HELI G3 Series, Operation & Service Manual

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Page 2: ...g the lithium battery forklift truck strictly abide by the provisions and precautions in the manual and carefully use it so that your forklift truck will be in the best working condition for a long time and exert its maximum efficiency This product is not suitable for cold storage dusty electrify dust high temperature high corrosion environment For a small amount of dust non conductive environment...

Page 3: ...on Principle Adjustment and Maintenance of Forklift Trucks 4 1 Transmission system 4 2 Brake system 10 3 Steering system 14 4 Electric system 24 5 Hydraulic system 92 6 Lifting system 95 III Lithium battery changing 101 1 General description 101 2 Truck selection for lithium battery changing 101 3 Steps to change the lithium battery 102 4 Steps to install the lithium battery 104 ...

Page 4: ...1 I Main specifications of forklift trucks 1 External view of the truck P1 R G F C D ...

Page 5: ...0 8 Front overhang 560 560 560 9 Max lifting height 3000 3000 3000 10 Min steering radius 2580 2580 2580 11 Max lowering speed Unladen mm s 450 450 450 Laden 500 500 500 12 Max lifting speed Unladen 450 450 450 Laden 310 280 260 13 Max travelling speed Unladen km h 14 Laden 13 14 Max gradeability laden 16 15 14 15 Max drawbar pull laden kN 21 21 21 16 Mast tilting angle front rear 6 8 6 8 6 8 17 F...

Page 6: ...it Model CPD40 CPD45 CPD50 1 Overhead guard Max dimension mm 1625 1274 1511 Weight kg 132 3 2 Mast M300 Max dimension mm 540 1334 2250 Weight kg 1015 3 Drive axle Max dimension mm φ350 1326 Weight kg 240 4 Balance weight Max dimension mm 1330x750x910 1330x750x910 1330x750x910 Weight kg 2215 2280 2550 ...

Page 7: ... motor adopts IP54 protection grade design and almost completely closed design with stronger applicability in working conditions which can be applied to harsh working conditions such as large dust and oil pollution The whole bridge adopts multi chip wet friction brake which is located in a sealed cavity to effectively avoid external pollution greatly extending the service life of the brake and red...

Page 8: ...sembly Lift and erect the integrated bridge assembly remove the connection bolts of the reduction box assembly specification 14 M12 1 25 When installed the bolt torque is 124 165N m Remove the reduction box assembly and the primary planetary reduction assembly ...

Page 9: ...e retainer ring secondary reduction assembly gear ring cylindrical pin and gear ring from the other side in turn and the disassembly complete The removal of the left reduction box assembly shall be consistent with this 1 2 2 Disassembly of wet friction plate After removing the right reduction box assembly remove the short axle press plate ...

Page 10: ... small cylinder pin baffle spline compression spring etc in turn 1 2 3 Disassembly of piston assembly Remove the piston bolt bolt head specification M17 remove the compression spring then remove the piston Torque for piston bolt installation is 22 30N m ...

Page 11: ...sen the bolt remove the flange and brake fork 1 3 Announcements in daily maintenance 1 Replace the brake pull lock or adjust the brake structure When the hand brake pull lock is released completely the wheel is suspended and the wheel hub of the disk rotating drive axle can make it rotate freely If it is found that the ...

Page 12: ...he working environment are large dust and oil on the motor surface need to be cleaned regularly to ensure the normal heat dissipation of the motor 3 Brake maintenance Wet braking is a completely closed structure which is maintenance free and has a design life of 6000h When the braking failure occurs relevant investigations should be conducted to further ensure the cause 4 Vulnerable parts of Integ...

Page 13: ...ng mode is adopted for driving brake and the power source for brake is hydraulic gear pump The service brake system is mainly composed of brake pedal brake pump brake valve and oil cooled disc brake The driving brake schematic diagram is shown in Fig 2 1 Figure 2 1principle diagram of service brake Figure 2 2 Brake pedal ...

Page 14: ...inciple of brake valve is introduced in hydraulic system Figure 2 3 Shape of the brake valve and the position of each interface 2 1 3 Connection between brake system and drive axle There are two connections between the brake system and the driving axle one is the connection between the brake oil outlet of the vehicle and the other is the connection of the parking brake cable 1 The connection of se...

Page 15: ... rod Note The bending radius of brake cables shall be as large as possible Figure 2 5 2 1 4 Gas exhausting of brake system When the braking system is installed the air mixed in the braking system must be discharged to achieve a good braking effect The specific steps are as follows 1 As shown in Figure 2 4 open the gas exhaust plug part 2 of brake from the discharge valve to the appropriate positio...

Page 16: ... driving unit by the brake cable The parking brake can be realized through pulling down the parking brake handle by hand 2 2 Maintenance and adjusting of brake system This section mainly describes the inspection and maintenance of the brake system and the adjustment method of the brake pedal 2 2 1 Inspection and maintenance of brake system 1 Inspection of parking braking performance Daily inspecti...

Page 17: ...ch to make the clearance A 1mm 4 Make sure that the brake lamp should be on when the brake pedal is down 3 Steering system 3 1 General description The steering control mechanism of G3 series 4 5t forklift trucks is mainly composed of steering wheel pipe column coupling shaft steering unit and installation bracket as shown in Figure 3 1 They are fixed on the panel of instrument bracket by installat...

Page 18: ...ing the driving of forklift truck the driver should hold the steering wheel with both hands In order to facilitate the rapid steering of the driver there is a handle ball on the steering wheel of the forklift truck The driver can turn the steering wheel quickly by holding the handle ball in one hand The driver can also grasp the handle ball in one hand and control the multi way valve in one hand t...

Page 19: ...integrates an oil gauge a breather and a return oil filter Figure 3 2 Oil can for steering 3 1 3 Duplex pump The steering pump and brake pump are combined to form a duplex pump which is driven by a single motor The duplex pump sucks oil from the crude oil pipe and the front pump supplies the steering gear The pressure oil from the back pump enters the driving axle through the brake valve to meet t...

Page 20: ...pump fails to work properly due to faults the driver needs to turn the steering wheel directly with force to achieve steering which is also called manpower steering The steering unit on the truck adopts priority distribution technology When there is steering operation the hydraulic system first meets the needs of the steering system When there is no steering or only minor steering action the remai...

Page 21: ...g axle Fig 3 5 consists of steering axle body steering cylinder connecting rod steering knuckle assembly steering hub and steering wheel The steering axle drives the connecting rod motion by moving of steering cylinder s piston rod The motion of the connecting rod drives the steering knuckle assembly to rotate around the main pin connected to the steering axle thus realizing the steering The steer...

Page 22: ...self lubricating as the axle sleeves The connection between the main pin and the steering knuckle assembly is achieved by tightening the screw and the main pin and the steering knuckle assembly are relatively fixed Note There is no need to add grease oil to the sleeves and thrust gaskets as they are self lubricating bearings ...

Page 23: ...34 bearing 31311 15 retainer ring 16 35 bearing 31309 16 locating pin 36 nut M40x1 5 17 washer 20 37 washer 40 18 bolt M20x1 5x40 19 bolt M16x1 5x65 20 washer 16 Figure 3 5 Steering axle 3 1 6 Steering cylinder Steering cylinder is a double acting piston cylinder fig 3 4 Both ends of piston rod are connected with steering knuckle assembly through connecting rod The output pressure oil of full hydr...

Page 24: ... its connection on the steering axle see Fig 3 7 The axial clearance of the two bearings connected with the hub can be adjusted by a round nut for the axial fixing of the bearing The main pin and the steering knuckle assembly can be joined by tightening screws and rotate together with the steering knuckle assembly Axial clearance of hub bearing in steering knuckle assembly has been adjusted before...

Page 25: ...ing 1 As shown in Fig 3 8 grease should be added to the inner cavity of hub hub bearing and hub cover and some grease should also be applied to the lip of oil seal 2 Install the outer ring of hub bearing on the hub and install the hub on the steering knuckle assembly 3 Add shims and tighten the first round nut The tightening torque is 206 235N m about 21 24kg m loosen the round nut and then tighte...

Page 26: ...t a and tighten the round nut to align the groove with the stop gasket 7 Press the stop gasket into the slots of the first round nut and the second round nut respectively Figure 3 8 pre tightening adjusting of bearing 3 2 2 Inspect after reassembling the steering system 1 Turning the steering wheel right and left inspect whether the force applied is proper and the steering power is smooth 2 Check ...

Page 27: ...al or brake pedal is pressed the steering system is in working state When eliminating the gas in the steering pipeline the steering system should be in working state turning the steering wheel slowly to the left and right limit positions so that the steering wheel can be deflected to the left and right limit positions Note If abnormal phenomena occur at this time the power should be switched off i...

Page 28: ...he right to continuous improvement of the product If there is any discrepancy between the physical object and the instructions please consult the manufacturer The principle diagram of the electrical system is shown in Fig 4 1 and Fig 4 2 ...

Page 29: ...26 Figure 4 1 Principle diagram of electric system CPD40 50 GB3Li ...

Page 30: ...27 Figure 4 2 Principle diagram of electric system CPD40 50 GB2Li ...

Page 31: ...ng state of the vehicle and has diagnostic function 2 Instruments can read or modify the settings of all control modules connected to CAN bus network Its node definition is shown in the following table Figures in CAN bus Module 08 Traction controller 07 Pump controller 05 Steering controller 16 Instrument 3 The instrument is suitable for CPD40 50 GB3Li 4 2 1 2 Panel layout Fig 4 3 Introduction of ...

Page 32: ... Functions and applications 1 Hour meter The number shows the cumulative working time of the current truck The key switch is connected to the power supply After the truck starts to work the working timer starts to count 2 Direction indication Indicates whether the current truck is in forward or backward gear 3 Indicator of electric quantity ...

Page 33: ... the turtle speed light is on When the direction switch is in the middle position the neutral light is on When the battery electric quantity is less than or equal to 20 the low power indicator turns on When the power is less than or equal to 10 the lifting lock indicator turns on When the driver leaves the seat the seat indicator turns on When the parking brake switch closes the parking brake indi...

Page 34: ... Pump main CPU5 0 Pump main CPU5 1 Pump controller Independent steering CPU13 0 Independent steering CPU13 1 Steering controller Instrument 16 0 Instrument 16 1 Instrument 3 The instrument is suitable for CPD40 50 GB2Li truck models 4 2 2 2 Panel layout Fig 4 6 Instrument panel introduction 4 2 2 3 Display interface Fig 4 7 Instrument interface display information introduction ...

Page 35: ...indication Represents the direction of the steering wheel 5 Travelling speed Display the current vehicle driving speed with unit km h 6 Fault code display Display vehicle current fault code 7 LED indicator light When the battery power is less than or equal to 20 the low power indicator is on Fault warning light when there is a fault this LED light will always flash Controller high temperature warn...

Page 36: ...oprocessor based on motor speed feedback The allowable working ambient temperature range is 40º C 50º C and the maximum allowable working temperature is 85º C Protection functions of AC motor controller a Battery polarity protection b Incorrect connection protection c Over heat protection overload protection short circuit protection d Mis starting protection e Out of control protection f Battery o...

Page 37: ...ller Inmotion ACS80L 440C 35P 80V 440A Model of steering controller Inmotion ACS80S 220C 35P 80V 220A 4 3 3 ZAPI Control system composition Figure 4 10 Assembly of control device CPD40 50 GB2Li Model of traction controller ZAPI ACE3 80V 550A Model of pump controller ZAPI ACE3 80V 450A Model of steering controller ZAPI ACE0 80V 200A 2uc Note ...

Page 38: ... the after sale service Do not repair as will unless getting the permission from the producer Or the user should bear the personal and property damage caused by the unauthorized repair by oneself 4 4 Motor Motor type three phase AC type induction motor free from maintenance Table 4 1 Motor specification Traction motor Pump motor Steering motor Model JXQ 20 TSA200 200 242 JXQ 2 5 HL Power 20KW 26 5...

Page 39: ...ium battery at around 5 50 during use It is forbidden to store it under 25 or above 55 and operate for a long time 6 If there is leakage flatulence exposed wiring battery scratches edge and corner deformation should stop using 4 5 4 Lithium battery storage and keep 1 In the use of lithium battery the voltage is not allowed to be less than 85 of the rated voltage and over discharge is strictly proh...

Page 40: ...three months 4 Check the mechanical movement of the pedal or handle See if the spring can deform normally and if the potentiometer spring can expand to the maximum or setting level Check once every three months 5 Check the mechanical movement of the contactor It should move freely and not stick and the mechanical action of the contactor should be checked every three months If any damage or safety ...

Page 41: ...heck when working the circuit of the watch dog the driving of the connector the current sensor can bus connector 4 Continuously check inverter temperature motor temperature The information is transmitted through CAN bus and the fault code and module node are displayed on the color screen instrument meter 4 6 2 Fault diagnosis of INMOTION Table 4 3 Troubleshooting Fault code Description Remedy 20 A...

Page 42: ... 1 Make the temperature of driver to be lower than 85 2 Change the controller 83 ACS temperature sensor error Change the driver 84 Motor temperature low 1 The temperature of traction motor is over low 2 Check the motor temperature sensor and connection 85 Motor temperature high 1 The temperature of traction motor is over high 2 Check the motor temperature sensor and connection 86 Motor temperature...

Page 43: ...s 2 Fault of temperature sensor 121 ACS low temperature Over low temperature of controller 122 ACS high temperature Over high temperature of controller 123 ACS temperature sensor error Fault of controller s temperature sensor 124 Motor temperature low 1 Over low temperature of pump motor 2 Fault of motor temperature sensor or harness 125 Motor temperature high 1 Over low temperature of pump motor ...

Page 44: ...er high temperature of steering motor 2 Fault of motor temperature sensor or harness 205 Charging error 1 Change pre charging resistance 2 Low battery voltage 3 Fault of harness 206 DC bus low 1 Check battery voltage 2 Check battery parameters 3 Check if the contactor is connected 207 DC bus high HW detected 1 Check battery voltage 2 Check battery parameters 210 Feedback Sensor error Fault of moto...

Page 45: ...cation harness of lithium battery 161 Instrument CAN communication failure Check CAN communication wiring harness and data between instrument and controller 251 Authentication failed Use the correct authentication information 252 Primary lock Unlock primary lock 253 Secondary lock Unlock secondary lock 254 Remote terminal communication is down Check the CAN communication line between the control s...

Page 46: ...ng motor acceleration or when there is a hydraulic related request check the battery charge the battery health and power cable connections 28 PUMP VMN LOW Cause The pump motor output is lower than expected considering the PWM duty cycle applied Troubleshooting A If the problem occurs at start up the LC does not close at all check Motor internal connections Motor power cables connections If the mot...

Page 47: ...e phase voltages decrease down to B If the phase voltages are higher than a certain percentage of the nominal battery voltage this alarm occurs Cause 2 This alarm may also occur when the start up diagnosis has succeeded and so the LC has been closed In this condition the phase voltages are expected to be lower than half the battery voltage If one of them is higher than that value this alarm occurs...

Page 48: ...urrent feedback circuit is damaged Replace the controller 60 CAPACIT OR CHARGE Cause When the key is switched on the inverter tries to charge the power capacitors through the series of a PTC and a power resistance checking if the capacitors are charged within a certain timeout If the capacitor voltage results less than 20 of the nominal battery voltage the alarm is raised and the main contactor is...

Page 49: ...r 66 BATTER Y LOW Cause The battery charge is evaluated to be lower than 10 10 with lithium battery 15 with lead acid battery of the full charge and the BATTERY CHECK setting is other than 0 refer to SET OPTION menu Troubleshooting Check the battery charge and charge it if necessary If the battery is actually charged measure the battery voltage through a voltmeter and compare it with the value in ...

Page 50: ...time Check the FW and BW input states through the TESTER function Check the wirings relative to the FW and BW inputs Check if there are failures in the microswitches If the problem is not solved replace the logic board 82 ENCODE R ERROR Cause This fault occurs in the following conditions the frequency supplied to the motor is higher than 40 Hz and the signal feedback from the encoder has a jump hi...

Page 51: ...p current also will be reduced to 50 of maximum current tilt and steering function can work as normal Troubleshooting Check the lithium battery ask for help to the lithium battery manufacturer 135 BMS6 Cause Lithium battery alarm Battery stop temperature battery temperature is high when this alarm appears the truck should stop to work inhibit traction and lifting and tilt only steering function ca...

Page 52: ...mal Troubleshooting Check the lithium battery recycle the key switch or ask for help to the lithium battery manufacturer 143 2F0 INIT ERR Cause Lithium battery alarm when key switch is closed traction inverter will try to receive the 2F0 message from the lithium battery if inverter can t receive this message within 1500ms this alarm will appears and truck should stop work inhibit traction and lift...

Page 53: ...CODE R PHASES Cause Encoder phases signals not consistent Troubleshooting Try to recycle the key or change the encoder 151 POT MISMAT CH Cause Twin potentiometer signals not consistent only with twin potentiometer Troubleshooting check the signals of the twin potentiometer 153 OFFSET SPD SENS Cause It is necessary to acquire the offset angle between the stator and the speed sensor i e they mutual ...

Page 54: ... phases are correctly connected Verify that motor phases are not shot circuited Replace the controller In case the problem is not solved replace the motor 167 IMS ERROR Cause At start up the controller checks the presence of IMS board If the IMS board is not well connected this alarm appears Troubleshooting Replace the controller 168 SIN COS D ERR X X Cause This alarm occurs only when the controll...

Page 55: ...n and if it works properly Also the electromagnetic noise on the sensor can be a cause for the alarm If no problem is found on the motor or on the speed sensor the problem is inside the controller it is necessary to replace the logic board 176 HOME SNES ERR XX Cause The controller detected a difference between the estimated absolute orientation of the rotor and the position of the index signal ABI...

Page 56: ...ty of the potentiometer If the problem is not solved replace the logic board 180 OVERLO AD Cause The motor current has overcome the limit fixed by hardware Troubleshooting Reset the alarm by switching key off and on again If the alarm condition occurs again ask for assistance to a Zapi technician The fault condition could be affected by wrong adjustments of motor parameters 181 WRONG ENC SET Cause...

Page 57: ... switch inputs Check if there is short circuit between A6 and A1 In case no failures problems have been found the problem is in the controller which has to be replaced 186 WAIT MOT P STILL Cause If DC Pump option is set to ON the software expects the voltage on P output to be at a steady state value before switching the LC on If the voltage is different it could be due to the fact that the motor c...

Page 58: ... 30 seconds before showing this alarm During this time it shows the WAIT MOTOR STILL warning Motor internal connections Motor power cables connections Motor leakage to truck frame If the motor connections are ok the problem is inside the controller it is necessary to replace the logic board 191 PUMP I NO ZERO Cause In standby condition pump motor not driven the feedback coming from the current sen...

Page 59: ...LLER input 2 PEB comes from PAUX PAUX must be connected to terminal B of the controller This is the default configuration for 36 48V and 80V version This alarm can only appear if POSITIVE E B is set as 1 TILLER SEAT Troubleshooting Verify that the parameter POSITIVE E B is set in accordance with the actual coil positive supply see paragraph 8 2 5 In case no failures problems have been found the pr...

Page 60: ...is constantly out of range above the maximum allowed value Troubleshooting Check that the battery has the same nominal voltage of the inverter Check the battery voltage if it is out of range replace the battery In case the problem is not solved replace the logic board 201 TORQUE PROFILE Cause There is an error in the choice of the torque profile parameters Troubleshooting Check in the HARDWARE SET...

Page 61: ... to be in a steady state value If it is too high this alarm occurs Troubleshooting Check the motor power cables Check the impedance between U V and W terminals and Batt terminal of the controller Check the motor leakage to truck frame If the motor connections are OK and there are no external low impedance paths the problem is inside the controller Replace it 207 INIT VMN LOW Cause Before switching...

Page 62: ...ogic board 211 STALL ROTOR Cause The traction rotor is stuck or the encoder signal is not correctly received by the controller Troubleshooting Check the encoder condition Check the wiring Through the TESTER function check if the sign of FREQUENCY and ENCODER are the same and if they are different from zero during a traction request If the problem is not solved replace the logic board 212 POWER MIS...

Page 63: ...OK Cause The PEV connector B1 only for ACE3 Premium version is not connected to the battery or the voltage is different from expected This alarm occurs if one output among EVP EV1 EV2 EV3 EV4 and EV5 is present or the AUX OUT function is active POSITIVE EB 1 or 2 Troubleshooting Check connector B1 it must be connected to the battery voltage after the main contactor 218 SENS MOT TEMP KO Cause The o...

Page 64: ...that the seat inputs are in accordance with the actual state of the external switch In case no failures problems have been found the problem is in the controller which has to be replaced 223 COIL SHOR MC Cause This alarm occurs when an overload of the MC driver occurs Troubleshooting Check the connections between the controller outputs and the loads Collect information about characteristics of the...

Page 65: ...input state through the TESTER function Check the wirings Check if there are failures in the microswitches If the problem is not solved replace the logic board 229 HW FAULT EB Cause At start up the hardware circuit dedicated to enable and disable the EB driver is found to be faulty The hexadecimal value XX facilitates Zapi technicians debugging the problem Troubleshooting This type of fault is not...

Page 66: ...r to do the adjustment procedure of the current gain parameters 237 ANALOG INPUT Cause This alarm occurs when the A D conversion of the analog inputs returns frozen values on all the converted signals for more than 400 ms The goal of this diagnosis is to detect a failure in the A D converter or a problem in the code flow that skips the refresh of the analog signal conversion Troubleshooting If the...

Page 67: ...1 output and the positive terminal PCOM Troubleshooting Check the EB coil Check the wiring If the problem is not solved replace the logic board 243 THROTT LE PROG Cause A wrong profile has been set in the throttle profile Troubleshooting Set properly the throttle related parameters 244 WARNIN G SLAVE Cause Warning on supervisor uC Troubleshooting Connect the Console to the supervisor uC and check ...

Page 68: ...it is within a range of 20 around the nominal value Troubleshooting Check that the SET BATTERY parameter inside the ADJUSTMENT list matches with the battery nominal voltage Through the TESTER function check that the KEY VOLTAGE reading shows the same value as the key voltage measured with a voltmeter on pin A1 If it does not match then modify the ADJUST BATTERY parameter according to the value rea...

Page 69: ...r detects an undervoltage condition at the key input Undervoltage threshold is 11V for 36 48V controllers and 30 V for 80V controllers Fault can be caused by a key input signal characterized by pulses below the undervoltage threshold possibly due to external loads like DC DC converters starting up relays or contactors during switching periods solenoids energizing or de energizing Consider to remov...

Page 70: ...d for undervoltage detection uC discerns between the two evaluating the voltage present across DC link capacitors High voltage àOvervoltage condition Low normal voltage àUndervoltage condition Troubleshooting If the alarm happens during the brake release check the line contactor contact and the battery power cable connection 208 EEPROM KO Cause A HW or SW defect of the non volatile embedded memory...

Page 71: ...api technician If the problem is not solved replace the logic board 227 OUT MISMAT CH XX Cause This is a safety related test Supervisor μC has detected that master μC is driving traction motor in a wrong way not corresponding to the operator request Troubleshooting Checks the matching of the parameters between Master and Supervisor Ask for assistance to a Zapi technician If the problem is not solv...

Page 72: ...is driving DC motor in a wrong way not correspondent to the status of operator commands Troubleshooting Checks the correspondence of the parameters between Master and Supervisor Ask the assistance of a Zapi technician If the problem is not solved it is necessary to replace the logic board 241 SP MISMAT CH PUMP Cause This is a safety related test The Master μC has detected a Supervisor μC wrong set...

Page 73: ...the key input A1 Undervoltage threshold is 11V for 36 48V controllers and 30 V for 80V controllers Fault can be caused by a key input signal characterized by pulses below the undervoltage threshold possibly due to external loads like DC DC converters starting up relays or contactors during switching periods solenoids energizing or de energizing Consider to remove such loads If no voltage transient...

Page 74: ...ted to be lower than half the battery voltage If one of them is higher than that value this alarm occurs Troubleshooting If the problem occurs at start up the LC does not close check o motor internal connections ohmic continuity o motor power cables connections o if the motor connections are OK the problem is inside the controller Replace it If the alarm occurs while the motor is running check o m...

Page 75: ...rging resistance or PTC may be broken Insert a power resistance across line contactor power terminals if the alarm disappears it means that the charging resistance is damaged The charging circuit has a failure or there is a problem in the power section Replace the controller 62 TH PROTECTION Cause The temperature of the controller base plate is above 85 C The maximum current is proportionally decr...

Page 76: ...R SHORTED Cause The driver of the LC coil is shorted Troubleshooting Check if there is a short or a low impedance pull down between NLC and BATT The driver circuit is damaged replace the logic board 75 CONTACTOR DRIVER Cause The LC coil driver is not able to drive the load The device itself or its driver circuit is damaged Troubleshooting This type of fault is not related to external components re...

Page 77: ... This condition is related to an encoder failure Troubleshooting Check the electrical and the mechanical functionality of the encoder and the wires crimping Check the mechanical installation of the encoder if the encoder slips inside its housing it will raise this alarm Also the electromagnetic noise on the sensor can be the cause for the alarm In these cases try to replace the encoder If the prob...

Page 78: ...nd ask for assistance to a Zapi technician in order to verify that the maximum current that can be supplied by the hardware is not exceeded In case no failures problems have been found the problem is in the controller which has to be replaced 178 MOTOR TEMP STOP Cause The temperature sensor has overtaken the STOP MOTOR TEMP threshold if analog Troubleshooting Check the temperature read by the ther...

Page 79: ... wrong connections in the external wiring Using the TESTER function verify that inputs are in accordance with the actual state of the external switches Check if there is a short circuit between A11 and A6 In case no failures problems have been found the problem is in the controller which has to be replaced 186 WAIT MOT P STILL Cause If DC Pump option is set to ON the software expects the voltage o...

Page 80: ...er 190 PUMP VMN NOT OK Cause Before switching the LC on the software checks the output voltage on P connector and expects it to be at a steady state value if DC PUMP options is set to ON If the voltage is too low this alarm occurs Troubleshooting Please check The motor connected to P must be completely still before this alarm occurs The software waits 30 seconds before showing this alarm During th...

Page 81: ...iver is not installed 36 48V and 80V it is possible to decide where the positive supply for pin A2 is taken from by dedicated hardware configuration pin A3 PAUX pin A1 TILLER externally from other module i e EPS The parameter Positive EB has to be set in accordance with hardware configuration Troubleshooting Verify that the parameters Positive EB is set in accordance with the actual coil positive ...

Page 82: ... is transferring parameters to the supervisor Troubleshooting Wait until the end of the procedure If the alarm remains longer re cycle the key 200 VDC OFF SHORTED Cause The logic board measures a key voltage value that is constantly out of range above the maximum allowed value Troubleshooting Check that the battery has the same nominal voltage of the inverter Check the battery voltage if it is out...

Page 83: ...otentiometer If the alarm is still present replace the logic board 205 EPS RELAY OPEN Cause The controller receives from EPS information about the safety contacts being open Troubleshooting Verify the EPS functionality 206 INIT VMN HIGH Cause Before switching the LC on the software checks the power bridge voltage without driving it The software expects the voltage to be in a steady state value If ...

Page 84: ...een made before the last key re cycle this warning informs you that EEPROM was correctly cleared Troubleshooting A travel demand or a pump request cancels the alarm If the alarm appears at key on without any CLEAR EEPROM performed replace the controller 210 WRONG RAM MEM Cause The algorithm implemented to check the main RAM registers finds wrong contents the register is dirty This alarm inhibits t...

Page 85: ...RT Cause The EVP driver is shorted The microcontroller detects a mismatch between the valve set point and the feedback of the EVP output Troubleshooting Check if there is a short circuit or a low impedance conduction path between the negative of the coil and BATT Collect information about the voltage applied across the EVP coil the current in the coil features of the coil Ask for assistance to Zap...

Page 86: ... constantly out of range below the minimum allowed value Troubleshooting Check that the battery has the same nominal voltage of the inverter Check the battery voltage if it is out of range replace the battery In case the problem is not solved replace the logic board 221 HANDBRAKE Cause Handbrake input is active Troubleshooting Check that handbrake is not active by mistake Check the SR HB input sta...

Page 87: ...the functionality of the potentiometer If the problem is not solved it is necessary to replace the logic board 227 HW FAULT Cause1 At each start up the supervisor microcontroller checks that the hardware circuit for enabling and disabling of the power bridge works properly Cause2 At each start up the supervisor microcontroller checks that the hardware circuit intended to enable and disable the LC ...

Page 88: ...eaning of code XX refer to paragraph 0 Troubleshooting Check if there is a short circuit or a low impedance path between the negative terminals of the involved coils and B If the problem is not solved replace the logic board 235 CTRAP THRESHOLD Cause This alarm occurs when a mismatch is detected between the setpoint for the overcurrent detection circuit dependent on parameter DUTY PWM CTRAP and th...

Page 89: ...rrect 240 EVP DRIVER OPEN Cause The EVP driver is not able to drive the EVP coil The device itself or its driving circuit is damaged Troubleshooting This fault is not related to external components Replace the logic board 241 COIL SHOR EVAUX Cause This alarm occurs when there is an overload of one or more EV driver As soon as the overload condition has been removed the alarm disappears by releasin...

Page 90: ...n master and supervisor microcontrollers Troubleshooting This alarm could be caused by a CAN bus malfunctioning which blinds master supervisor communication 249 CHECK UP NEEDED Cause This is a warning to point out that it is time for the programmed maintenance Troubleshooting Turn on the CHECK UP DONE option after that the maintenance service 250 THERMIC SENS KO Cause The output of the controller ...

Page 91: ...ATT Check if the voltage applied is in accordance with the parameters set If the problem is not solved replace the controller Table 4 7 Fault list of steering pump auxiliary CPU CODE ALARM NAME ACE0 independent steering pump slave alarms node 13 1 8 WATCHDOG Cause This is a safety related test It is a self diagnosis test that involves the logic between master and supervisor microcontrollers Troubl...

Page 92: ...ooting If the alarm happens during the brake release check the line contactor contact and the battery power cable connection 208 EEPROM KO Cause A HW or SW defect of the non volatile embedded memory storing the controller parameters This alarm does not inhibit the machine operations but it makes the truck to work with the default values Troubleshooting Execute a CLEAR EEPROM procedure refer to the...

Page 93: ...not corresponding to the operator request Troubleshooting Checks the matching of the parameters between Master and Supervisor Ask for assistance to a Zapi technician If the problem is not solved replace the logic board 229 NO CAN WR MSG XX Cause CANbus communication does not work properly The hexadecimal value XX identifies the faulty node Troubleshooting Verify the CANbus network external issue R...

Page 94: ...dence of the parameters between Master and Supervisor Ask the assistance of a Zapi technician If the problem is not solved it is necessary to replace the logic board 241 SP MISMATCH PUMP Cause This is a safety related test The Master μC has detected a Supervisor μC wrong set point for DC Pump motor Troubleshooting Checks the correspondence of the parameters between Master and Supervisor Ask the as...

Page 95: ...l is distributed to working cylinder by multi way valve through gear oil pump The schematic diagram of the hydraulic system is shown in the following figure Figure 5 1 Principle diagram of hydraulic system 5 1 Main pump The main pump is a gear pump with low noise It is driven by motor The hydraulic oil from the main pump driven by motor enters the multi way valve and is distributed to each working...

Page 96: ...uences of load movement caused by misoperation of the valve stem in the case of no pressure source Each valve is equipped with shuttle valves whose function is to feed back the sampled instantaneous load signals to the pressure compensator Pressure compensator continuously regulates the flow through the valve core and maintains a constant pressure difference between the pump and the working oil po...

Page 97: ... Oil inlet piece of multi way control valve Figure 5 4 Lifting and lowering piece of multi way control valve Figure 5 5 Tilting piece of multi way control valve Figure 5 6 Auxiliary piece of multi way control valve ...

Page 98: ...n of inner mast Cross section of outer mast Max lifting height standard mast 3000mm Height mast lowered L standard mast 2230mm Tilting angle front rear 6 8 Roller Outer diameter of main roller Φ128 Outer diameter of side roller Φ58 Outer diameter of combined roller fork carrier Φ128 Lifting chain HRLH1644011 N pitch 25 4 Lifting mode of fork Hydraulic type Tilting mode of mast Hydraulic type Adjus...

Page 99: ...n It consists of the inner mast the outer mast two rear lifting cylinder fork carrier backrest and fork 6 2 Inner and outer mast The inner and outer portal frames are welded parts and the whole mast is mounted on the frame by supporting axle The middle part of the outer mast is connected with the frame ...

Page 100: ... The side rollers rolling along the inner side of the inner mast are fixed by bolts and adjusted through shim The longitudinal load is borne by the main roller When the fork rises to the maximum lifting height the main roller mounted on the top of the mast is exposed At this time the combined roller bears both lateral load and longitudinal load Rigidity and strength as well as smooth operation sha...

Page 101: ...inders are synchronization The thickness of shim is 0 2mm and 0 5mm 3 Slowly lower the inner mast and observe whether the two cylinder travel terminals are synchronized referring to the adjustment method of rising synchronization 4 Adjust the tension of the chain Take care when adjusting the lifting cylinder 6 4 2 Adjustment of fork carrier s height 1 Park the truck on a level ground and ensure th...

Page 102: ... top of the chains And take out chains from chain wheel 4 Make the inner mast rise 5 The forklift can be reversed when the fork carrier disengaged from the outer mast 6 Replacing main rollers a Take apart all of snap ring from the fork carrier and take out main rollers Take care to keep the shims inside of combined roller b Fit the new main roller the same type as the old one on the fork carrier a...

Page 103: ...nipple 6 Lay down the inner mast and remove the main roller at the bottom of the inner mast 7 When the main rollers on the upper outer mast will come out from the inner mast top end then the main roller can be removed 8 Replacing main rollers a Take apart the upper main rollers without losing shims b Fit the new main roller and shims together on the outer mast 9 Hang up the inner masts and let all...

Page 104: ...own in the following figure 2 Truck selection for lithium battery changing The following factors should be taken into account when selecting the truck for picking up lithium batteries 1 Limited by the lithium battery compartment when the fork picking up the lithium battery the maximum fork intake L9 is 785 mm As shown in the figure below the larger the fork intake is the better the fork intake is ...

Page 105: ... t electric forklift truck It is known that the fork length L4 of the 2 5 t electric forklift truck of Heli H3 series is 1070 mm The front overhang L2 of the truck is 465 mm the fork feed L9 is about 720 mm and the lithium battery weight Q1 of 80V 600Ah is 1185 kg Substitute the above data are into the formula to calculate The calculation results show that Q2 is 1620 kg and the rated lifting weigh...

Page 106: ...103 2 Disconnect the lithium battery connections 3 Loose and remove the lithium battery limit block 4 Pick up the lithium battery with forklift truck electric pallet truck or pallet stacker ...

Page 107: ...e reserve enough space for fork in and out 6 Use the crane to separate the lithium battery pack from the bottom counterweight 4 Steps to install the lithium battery Please install the lithium battery according to following steps 1 Install the lithium battery pack together with the auxiliary counterweight by crane ...

Page 108: ...pallet truck or forklift truck 3 Put down the lithium battery until the right side of lithium battery coincide with the inner side of lithium battery limit block 4 Put down lithium battery limit block and adjust the limit screw to the end face of the lithium battery box ...

Page 109: ...106 5 Connect the battery 6 Close the side door ...

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