCH DOG protection is not tinuity of the three motor phases.
able either to cut off the power If the alarm occurs permanently, it is nec-
stage when not triggered or it essary to replace the controller.
is not able to activate the power
stage when triggered.
16 AUX OUTPUT KO This alarm occurs when the Probably it is necessary to replace the
feedforward PWM generated controller because the driver of the
by the controller to supply the Electromechanical Brake has a failure.
Electromechanical Brake and
the actual feedback voltage
on the Electromechanical Brake
are not matched in between.
The diagnosis is made only
when the Tiller Switch is active.
13 EEPROM KO It occurs due to a HW or SW Try to execute a CLEAR EEPROM opera-

defect of the non-volatile tion. This consists of Entering the
embedded memory supporting ALARMS item in the MAIN MENU. Push
the controller regulations at the same time the two right side but-
tons to enter the hidden ZAPI MENU.
Roll up and Down until the CLEAR
EEPROM appears on the hand set display.
Push Twice the Enter Button. Switch the
key off and on to check the result.
If the alarm occurs permanently, it is nec-
essary to replace the controller.
17 LOGIC FAILURE #3 It occurs when the circuit to limit It is probably a power failure or a logic
via HW the current peak in the failure.
controller is active. If it occurs permanently it is necessary to
replace the controller.
18 LOGIC FAILURE #2 It occurs when the circuit, to It is necessary to replace the controller.
compensate for the dead times
of the sine waves, is failed.
SM2214 05.15
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Table 4-6 TRACTION CONTROLLER-Continued
Error Message
Code Error Text
19 LOGIC FAILURE #1 This alarm signals that an Normally the overvoltage occurs due to the
overvoltage / undervoltage regenerative braking energy increasing
protection operation has the battery voltage; the undervoltage of
occurred. the logic supply, can be due to a depletion
in the key voltage .
So first of all check for your failure mode
then contact the Zapi technician to look for
a countermeasure.
As a matter of fact this alarm may occurs
also for a HW failure and, in this case, it is
necessary to replace the Controller.
30 VMN LOW Before to switch the main contac- If the problem occurs before the Main Con-
tor on, the SW turns on sequen- tactor closes,probably a Power failure
ce the Top side Power Mosfets (e.g.a Bottom side Power Mosfet short
and expects the phase V voltage circuited or a Top side Power Mosfet
increases toward the rail capaci- broken) or a Logic Failure occurred in the
tor value. If the phase V does controller. If the problem occurs when the
not increases this alarm occurs. operator turns the truck moving the
This alarm may occur also when problem is the Battery positive is not con-
the initial diagnosis is overcome, nected to the +Batt terminal of the
and so the Main Contactor is controller(check the continuity of the
expected to be closed. main contactor).
Then, when the operator asks the If the problem occurs permanently it is
truck moving but the +Batt ter- necessary to replace the controller.
minal of the controller is lower
voltage than the Battery voltage,
this alarm occurs (Main Contac-
tor has lost the contact although
it is closed).
31 VMN HIGH Before to switch the main contac- Two possibilities:
tor on, the SW turns on sequence - At least a motor phase is not connected to
the Bottom side Power Mosfets the controller or broken.
and expects the phase V voltage - A Power Failure (e.g. a Bottom side Power
falls to GND value. If the phase Mosfet opened) or a Logic Failure occurred
V remains high level this alarm in the controller. In this case it is necessary
occurs. to replace the controller.
37 CONTACTOR The controller checks if the MC It is suggested to check the contactor

CLOSED contact is closed when the coil contact, if it is mechanically stuck or
isn’t driven, trying to discharge pasted.
the capacitor bank. If they don’t
discharge, the fault condition is
entered.
38 CONTACTOR The main contactor coil has been Two possible reasons:
OPEN driven by the logic board, but the the wires to the coil are interrupted or not
contactor does not close. well connected or the contact of the
contactor is not properly working
SM2214 05.15
28
Error Message
Code Error Text
49 I=0 EVER This test is carried out when the If everything is ok for what it concerns the
motor is running, and it verifies motor, the problem could be in the current
that the current feedback sensor sensor or in the related circuit.
is not constantly stuck to 0.
55 PROGRAM LIFT The SW continuously matches the Check the Main Lifting/Lowering pair
LEVER potentiometer connected to (CNB#8 and CNB#9) and the voltage on
CNA#18 with the Main Lifting/ the potentiometer connected to CNA#18.
Lowering pair request (CNB#9 (Use the readings LIFTING SWITCH,
and CNB#8). DESCENT SWITCH and LIFTING
When the TRUCK TYPE is set 2, CONTROL in the TESTER to facilitate the
the alarms occurs in the follow- troubleshooting).
ing conditions:
- If both the Main Lifting and Main
Lowering request are disactive
and the potentiometer voltage is
higher than 60 mV over either
the MIN LIFT or the MIN LOWER
setting.
- If the Main Lifting request is acti-
ve and the potentiometer voltage
is higher than 200 mV over the
MAX LIFT setting
- If the Main Lowering request is
active and the potentiometer
voltage is higher than 200 mV
over the MAX LOWER setting
- If the MIN LIFT setting is higher
than the MAX LIFT setting.
- If the MIN LOWER setting is
higher than the MAX LOWER
setting.
When the TRUCK TYPE is set 3,
the alarms occurs in the follow-
ing conditions:
- If the Main Lowering request is
disactive and the potentiometer
voltage is higher than the MIN
LOWER
- If the MIN LOWER setting is
higher than the MAX LOWER
setting.
53 STBY I HIGH This diagnosis is executed only If the alarm occurs permanently, it is
when the main contactor is necessary to replace the controller.
opened and asked to be closed
(e.g. at key on or when the main
contactor is opened and a new
motion request turns active).
Then the outputs of the Current
amplifiers must be in a narrow
window close to 2.5 Vdc (from
2.26 V to 2.74 V). Otherwise this
STBY I HIGH alarm occurs.
SM2214 05.15
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Error Message
Code Error Text
60 CAPACITOR In working condition, a resistance Three possibilities:
CHARGE connected between the key and - Another device, connected in parallel with
the Rail Capacitors, keeps the the Rail Capacitors, has a failure
Rail Capacitors charged before - At least a motor phase is not connected to
the Main Contactor closes. the controller or broken.
When the voltage on the Rail - A Power failure or a Logic Failure occurred
Capacitors (measured on the in the controller.In this case it is necessary
phase V) is low and does not to replace the controller.
increase when the main contac-
tor is opened this alarm occurs.
61 HIGH This alarm occurs when the Improve the air cooling of the controller.
TEMPERATURE temperature of the base plate is
higher than 78 °C. Then the
maximum current decreases
proportionally with the temper-
ature increases from 78 °C up
to 100 °C. At 100 °C the current
is limited to 0 Amps.
65 MOTOR This is just a warning with no Check the thermal sensor inside the motor
TEMPERAT effect on the truck performance. (use the MOTOR TEMPERATURE reading
It occurs when the temperature in the TESTER menu). If the sensor is OK,
of the motor winding overtakes improve the air cooling of the motor.
the MOTOR OVERTEMP setting.
67 CAN BUS KO It occurs if the controller does not First of all, check the wiring. If it is OK, try
receive any message from the to disconnect one to one the module con-
CAN Bus line. nected to the CAN Bus and check if this
alarm disappears. When you are quite
sure the problem is in the present module,
it is necessary to replace the controller.
70 ENCODER ERROR Two consecutive readings of the Check both the electric and the mechanical
encoder speed are too much diff- encoder functionality. Frequently we exper-
erent in between: because of the ienced one of the two Sensor bearing’s
inertiality of the system it is not ring, slips inside its seat raising this alarm
possible the encoder changes its condition.Also the electromagnetic noise
speed a lot in a short period. on the sensor bearing can be a cause for
Probably an encoder failure has the alarm.
occurred (e.g. one or two chan-
nels of the encoder are corrupted
or disconnected).
71 HANDBRAKE This alarm occurs when the Check the handbrake switch and its wiring
operator try to travel with the to CNA#13. The handbrake switch must
handbrake active. be connected between CAN#13 and GND
voltage. When it is closed to GND the
handbrake is considered active. A failure
in the logic is possible too. In this case it is
necessary to replace the controller.
SM2214 05.15
30
Error Message
Code Error Text
73 THERMIC SENS When the output of the thermal It is necessary to replace the controller.
KO sensor on the base plate is
higher than 4.95 V or lower than
0.1 V, the sensor is assumed
failed and this alarm occurs.
74 DRIVER SHORTED This alarm occurs when the volt- Probably it is necessary to replace the
age on the Main Contactor is hig- controller because the driver of the Main
her than expected: this means Contactor is short circuited.
that the Main Contactor Coil has
a high voltage although it is not
supplied.
75 CONTACTOR This alarm occurs when the Check the coils of the Main Contactor
DRIVER voltage on the Main Contactor is (CNA#1) is not short circuited. If it isn’t,
smaller than expected: this means probably it is necessary to replace the
that the Main Contactor Coil has a controller because the driver of the Main
null voltage when supplied. Contactor is broken.
76 COIL SHORTED This alarm occurs when there is Check the coils of the main contactor
an overload on one of the (CNA#1), of the electromechanical brake
following connections: CNA#1, (CNA#3), of the pump contactor (CNA#4),
CNA#3, CNA#4 and CNA#6. of the Aux valve (CNA#6).
Typically the problem is due to a
short circuit of one of the coils
connected to these outputs.
After the overload has removed,
the alarm exits automatically by
releasing and then enabling a
travel demand.
78 VACC NOT OK The test is made at key-on and Check the mechanical calibration and the
after 20 sec that both the travel functionality of the potentiometer.
demands have turned disactive.
This alarm occurs if the ACCEL-
ERATOR reading in the TESTER
menu is higher than 1.0 V (it
means the wiper of the potentio-
meter is higher than 2 Vdc) when
the accelerator is released.
79 INCORRECT This is just a warning for an in- The possible reasons for this alarm are (use
START correct starting sequence. the readings in the TESTER to facilitate
the troubleshooting):
a) A travel demand active at key on
b) The tiller switch active at key-on
c) The H&S input active at key-on
d) The Quick inversion active at key-on
A failure in the logic is possible too. When all
of the above conditions were checked and
nothing was found, replace the controller.
SM2214 05.15
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Error Message
Code Error Text
80 FORW+BACK This alarm occurs when both the Check the wiring of the Fwd and Bwd travel
travel demands (Fwd and Bwd) demand inputs (use the readings in the
are active at the same time. TESTER to facilitate the troubleshooting).
A failure in the logic is possible too.When
you have verified the travel demand switc-
hes are fine working and the wiring is right,
it is necessary to replace the controller.
86 PEDAL WIRE KO The SW continuously checks for Check the voltage on NPOT (CNB#11) and
the connection of the two supply the potentiometer connections.
ends of the potentiometer in the
accelerator. The test consists of
reading the voltage drop on a
sense diode, connected between
NPOT (CNB#11) and GND and
cascaded with the potentiometer:
if the potentiometer gets discon-
nected on PPOT or NPOT, no
current flow in this sense diode
and the voltage on the NPOT
connection collapses down.
When the NPOT voltage is less
than 0.3 V this alarm occurs.
This alarm occurs also when the
NPOT voltage is higher than 2
Vdc (to detect also the condition
of a broken sense diode).
91 LIFT LOW ACTIVE This is just a warning when a The possible reasons for this alarm are (use
Lifting/Lowering request is active the readings in the TESTER to facilitate
at key-on. the troubleshooting):
- When MDI-PRC is absent: at least one
between LIFTING SWITCH (CNB#9) or
DESCENT SWITCH (CNB#8) active at
key-on.
- When TRUCK TYPE is Level=1: at least
one between LIFTING SWITCH (CNB#9),
DESCENT SWITCH (CNB#8), DIGITAL
INPUT#1 (CNA#14) or DIGITAL INPUT#2
(CNA#15) active at key-on.
one between LIFTING SWITCH (CNB#9)
or DESCENT SWITCH (CNB#8) active at
key-on.
one between LIFTING SWITCH (CNB#9)
or DESCENT SWITCH (CNB#8) active at
key-on.
A failure in the logic is possible too. When
all of the above conditions were checked
and nothing was found, replace the control-
ler.
SM2214 05.15
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Error Message
Code Error Text
90 LIFT+LOWER This alarm occurs when both a If the MDI-PRC is absent, check only the
Lifting request and a Lowering wiring of the main Lifting/Lowering pair
request are active at the same (CNB#8 and CNB#9); if the MDI-PRC is
time. present check also the wiring of the Aux
Lifting/Lowering pair (CNA#14 and
CNA#15). (Use the readings in the
TESTER to facilitate the troubleshooting).
A failure in the logic is possible too. When
you have verified the Lifting/Lowering
switches are fine working and the wiring is
right, it is necessary to replace the
controller.
93 WRONG SET When the key is turned ON, the Replace the battery with a correct battery.
BATT. controller check the battery
voltage and verifies it is within a
window around the nominal
value.
94 CURRENT SENS This alarm occurs when the proce- The maximum current set-up is factory
KO dure for the maximum current adjusted and so this alarm never should
set-up is in progress. happen when the controller is on the field.
So ask for the assistance of a Zapi tech-
nicians when this alarm occurs.
97 INPUT ERROR #1 This alarm occurs when the PLD It is necessary to replace the controller.
device has a failure. The PLD
device is used for both, the
Passive Emergency Cell and a
Multiplexer on the Main Lifting/
Lowering requests. This Multi-
plexer exits the Lifting and the
Not Lifting level on two distinct
addresses. When the Lifting and
the Not Lifting outputs have the
same Logic Level the PLD
device has failed and this alarm
occurs.
99 CHECK UP This is just a warning to call for the It is just enough to turn the CHECK UP
NEEDED time programmed maintenance. DONE option to level ON after the
maintenance is executed.
SM2214 05.15
33
Table 4-7 STEERING CONTROLLER
Error Message
Code Error Text
6 SERIAL ERR #1 Main uC and slave uC communi- It is necessary to replace the controller.
cate via a local serial interface.
This alarm occurs when the
slave uC does not receive the
communication from the main
uC through this serial interface.
13 EEPROM KO It occurs if a test to write and read It is necessary to replace the controller.
one location in EEPROM fails.
The SW expects to read the
written value.
It also occurs when the hour
meter gives different values
between the three redundant
locations in which it is
recorded.
It also occurs when the busy bit of
the EEPROM does not rise
within 12 msec.
16 LOGIC FAILURE This alarm occurs in the rest state It is necessary to replace the controller.
#4 if the output of the voltage
amplifier of the phase Vw-Vv
have a drift larger than ±0.25 V.
17 LOGIC FAILURE This alarm occurs in the rest state It is necessary to replace the controller.
#3 if the output of the voltage
amplifier of the phase Vu-Vw
have a drift larger than ±0.25 V.
18 LOGIC FAILURE This alarm occurs when the real It is necessary to replace the controller.
#2 voltage between phases W
and V of the motor is different
from the desired voltage.
19 LOGIC FAILURE This alarm occurs when the real It is necessary to replace the controller.
#1 voltage between phases W
and U of the motor is different
from the desired voltage.
32 VMN NOT OK This alarm occurs in the initial rest It is necessary to replace the controller.
state after key-on it the inputs
of motor voltage amplifiers are
not in the window from 2.2 to
2.8 Vdc.
48 MAIN CONT. This alarm occurs only when the Find, on the traction controller, the reason
OPEN setting CAN BUS is PRESENT. for keeping the main contactor open.
Then the EPS-AC0 waits for a
via CAN information that the
traction controller has closed
the main contactor. If this infor-
mation lacks more than about
1.5 secs, this alarm occurs.
SM2214 05.15
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Table 4-7 STEERING CONTROLLER-Continued
Error Message
Code Error Text
53 STBY I HIGH This alarm occurs two ways: It is necessary to replace the controller.
1) In the initial rest state after key-
on, if the outputs of the current
amplifiers are not comprised in
the window 2.2 to 2.8 Vdc.
2) After the initial diagnosis this
alarm occurs when the outputs
of the current amplifiers at rest
have a drift larger than ±0.15V.
61 HIGH TEM- This alarm occurs if the tempera- Improve the cooling of the controller;
PERATURE ture of the controller base plate otherwise it is necessary to replace the
overtakes 75 degrees. controller.
65 MOTOR This alarm occurs only when DIA Check that the thermal sensor in the motor
TEMPERAT MOTOR TEMP is on and the is working correctly. If it is, improve the
thermal sensor inside the cooling of the motor.
motor measures a temperature
higher than 150 degrees. It
also occurs when trying to
acquire the motor resistance
with a temperature in the motor
higher than 150 degree (still
with DIAG MOTOR TEMP to
ON).
70 HIGH CURRENT This alarm occurs if the circuit to Check the motor is suited to work with the
limit via hardware the current in EPS-DC0 (not oversized). Otherwise it is
the motor is either always necessary to replace the controller.
active at key-on or repeatedly
active when the motor is turning.
71 POWER This alarm occurs when the cur- Check the power fuse is OK. Check the
FAILURE #3 rent in the phase V of the battery positive arrives to the controller.
motor is zero and the motor is Check the continuity of the wire in the
commanded for moving. phase V of the motor. Otherwise it is nece-
ssary to replace the controller.
FAILURE #2 rent in the phase U of the battery positive arrives to the controller.
commanded for moving. phase U of the motor. Otherwise it is nece-
FAILURE #1 rent in the phase W of the battery positive arrives to the controller.
commanded for moving. phase W of the motor. Otherwise it is nece-
SM2214 05.15
35
Error Message
Code Error Text
83 BAD ENCODER It occurs in applications with tog- Swap in between two encoder channels
SIGN gle switches when the applied (CNB#7 with CNB#8).
frequency (FREQUENCY) and
motor sped (ENC SPEED)
have opposite sign.
84 STEER This alarm occurs if the command Change the steer pot.
SENSOR KO potentiometer (CPOC1 on
CNA#9 or CPOC2 on CNA#8)
changes with a jerk larger than
MAX SP SLOPE. This alarm is
used to catch a discontinuity in
the voltages of the command
potentiometer.
85 STEER HAZARD This is just a warning to inform
that the steering controller is
limiting the angle in the steering
direction. No speed reduction
occurs on the traction.
218 CLOCK PAL The main uC sends an analog It is necessary to replace the controller.
NOT OK signal towards trhe slave uC to
reset the slave uC on demand.
When the slave uC detects the
analog signal external to a win-
dow from 2.2 to 2.8 and not in
the range to generate the reset
on demand, the slave uC
raises this alarm.
99 INPUT ERROR It occurs when the voltage on When the safety contacts are open, the
#1 CNA#4 (NK1: Lower Potential voltage on CNA#4 is expected to be close
Terminal of the Safety Contacts) to 0 Vdc and this is independent from
is higher than 12 V before to turn whether the safety contacts are connected
the safety contacts closed. to a plus battery or to a minus battery. In
the first case (safety contacts connected
to a plus battery), when the safety con-
tacts are open, CNA#4 is connected to a
minus battery through a load. Only a
harness mistake may connect NK1 to a
higher than 12 voltage.
212 MICRO SLAVE It occurs when the encoder It is necessary to replace the controller.
#8 counting of the main uC is not
matched with the encoder
counting the slave uC.
SM2214 05.15
36
Error Message
Code Error Text
219 STEPPER This alarm occurs if the frequency It is necessary to replace the controller.
MOTOR MISM and the amplitude of the vol-
tages from the stepper motor
lines are mismatched in
between. In normal condition
when the amplitude of the
stepper motor lines increases,
the frequency of the stepper
motor lines must increase too.
220 MOTOR This alarm occurs if the current in Search for a mechanical problem locking
LOCKED the steering motor stays close the motor. To help in the fault finding, set
to the maximum current longer DEBUG OUTPUT to level 11.
tan 1 sec.
221 MICRO SLAVE It occurs in one or the following It is necessary to replace the controller.
#4 conditions:
(Open loop application only) If the
slave uC detects the stator
voltage phasor rotates in the
opposite direction respect to
the sign of the stepper motor
speed.
(Closed loop application only) If
the slave uC detects the stator
voltage phasor rotates in the
opposite direction respect to
the commanded position.
222 FB POT LOCKED In application with a feedback In application with the feedback potentiome-
potentiometer, this alarm ter,verify potentiometer is not mechanically
occurs if the feedback potenti- loosened. Check there is not a mechanical
ometer (CPOT on CNB#6) block of the steered wheel. Be sure the
does not change (or changes wiper has not reached its own electrical
in the opposite direction) its limit because of too much angle of the
value even if commanded to steered wheel. Besides, this alarm may
change. occur at the installation when the motor
In application with toggle switches rotates in the wrong direction turning away
with ENCODER CONTROL to from the desired direction.
off, this alarm occurs if the
feedback encoder counting
does not change its value even
if commanded to change.
223 JERKING FB This alarm occurs if the feedback Change the feedback potentiometer.
POT potentiometer (CPOT on
CNB#6) changes with a jerk
larger than 0.3V in 16 msec.
This alarm is used to catch a
discontinuity in the voltages of
the feedback potentiometer.
SM2214 05.15
37
Error Message
Code Error Text
225 CURRENT GAIN This alarm occurs when the It is necessary to send the controller to Zapi
parameter to compensate for to perform,the maximum current regulation.
the gain of the current amplifi-
ers (ADJUSTMENT #03 and
ADJUSTMENT #04) have the
default values.
226 NO SYNC Every 16msec, inside the code It is necessary to replace the controller.
cycle, the main uC rises and
then lowers an input for the
slave uC (SYNC). When the
slave uC detects no edge for
more than 100 msec on this
input, this alarm occurs. This is
just a watch dog function:
when the main uC does not
execute the code cycle it does
not update the SYNC signal
and the slave uC cuts off the
steer and traction.
227 SLAVE COM. Main uC and Save Uc communi- It is necessary to replace the controller.
ERROR cate via a local serial interface.
This alarm occurs when the
main uC does not receive the
communication from the slave
uC through this serial interface.
237 WAITING DATA This warning occurs only if CAN

BUS is PRESENT. At key-on
the EPS-AC0 asks the traction
controller to send a list of
parameters via CAN BUS.
From the request until the
parameter are correctly
received, this warning occurs.
The steer is not activated yet,
and the safety relays remain
open when this warning is
present.
228 POSITION This alarm occurs for a error in Check the potentiometer connected to
ERROR the redundant test of the feed- CNB#6 is working correctly. If toggle
back sensors. switches are connected to CNA#2 and
CNA#3, verify they are working correctly
and the setting AUX FUNCTION 11 is
correct. Verify that sensor bearing in the
motor (encoder) has not slipped (the
sensor bearing has two rings: one is
connected to the rotor shaft; the other is
connected to trhe motor frame.
Check these two rings are securely con-
nected to their structure without slippage.
SM2214 05.15
38
Error Message
Code Error Text
238 EPS NOT This is a real alarm that cuts off
ALIGNED the traction. It occurs at the ini-
tial alignment if the straightahead
condition is not matched
within 6 sec. Throughout the 6
sec delay, steering is not activ-
ated, the safety relays are open
and the traction is stopped.
239 WAITING FOR At key-on the EPS-AC0 needs an

TRAC assent from the traction contro-
ller to close the safety contacts
and to turn on the operational
mode. Until this happens, this
warning occurs.The steer is not
activated and the safety relays
remain open when this warning
is present.
241 ENCODER It occurs when ENCODER CON- This condition is several times due to either,
ERROR TROL is set ON and the real a mismatching between the Encoder
frequency does not pursuit the resolution used in the SW and the real
commanded frequency. encoder resolution, or a wrong connection
between the two encoder channels. In this
latest case, exchange the connections.
242 Q LINE SENSOR This alarm occurs when the mean Check the continuity of the stepper motor
KO voltage of the Quadrature line connections. In particular the resistance
of the stepper motor (connection between CNA#8 and the negative battery
CNA#8) is not null: the voltage (with the stepper motor at rest) is expe-
on every stepper motor line is a cted to be very low (close to 30 ohms).
sine wave with null mean voltage.
243 D LINE SENSOR This alarm occurs when the mean Check the continuity of the stepper motor
KO voltage of the Direct line of the connections. In particular the resistance
stepper motor (connection between CNA#9 and the negative battery
CNA#9) is not null: the voltage (with the stepper motor at rest) is expe-
on every stepper motor line is a cted to be very low (close to 30 ohms).
sine wave with null mean voltage.
245 DATA ACQUISI- This alarm occurs when acquiring Recycle the key.
TION the motor resistance or when
adjusting the parameters to
compensate for the gain of the
current amplifiers (maximum
current factory adjusted).
SM2214 05.15
39
Error Message
Code Error Text
244 GAIN EEPROM The parameters to compensate It is necessary to send the controller to Zapi
KO for the gain of the current to execute the maximum current
amplifiers (ADJUSTMENT #03 regulation.
and ADJUSTMENT #04 are
recorded in a not volatile mem-
ory (eeprom) with a redundant
handling. In fact every adjust-
ment is recorded in three
eeprom locations. If the values
in these thee location are diffe-
rent, this alarm occurs.
246 MICRO SLAVE In stepper motor application, this It is necessary to replace the controller.
KO alarm occurs if the main uC is
detecting a direction of the
stepper motor not matched
with the one that the slave uC
is detecting.
In closed loop application, this
alarm occurs if the main uC is
detecting a direction of the
steering error not matched with
the one that the slave uC is
detecting.
Furthermore, this alarm occurs if
the main uC is detecting no
steering limitation meanwhile
the slave uC is detecting a
steering limitation.
247 CAN BUS KO This alarm occurs only when the Check the CAN Bus communication system
setting CAN BUS is PRESENT. and analyse the frames from the traction
Then the EPS-AC0 must controller to the steer controllers.
receive the event messages
from the traction controller. If
these messages lack more
than about 1 sec, this alarm
occurs.
248 S.P OUT OF This alarm occurs for a fault on Check the connections of the potentiometer.
RANGE the command potentiometer This alarm occurs when one connection of
(CPOC2on CNA#8). When a the command potentiometer is broken.
single command pot is chosen,
the alarm occurs if the wiper
(CPOC1) exits the range from
0.8 Vdc to 4.2 Vdc. When the
twin pot is chosen, the alarm
occurs if the sum of the two
wiper voltages (CPOC1 +
CPOC2) exists the range from
4.5 Vdc to 5.5 Vdc.
SM2214 05.15
40
Error Message
Code Error Text
249 F.B OUT OF This alarm occurs for a fault on Check the connections of the feedback
RANGE the feedback potentiometer potentiomerter. This alarm occurs when
(CPOT on CNB#6). This alarm one connection of the feedback poten-
occurs in CPOT exits the range tiometer is broken.
from 0.3 Vdc to 4.7 Vdc.
250 MICRO SLAVE It occurs when the information on It is necessary to replace the controller.
the status bus between the
main uC and the slave uC is
frozen to the OFF value (the
slave uC does not update the
status bus configuration).
251 KM OPEN This alarm occurs if the slave uC It is necessary to replace the controller.
detects the safety contact, of
the main uC, o[pen when
expected being closed.
252 KS OPEN This alarm occurs if the slave uC It is necessary to replace the controller.
detects the safety contact, of
the main uC, open when
expected being closed.
253 KM CLOSED This alarm occurs at key-on if the This alarm occurs if the connection CNA#5
slave uC detects the safety (K1) is around a voltage of 12 Vdc when
contact, of the main uC, closed switching on the key. In fact, when the
prior to being commanded. safety contacts are open, K1 is expected
to be plus battery voltage (not 12 V).
Search for a harness problem or replace
the controller.
254 KS CLOSED This alarm occurs if the main uC This alarm occurs if the connection CNA#4
detects the safety contact, of (NK1) is around a voltage of 12 Vdc when
the slave uC, closed prior to switching on the key. In fact, when the
being commanded. safety contacts are open, NK1 is expected
to be a minus battery voltage (not 12 V).
Search for a harness problem or replace
the controller.
SM2214 05.15
41
42
VALVE 2 LOWER SW 2
（18）（3）（1）
LOWER SW 1
VALVE 1 LOWER SW 1
（1 8）（3）（1）
SM2214 05.15
（18）（1）
M
（18）（4）（1）
（18）（1）
-BATT +BATT
（2 8） PPOT
（1） B5
（2 9） CPOC1
（18） A9
（3 0） CPOC2 PM
（1）（0） A8 MOTOR
（3 1） GND
（2 5） A10
（2 6）
（1 0）
CNB M
（1 2）（8）（2 5） 5 1
（1 1）（3 3）
B2
（8）（1）（3 4）
B6
（3 5） B1 8 4
8 1
（1 8）
M
（2）（1）
（6）（1）（2 6） 14 7
CNA
SPEED MODE SW
（7）（2 5）
（5）（2 5）
（2 5）
Figure 4-6 Wiring Diagram

NMC （1 3）
PMC/PEB
（1 4）（1） KEY A7
NEB （9） E-BRAKE
NPC （21）（4 0）
A4 （4 1）
PPC/PEV （22）（4 2）
A5
（4 3）
A6
（20）
（4 4）
（24）
ENCODER
（15）（4 5）
（19）
（17）
（16）
（32）（32） A14
A7
（27）（27）
A6
C3
C4
SECTION 5
OPERATING CONTROL SYSTEM
5-1. CONTROL HEAD 2. Remove four screws (17, Figure 5-1), lift up cap
assembly (1) and disconnect harness from har-
5-1.1. Cap Assembly Removal ness (15, Figure 5-2).
1. Engage the emergency stop switch (12, Figure
10-1) and turn off key switch (15).
Figure 5-1 Control Head
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5-1.2. Cap Assembly Installation 2. Position cap assembly (1, Figure 5-1) on control
head and secure with four screws (17).
1. Hold cap assembly (1, Figure 5-1) in place and
3. Disengage the emergency stop switch (12, Figure
connect harness to harness (15, Figure 5-2).
10-1) and turn on key switch (15).
Figure 5-2 Steering Arm
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5-1.3. Control Head Removal 7. Position new potentiometer (21) in bracket (20)
and secure with screw (16), lock washer (6) and
1. Remove the cap assembly as described in para- flat washer (7).
graph 5-1.1.
8. Install screw (22), lock washer (6) and flat washer
2. Disconnect harness (15, Figure 5-2) from potenti- (7).
ometer (21, Figure 5-1) and switch assembly (15).
9. Install control knob (14) on potentiometer (21) and
3. Remove two screws (11), two lock washers (12) secure with screw (4), and washer (3).
and two flat washers (13).
10. Install control knob (2) on the other side of poten-
tiometer (21) and secure with screw (4), and
WARNING: When removing the control head in the
washer (3).
following steps, be sure to hold it in place
until the control harness is disconnected. 11. Connect harness (15, Figure 5-2) to potentiome-
ter (21, Figure 5-1).
4. Remove two screws (5), two washers (6) and two 12. Install the cap assembly as described in para-
flat washers (7). graph 5-1.2.
5. Remove the control head and handle (19).
5-1.6. Belly-Button Switch Replacement
5-1.4. Control Head Installation
1. Remove the cap assembly as described in para-
1. Hold control head and handle (19, Figure 5-1) in graph 5-1.1.
place and install two screws (5), two washers (6) 2. Disconnect harness (15, Figure 5-2) from switch
and two flat washers (7). assembly (15, Figure 5-1).
2. Install two screws (11), two lock washers (12) and 3. Remove screw (22), lock washer (6) and flat
two flat washers (13). washer (7).
3. Reconnect harness (15, Figure 5-2) to potentiom- 4. Remove screw (16), lock washer (6) and flat
eter (21, Figure 5-1) and switch assembly (15). washer (7) and remove switch assembly (15) from
4. Install the cap assembly as described in para- bracket (20).
graph 5-1.2. 5. Remove pin (5, Figure 5-3), bracket (4), and
spring (2) from button (1).
5-1.5. Potentiometer Replacement
6. Remove two pins (3) and reversing switch (6)
1. Remove the cap assembly as described in para- from bracket (4).
graph 5-1.1. 7. Position the new reversing switch (6) in bracket (4)
2. Disconnect harness (15, Figure 5-2) from potenti- and secure with two pins (3).
ometer (21, Figure 5-1). 8. Position bracket (4) in button (1) and install pin
3. Remove screw (4), washer (3) and control knob (5).
(2) from potentiometer (21). 9. Position switch assembly (15, Figure 5-1) on
4. Remove screw (4), washer (3) and control knob bracket (20) and secure with two screws (22 &
(14) from other side of potentiometer (21). 16).
5. Remove screw (22), lock washer (6) and flat 10. Reconnect harness (15, Figure 5-2) to switch
washer (7). assembly (15, Figure 5-1).
6. Remove screw (16), lock washer (6) and flat 11. Install the cap assembly as described in para-
washer (7) and remove potentiometer (21) from graph 5-1.2.
bracket (20).
SM2214 05.15
45
Figure 5-3 Emergency Reverse Switch Assembly
5-1.7. Horn Switch Replacement 4. Position the new switch in bracket (16) and
secure with two pins (18).
1. Remove the cap assembly as described in para-
5. Position horn switch assembly (10) in cover (1)
graph 5-1.1.
and secure with three screws (11).
2. Remove three screws (11, Figure 5-4), bracket
6. Install the cap assembly as described in para-
(16) and springs (19).
graph 5-1.2.
3. Remove two pins (18) and defective switch from
bracket (16).
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46
Figure 5-4 Cap Assembly
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5-1.8. Lift and Lower Switch Replacement 5-3. STEERING ARM
1. Remove the cap assembly as described in para- 5-3.1. Return Spring Replacement
graph 5-1.1.
The steering arm gas return spring (11, Figure 5-2) is
2. Remove switch assembly (13 or 14, Figure 5-4)
replaced while the steering arm (2) is in the upright
form cap (1).
position.
3. Remove pin (6) securing buttons (2 and 3 or 7
and 8) and remove the buttons.
4. Remove two pins (6), two switches and four
2. Secure the steering arm (2, Figure 5-2) in the
springs (4) from bracket (5 or 9).
upright position.
5. Position the new switches and four springs (4) in
3. Remove screw (12) and free the gas return spr-
bracket (5 or 9) and secure with two pins (6).
ing (11) from bracket (16).
6. Position switch assembly (13 or 14) in cover (1)
4. Pull downward on the gas return spring (11) to
and secure with pin (6).
free it from its seat inside steering arm (2).
7. Install the cap assembly as described in para-
5. Position the new gas return spring (11) inside the
graph 5-1.2.
steering arm being sure it fully engages its seat.
5-2. COMPARTMENT COVERS 6. Position the opposite end of the gas return spring
(11) on bracket (16) and install screw (12).
5-2.1. Removal 7. Disengage the emergency stop switch (12, Fig-
ure10-1) and turn on key switch (15).
5-3.2. Steering Arm Removal
2. Remove four screws (5) , two screws (1) and the
lower cover (2). 1. Engage the emergency stop switch (12, Figure
3. Remove two screws (5, Figure 5-5) and upper 10-1) and turn off key switch (15).
cover (4). 2. Remove the return spring as described in para-
graph 5-3.1.
5-2.2. Installation 3. Disconnect harness (15, Figure 5-2) from main
harness (1, Figure 10-3).
1. Install upper cover (4) and secure with two sc-
rews (5). 4. Attach a hoist to steering arm (2, Figure 5-2).
2. Position lower cover (2) on the frame and secure 5. Remove shaft (6) and the steering arm (2).
with screws (1&5).
3. Disengage the emergency stop switch (12, Fig- 5-3.3. Steering Arm Installation
ure10-1) and turn on key switch (15). 1. Position steering arm (2, Figure 5-2) in bracket
(16) and secure with shaft (6) and screw (7).
2. Install the return spring as described in paragraph
5-2.1.
3. Reconnect harness (15) to main harness (1, Fig-
ure 10-3).
SM2214 05.15
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Figure 5-5 Compartment Cover
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NOTES
SM2214 05.15
50
SECTION 6
BRAKE SERVICING
6-1. BRAKES 4. Remove the three mounting screws (1, Figure 6-
1) and the brake.
The brake system consists of a drive motor mounted
brake. This brake is spring applied and electrically 5. Place the new brake into position and secure with
released. the three mounting screws.
6-1.1. Brake Assembly Replacement 6. Reconnect electric brake to driving harness .

7. Remove load wheel blocks and check operation.
1. Block load wheels.
8. Install the compartment covers as described in
2. Remove the compartment covers as described in paragraph 5-2.
paragraph 5-2.
3. Disconnect electric brake (2, Figure 6-1) from
wiring harness (1, Figure 10-3).
Figure 6-1 Brake Assembly
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NOTES
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SECTION 7
DRIVING SYSTEM
7-1. DRIVE WHEEL 7-3. STEERING MOTOR
1. Engage the emergency stop switch (12, Figure 1. Engage the emergency stop switch (12, Figure
10-1) and turn off key switch (15). 10-1) and turn off key switch (15).
2. Remove the compartment covers as described in 2. Remove the compartment covers as described in
paragraph 5-2. paragraph 5-2.
3. Loosen but do not remove the five nuts (22,Figure 3. Disconnect encoder (27, Figure 7-1) from harness
7-1). (1, Figure 10-3).
4. Jack up the truck so the drive wheel is off the 4. Remove three screws (26) and encoder(27) from
ground; then securely block the truck to prevent the steering motor (23).
movement.
5. Disconnect harness (1, Figure 10-3) from steering
5. Remove five nuts (22), five washers (21), and motor (23, Figure 7-1).
drive wheel (13) from transmission (12).
6. Remove screw (8), lock washer (7), washer (25)
6. Install new drive wheel in reverse order of and gear (24) from steering motor (23).
removal.
7. Remove four screws (9) and lift steering motor
7. Install the compartment covers as described in (23) from the frame.
paragraph 5-2.
8. Install new steering motor by reversing the steps
8. Disengage the emergency stop switch (12, Figure above.
7-2. TRANSMISSION
2. Remove the compartment covers as described in
paragraph 5-2.
3. Remove the brake (3, Figure 7-1) as described in
paragraph 6-1.1 .
4. Disconnect harness (1, Figure 10-3) from drive
motor (4, Figure 7-1).
5. Remove six screws (14), six lock washers (15),
plat washers (16), and motor (4) from transmis-
sion (13).
6. Disconnect position switch (6) from harness (1,
Figure 10-3).
7. Remove position switch from the frame.
8. Support the transmission (12) and remove the six
screws (17), six lock washers (18) and six flat
washers (19).
9. Slowly lower the transmission out the bottom of
the frame.
10. Remove the eight screws (20), bearing (10) and
gear (11) from transmission (12)
11. Install new transmission by reversing the steps
above.
SM2214 05.15
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Figure 7-1 Transmission, Motor, Brake Mounting
SM2214 05.15
54
7-4. LOAD WHEEL 7-4.2. Repair
7-4.1. Removal 1. Remove bearings (4) from wheels .
2. Inspect bearings (4) and replace if necessary.
1. Raise forks.
3. Reassemble bearings (4) in wheels.
10-1) and turn off key switch (15). 4. Jack up the forks to raise the load wheels off the
floor. Securely block the forks in the raised posi-
3. Block the drive wheel to prevent the truck from
tion by positioning supports under both fork tips.
rolling.
4. Jack up the forks to raise the load wheels off the 7-4.3. Load Wheel Installation
floor. Securely block the forks in the raised posi-
tion by positioning supports under both fork tips. 1. Position load wheel (3) in the straddle.
2. Install shaft (2) and secure with pins (1).
NOTE: When shaft (2, Figure 7-2) is removed, load
wheel assembly (3) will drop free. 3. Remove blocking from under the truck.
4. Lower the forks.
5. Remove pins (1) securing shaft (2) and remove
shaft (2) and load wheel assembly (3). 5. Disengage the emergency stop switch (12, Figure
NOTE: Inspect the load wheel assembly. If the load
wheel is worn within 1/8" of the metal sleeve,
or is cracked or damaged, replace the entire
load wheel and bearing assembly.We recom-
mend that both load wheel assemblies be
replaced at the same time. This ensures level
and safe operation of the lift truck.
Figure 7-2 Load Wheel
SM2214 05.15
55
NOTES
SM2214 05.15
56
SECTION 8
ELEVATION SYSTEM SERVICING
8-1. GENERAL
The elevation system includes the outer mast, inner
mast, lift linkage, lift chains, lift cylinder and ram head.
8-2. LIFT CHAIN LENGTH ADJUSTMENT

NOTE: The Telescopic trucks have two lift chains that
are adjusted at the cross member of the outer
mast (13, Figure 8-2). TRIMAST trucks have
four lift chains. The free lift chains are
adjusted at the free lift cylinder (35, Figure 8-
3) close to the cross member of the inner
mast (34). The secondary lift chains are ad-
justed at the top of the outer mast (18).
1. Fully lower the lift carriage.

WARNING: Before attempting any adjustment, make
certain power is disconnected.
3. Loosen both upper jam nuts (2, Figure 8-1) to

allow for adjustment of middle jam nuts (2).
4. Break both lower jam nuts (2) free from the middle
jam nuts.
5. Take up slack in both lift chains with middle jam
nuts (2). Strive for equal tension on both chains.
6. Align anchor (1) so the clevis pins (4) is parallel to
the masts.
CAUTION: At least 3 full threads must be present
below lower nut (2) after adjustment.
7. Tighten jam nuts securely while maintaining

alignment of clevis pins (4).
9. Test chain by operating carriage. If slack is still
apparent, repeat above procedure.
Figure 8-1 Chain Assembly
SM2214 05.15
57
8-3. LIFT CHAIN WEAR INSPECTION 2. Lower inner mast onto the support. Check that
arrangement is secure before proceeding.
Both lift chains should be replaced when either chain
is worn enough to increase it’s length by 3% or more. WARNING: Before attempting any adjustment, make
To make this determination proceed as follows. certain power is disconnected.
Using a section of chain that sees the most frequent
operation over the chain sheaves, isolate a vertical
portion under tension from the weight of carriage and 3. Engage the emergency stop switch (12, Figure
forks. 10-1) and turn off key switch (15).
Measure the distance between pin centers on 20 4. Remove cotter pin (3, Figure 8-1) and clevis pin
vertical links. If the section measures 12.88” or more, (4) connecting chain (5) to chain anchor (6) at the
the chain should be replaced. lift carriage.
New chain anchor, clevis pins and cotter pins should 5. Remove cotter pin (3) and clevis pin (4) connect-
be installed when chains are replaced. Never replace ing chain (5) to chain anchor (1) at the outer
a partial section of chain and never repair chain. mast.
Refer to paragraph 8-4. when installing new chain. 6. Remove chain from sheave (22, Figure 8-2).
7. Position new chain on sheave (22).
8-4. LIFT CHAIN REPLACEMENT
8. Secure new chain to new chain anchor (1, Figure
8-4.1. Telescopic 8-1) at the outer mast with new clevis pin (4)
and new cotter pin (3).
1. With the lift truck wheels securely blocked, raise
the forks approximately three feet from floor and 9. Connect the opposite end of new chain to new
position blocks or strong supports under inner chain anchor (6) at the lift carriage with new
mast (25, Figure 8-2). clevis pin (4) and new cotter pin (3).
10. Adjust the chains according to paragraph 8-2.
11. Disengage the emergency stop switch (12, Fig-
ure 10-1) and turn on key switch (15).
SM2214 05.15
58
Figure 8-2 Mast (Telescopic)
SM2214 05.15
59
8-4.2. TRIMAST Free Lift Chain 8-4.3. TRIMAST Secondary Lift Chain
1. With the lift truck wheels securely blocked, raise 1. With the lift truck wheels securely blocked, raise
the forks approximately three feet from floor and the forks approximately three feet from floor and
position blocks or strong supports under the lift position blocks or strong supports under masts
carriage. (27 & 34, Figure 8-3).
2. Lower inner mast onto the support. Check that 2. Lower inner mast onto the support. Check that
arrangement is secure before proceeding. arrangement is secure before proceeding.
3. Engage the emergency stop switch (12, Figure 3. Engage the emergency stop switch (12, Figure
10-1) and turn off key switch (15). 10-1) and turn off key switch (15).
WARNING: Before attempting any adjustment, make WARNING: Before attempting any adjustment, make
certain power is disconnected. certain power is disconnected.
4. Remove cotter pin (3, Figure 8-1) and clevis pin 4. Remove cotter pin (3, Figure 8-1) and clevis pin
(4) connecting chain (5) to chain anchor (6) at the (4) connecting chain (5) to chain anchor (6) at the
lift carriage. inner mast.
5. Remove cotter pin (3) and clevis pin (4) connect- 5. Remove cotter pin (3) and clevis pin (4) connect-
ing chain (5) to chain anchor (1) at free lift ing chain (5) to chain anchor (1) at the outer
cylinder. mast.
6. Remove chain from sheave (32, Figure 8-3). 6. Remove chain from sheave (32, Figure 8-3).
7. Position new chain on sheave (32). 7. Position new chain on sheave (32).
8. Secure new chain to new chain anchor (1, Figure 8. Secure new chain to new chain anchor (1, Figure
8-1) at the outer mast with new clevis pin (4) 8-1) at the outer mast with new clevis pin (4)
and new cotter pin (3). and new cotter pin (3).
9. Connect the opposite end of new chain to new 9. Connect the opposite end of new chain to new
chain anchor (6) at the lift carriage with new chain anchor (6) at the inner mast with new
clevis pin (4) and new cotter pin (3). clevis pin (4) and new cotter pin (3).
10. Adjust the chains according to paragraph 8-2. 10. Adjust the chains according to paragraph 8-2.
11. Disengage the emergency stop switch (12, Fig- 11. Disengage the emergency stop switch (12, Fig-
ure10-1) and turn on key switch (15). ure10-1) and turn on key switch (15).
8-5. LIFT CYLINDERS

NOTE: Removal and repair of lift cylinders are
covered in SECTION 9.
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60
Figure 8-3 Mast (TRIMAST)
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61
NOTES
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62
SECTION 9
HYDRAULIC SYSTEM
9-1. LINES AND FITTINGS 9-2. HYDRAULIC PUMP, MOTOR, AND RESE-
RVOIR ASSY
WARNING: When forks are raised, pressure exists in
the hydraulic system lines and fittings. To The hydraulic pump/motor assembly can be disas-
ensure release of pressure, forks must sembled and repaired. However, a defective pump,
be fully lowered and the batteries discon- valve or motor requires replacement of that compo-
nected before performing any mainte- nent.
nance on the hydraulic system.
WARNING: When forks are raised, pressure exists in
NOTE: Leaking hydraulic fittings may be remedied by the hydraulic system lines and fittings. To
simply tightening fittings. If this does not rem- ensure release of pressure, forks must
edy the leak, the fittings or line must be be fully lowered and the batteries discon-
replaced. nected before performing any mainte-
nance on the hydraulic system.
1. Lower forks fully.
2. Engage the emergency stop switch (12, Figure 9-2.1. Removal
1. Lower forks fully.
3. Remove the compartment covers as described
in paragraph 5-2. 2. Engage the emergency stop switch (12, Figure
CAUTION: Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container 3. Remove the compartment covers as described in
under the line or fitting before discon- paragraph 5-2.
necting. NOTE: The reservoir and hose will be filled with
4. Telescopic Trucks: Refer to Figure 9-1 and re- hydraulic oil. Place a container under the
move leaking line or fitting and replace it with a pump assembly to catch any hydraulic oil.
new line or fitting. 4. Tag and disconnect electrical leads from motor
and solenoid. Refer to Figure 10-3 and Figure
TRIMAST Trucks: Refer to Figure 9-2 and re-
10-4.
move leaking line or fitting and replace it with a
new line or fitting. 5. Telescopic: Disconnect hose (12, Figure 9-1)
from pump/motor assembly.
5. Check level of hydraulic oil. With lift carriage fully
lowered, fill reservoir with hydraulic oil to 1 inch Trimast: Disconnect hose (17, Figure 9-2) from
below opening. Use hydraulic oil listed in Table pump/motor assembly.
3-2. 6. While supporting the pump/motor assembly (9,
6. Disengage the emergency stop switch (12, Figure Figure 9-3), remove four screws (7) and four
10-1) and turn on key switch (15). lock washers (8).
7. Operate the lift and lower buttons to refill the 7. Remove the pump/motor assembly.
cylinder and lines with hydraulic oil.
8. Check level of hydraulic oil. Hydraulic oil must be
1 inch below opening. If required, add hydraulic oil
to bring to proper level. Use hydraulic oil listed in
Table 3-2.
paragraph 5-2.
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63
Figure 9-1 Hydraulic System (Telescopic with Tubes)
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64
Figure 9-2 Hydraulic System (Trimast with Tubes)
SM2214 05.15
65
9-2.2. Disassembly and Reassembly 3. Connect electrical leads to motor and solenoid.
Refer to Figure 10-3 and Figure 10-4.
1. Remove the hydraulic pump/motor assembly as
4. Fill the hydraulic reservoir. Use hydraulic oil listed
described in paragraph 9-2.1.
in Table 3-2.
2. Refer to Figure 9-3 for disassembly and reas-
5. Disengage the emergency stop switch (12, Fig-
sembly.
ure10-1) and turn on key switch (15).
9-2.3. Installation 6. Operate the lift and lower buttons to refill the
1. While supporting the pump/motor assembly (9,
7. Check level of hydraulic oil. If required, add hydr-
Figure 9-3), secure with four screws (7) and four
aulic oil to bring to proper level. Use hydraulic
lock washers (8).
oil listed in Table 3-2.
2. Telescopic: connect hose (12, Figure 9-1) to
pump/motor assembly.
paragraph 5-2.
Trimast: connect hose (17, Figure 9-2) to
pump/motor assembly.
Figure 9-3 Hydraulic System
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66
Figure 9-4 Pump & Motor Assy
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67
9-2.4. Lift Cylinder (Telescopic)
9-2.4.1. Removal
1. With the lift truck wheels securely blocked, raise
the forks approximately three feet from floor and
position blocks or strong supports under inner
mast.
2. Lower inner mast onto the support. Check that
arrangement is secure before proceeding.
WARNING: Before attempting any replacement,
make certain power is disconnected.
4. Remove screw (23, Figure 8-2), lock washer (12)

and flat washer (24) securing the top of cylinder
(21) to mast (25).
5. Support cylinder (21, Figure 8-2) and remove two
bolts (11), two lock washers (12), block (18), sup-
port (19), block (10) and clamp (20).
any oil immediately. Provide a container
under the line or fitting before discon-
necting.
6. Disconnect the tube (2, Figure 9-1) from the lift
cylinder.
7. Raise lift cylinder assembly up and out of truck.
9-2.4.2. Repair
CAUTION: To prevent damage, use proper pipe Figure 9-5 Lift Cylinder (Telescopic)
clamp vise. The cylinder will be distorted
2. Slowly lower mast (22) while aligning cylinder (21)
if the vise is tightened too much.
with the top on mast (22).
1. Secure the lift cylinder in a vise, clamping lightly
3. Secure the top of cylinder (21) with flat washer
at the base of the cylinder.
(24), lock washer (12) and screw (23).
2. Remove gland nut (3, Figure 9-5).
4. Install clamp (20), support (19), block (10),block
3. Remove wiper (1) and seal (2) from gland nut (3). (18), two lock washers (12) and two bolts (11) .
4. Pull out piston rod (4). 5. Reconnect the tube to the lift cylinder.
5. Remove guide ring (5) and seal (6) from piston 6. Fill the hydraulic reservoir. Use hydraulic oil listed
rod (4). in Table 3-2.
6. Coat all parts with hydraulic oil (Table 3-2). 7. Disengage the emergency stop switch (9, Figure
7. Install guide ring (5) and seal (6) on piston rod (4). 10-1) and turn on key switch (14).
8. Insert rod (4) in cylinder tube (7). 8. Operate the lift and lower buttons to refill the
9. Install seal (2) and wiper (1) on gland nut (3).
9. Check level of hydraulic oil. If required, add
10. Install gland nut (3) in cylinder tube (7).
hydraulic oil to bring to proper level. Use hydrau-
lic oil listed in Table 3-2.
9-2.4.3. Installation
1. Using another lift truck or suitable jack, raise inner paragraph 5-2.
mast (25, Figure 8-3) far enough to allow install-
ation of the lift cylinder (21).
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68
9-2.5. Lift Cylinder (TRIMAST Free Lift)
9-2.5.1. Removal
3. Using another lift truck or suitable jack, raise lift

carriage far enough to remove pressure on the
free lift cylinder
4. Remove cotter pin (3, Figure 8-1) and clevis pin
(4) connecting chain (5) to chain anchor (6) at
free lift cylinder.
5. Remove chains from sheaves (32, Figure 8-3).
6. Remove screw (39), lock washer (14), flat washer
(29), bracket (31) and ram head (33) from cylin-
der (35).
necting.
screws (13),two lock washers (14) and two flat
washers (29). Figure 9-6 Free Lift Cylinder (TRIMAST)
9-2.5.3. Installation
9-2.5.2. Repair 1. Position cylinder (35, Figure 8-3) on inner mast
(34) and secure with two screws (13), two lock
CAUTION: To prevent damage, use proper pipe
washers (14) and two flat washers (29).
clamp vise. The cylinder will be distorted
if the vise is tightened too much. 2. Reconnect the tube to the bottom of the cylinder.
1. Secure the lift cylinder in a vise, clamping lightly 3. Position ram head (33) on cylinder (35) and sec-
at the base of the cylinder. ure with bracket (31), screw (39), lock washer (14)
and flat washer (29).
2. Remove gland nut (3, Figure 9-6).
4. Lift up the lift chains and position them on
3. Remove wiper (1) and O-ring (2) from gland nut
sheaves (32).
(3).
5. Adjust the chains according to paragraph 8-2.
4. Pull out piston rod (4).
5. Remove guide ring (5),seal (7) and snap ring (6)
from piston rod (4).
7. Operate the lift and lower buttons to refill the
6. Coat all parts with hydraulic oil (Table 3-2).
7. Install guide ring (5),seal (7) and snap ring (6) on
piston rod (4).
hydraulic oil to bring to proper level. Use hydrau-
8. Insert rod (4) in cylinder tube (8). lic oil listed in Table 3-2.
9. Install wiper (1) and O-ring (2) on gland nut (3). 9. Install the compartment covers as described in
10. Install gland nut (3) in cylinder tube (8). paragraph 5-2.
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9-2.6. Lift Cylinder (TRIMAST Secondary)
9-2.6.1. Removal
3. Remove screw (26, Figure 8-3), lock washer (10)

and flat washer (11) securing the top of cylinder
(25) to mast (27).
4. Using another lift truck or suitable jack, raise mid-
dle mast (27) far enough to remove pressure on
the secondary lift cylinder (25).
necting.
bolts (9), two lock washers (10), block (22), sup-
port (23), block (12) and clamp (24).
9-2.6.2. Repair Figure 9-7 Secondary Lift Cylinder (TRIMAST)
CAUTION: To prevent damage, use proper pipe 2. Slowly lower mast (27) while aligning cylinder (25)
clamp vise. The cylinder will be distorted with the top on mast (27).
if the vise is tightened too much. 3. Secure the top of cylinder (25) with flat washer
1. Secure the lift cylinder in a vise, clamping lightly (11), lock washer (10) and screw (26).
at the base of the cylinder. 4. Install clamp (24), support (23), block (22),block
2. Remove gland nut (3, Figure 9-7). (12), two lock washers (10) and two bolts (9) .
3. Remove wiper (1) and O-ring (2) from gland nut 5. Reconnect the tube to the bottom of the lift cylin-
(3). der.
4. Pull out piston rod (4). 6. Fill the hydraulic reservoir. Use hydraulic oil listed
in Table 3-2.
5. Remove guide ring (5) and seal (6) from piston
rod (4). 7. Disengage the emergency stop switch (12, Figure
6. Coat all parts with hydraulic oil (Table 3-2).
8. Operate the lift and lower buttons to refill the
7. Install guide ring (5) and seal (6) on piston rod (4).
8. Insert rod (4) in cylinder tube (7).
9. Install seal (2) and wiper (1) on gland nut (3). hydraulic oil to bring to proper level. Use hydrau-
10. Install gland nut (3) in cylinder tube (7). lic oil listed in Table 3-2.
9-2.6.3. Installation paragraph 5-2.
1. Using another lift truck or suitable jack, raise mid-
dle mast (27, Figure 8-3) far enough to allow
installation of the secondary lift cylinder (25).
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SECTION 10
ELECTRICAL COMPONENTS
10-1. ELECTRICAL CONTROL PANEL 4. Remove three screws (1), three lock washers (2),
three flat washers (3), horn (4) and control panel
10-1.1. Maintenance (6).
NOTE: Erratic operation of the truck may be caused
10-1.4. Panel Disassembly
by defective controller components. Before
removing the electrical panel, perform trou- Refer to Figure 10-2 for location and identity of the
bleshooting procedures per SECTION 4, to major replacement components mounted on the
determine corrective action to be taken. panel and remove defective parts.
There are no user-serviceable parts inside the con- NOTE: Contactor (3) is not repairable and must be
troller. No attempt should be made to open the replaced if defective.
controller. Opening the controller may damage it and
will void the warranty. 10-1.5. Panel Installation
The controller is programmed at the factory specifi- 1. Install the control panel (6, Figure 10-1) and
cally for the truck model on which it is equipped. It is secure with three screws (1), three lock washers
important to replace the controller with the correct (2), three flat washers (3) and horn (4).
preprogrammed unit to assure proper performance 2. Refer to Figure 10-3 and Figure 10-4 and connect
settings intended for that particular truck. See Figure all electrical cables to the control panel as noted
10-2 for the preprogrammed controller number. during removal.
It is recommended that the controller exterior be 3. Install the compartment covers as described in
cleaned periodically, and if a hand held programmer paragraph 5-2.
is available, this periodic cleaning provides a good
opportunity to check the controller’s diagnostic 4. Disengage the emergency stop switch (12, Figure
history file. It is also recommended that the 10-1) and turn on key switch (15).
controller’s fault detection circuitry be checked
whenever the vehicle is serviced. 10-2. HORN REPLACEMENT
10-1.2. Cleaning 10-1) and turn off key switch (15).
1. Engage the emergency stop switch (12, Figure 2. Remove the compartment covers as described
10-1) and turn off key switch (15). in paragraph 5-2.
2. Remove the compartment covers as described 3. Tag and disconnect all electrical connections from
in paragraph 5-2. horn (4).
3. Remove any dirt or corrosion from the bus bar 4. Remove screw (1), lock washer (2), flat washer
area. The controller should be wiped clean with a (3), and horn (4).
moist rag. Allow it to dry before reconnecting the
battery. 5. Install new horn (4) and secure with screw (1),
lock washer (2), flat washer (3).
4. Make sure the connections to the buss bars are
tight.Use two well insulated wrenches for this task 6. Install the compartment covers as described in
in order to avoid steering the buss bars. paragraph 5-2.
10-1.3. Panel Removal 10-1) and turn on key switch (15).
2. Remove the compartment covers as described
in paragraph 5-2.
3. Tag and disconnect all electrical cables which
connect to the control panel (6).
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Figure 10-1 Electrical System
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Figure 10-2 Electrical Panel
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Figure 10-3 Wiring Harness
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Figure 10-4 Wiring Cables
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10-3. PUMP MOTOR 10-5. DEADMAN SWITCH
The pump motor is replaceable but not repairable. 1. Disconnect harness (1, Figure 10-3) from the
Refer to paragraph 9-2. deadman switch (22, Figure 5-2).
2. Remove the two screws (23), and switch (22)
10-4. DRIVE MOTOR from bracket (21).
The drive motor exposed surfaces should be cleaned 3. Position the new switch (22) on bracket (21)
at least once a month to assure proper cooling of and secure with the two screws (23).
motor. Use an air hose to blow dust off of motor 4. Reconnect harness (1, Figure 10-3) to the dead-
surfaces. man switch (22, Figure 5-2).
The drive motor is replaceable but not repairable.
Refer to paragraph 7-2.
SM2214 05.15
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SECTION 11
OPTIONAL EQUIPMENT
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77
NOTES
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SECTION 12
ILLUSTRATED PARTS BREAKDOWN
Following is an illustrated parts breakdown of assemblies and parts associated with the Lift Truck.
SM2214 05.15
79

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Section Page Section Page

11 OPTIONAL EQUIPMENT ..................................77

12 ILLUSTRATED PARTS BREAKDOWN .............79

procedures, corrective maintenance procedures and Capacity: kg Lifting height: mm

Fork width: mm Selfweight with battery: kg

By following these requirements and the recomm-

endations contained in this manual, you will receive

SECTION DESCRIPTION SECTION DESCRIPTION

ITEM COMPONENT ITEM COMPONENT

Figure 2-1 Load Center

Table 2-1 Operator Checks

Truck No. Model No.

Check O.K.(√) Need maintenance

Figure 2-2 Sample of Operator Check List

2-8. LIFT AND LOWER CONTROLS

2-9. LOADING AND UNLOADING

Figure 2-6 Belly-Button Switch

3-3.1. General A voltage check from battery connector terminal

Table 3-1 Monthly and Quarterly Inspection and Service Chart

3-6. LIFT CHAIN MAINTENANCE

Table 3-3 Lubrication Chart

Table 4-1 Troubleshooting Chart

b. Fuse (12, Figure 10-2) blown. Check fuse and replace if

c. Battery dead or disconnected. Check battery connections and

d. Key switch (15, Figure 10-1) Bypass key switch to determine if it

e. Emergency stop switch (12, Bypass the switch to determine if it

f. Defective wiring. Check for open circuit. Repair as

b. Defective deadman switch (22, Check and replace switch if

TROUBLE WITH LIFTING OR

Drive motor is jerky. Motor internally damaged or worn. Replace motor.

AC-0 4. Press the ENTER button (3) to view the alarms.

NOTE: Refer to bigjoesupport.com for the Zapi sup-

4-2.3. Testing Truck Operation

Figure 4-2 Hand Held Programmer

Table 4-2 Set Options

STOP ON RAMP OFF Not used.

PERFORMANCE OPTION #1 This option can be set

MOT SET-UP LOCK OFF Not used.

Figure 4-3 Hand Held Programmer

Table 4-3 Adjustments

SET BATTERY 24V Selects the nominal battery voltage.

THROTTLE 0 ZONE 9% Establishes a deadband in the accelerator input curve.

Figure 4-4 Throttle Regulation

Figure 4-5 Hand Held Programmer

Table 4-4 Parameter Adjustments

MAXIMUM 96% It specifies the percentage of the absolute current at which

Table 4-6 TRACTION CONTROLLER

13 EEPROM KO It occurs due to a HW or SW Try to execute a CLEAR EEPROM opera-

37 CONTACTOR The controller checks if the MC It is suggested to check the contactor

237 WAITING DATA This warning occurs only if CAN

239 WAITING FOR At key-on the EPS-AC0 needs an

Figure 4-6 Wiring Diagram

Figure 5-1 Control Head

Figure 5-2 Steering Arm

6-1.1. Brake Assembly Replacement 6. Reconnect electric brake to driving harness .

Figure 6-1 Brake Assembly

Figure 7-2 Load Wheel

8-2. LIFT CHAIN LENGTH ADJUSTMENT

1. Fully lower the lift carriage.