Big Lift LLC

Service Manual
LPE80 / LPE100
Electric Forklift Truck
Big Joe Forklifts MANUAL NO. BL-LPE80-100-0624 – 06-21-2024
www.bigjoesupport.com
 Big Joe Forklifts
(Big Lift LLC)
2777 Finley Rd., Suite 16
Downers Grove, IL 60515
(630)916-2600

For Parts and Technical Support

 FOREWORD
This Service Manual can help readers learn more about the truck system components,
maintenance, troubleshooting, and other related information. The operation and
maintenance personnel must read this manual carefully before using the product.

With the constant update and improvement of our products, the equipment you are using
may be slightly different from what has been described in this manual, therefore, we
must reserve the right to modify the appearance, configuration, and technical
specifications. If you have any questions, contact our sales department or dealer.

Safety Notices and Text Mark-Ups

Safety instructions and important explanations are indicated by the following graphics:

DANGER

Means that failure to comply can cause risk to life and/or major damage to property.

WARNING

Please strictly adhere to these safety instructions to avoid personal injury or damage to
equipment or personal property.

CAUTION

Please pay attention to the important safety instructions.

NOTE
i Pay attention to information that could be helpful.
 WARNING
• Do not operate this truck unless authorized and trained to do so and have read all warnings and
instructions in this Operator’s Manual and on this truck. Read, understand, and comply with the
information on the truck’s nameplate at all times.

• Do not operate this truck until you have performed the Daily Operator Checklist. Report any
problems to the designated authority and do not use the truck until they are corrected by a qualified
technician.

• If there is a fault code on the BDI/display, recycle the key and see it the code displays again. If the code
displays again, do not operate the truck. Investigate the fault code and contact a service technician.

• This truck must not be modified without written manufacturer’s consent.

• Operate truck only from designated operating position. Use this truck indoors on level surfaces
only.

• Operate cautiously on ramps, slopes, and uneven floors. Travel slowly and do not angle or turn. This
truck is not for use on mezzanines or balcony areas.

• Before operating, inspect the floor area it will be used on and be certain it will support the truck at
full capacity and lift height. Identify and avoid holes, drop-offs, bumps, and obstructions.

• Keep hands, feet, and all body parts inside of the operator’s compartment. Never place any part of your
body into the mast structure or between the mast and the truck.

• Do not carry passengers.

• Before and during all truck operations ensure that adequate clearance is maintained from overhead
obstructions and energized electrical conductors and parts.

• Operate tilting mechanism slowly and smoothly. Do not tilt forward when elevated except when picking
up or depositing a load.

• Elevate forks only to pick up a load. Lift and lower with mast vertical or slightly tilted back, never forward.
Watch for obstructions overhead.

• Ensure loads are centered and do not contact any obstructions in the truck’s vicinity.

• Maintain a clear view of the ground while traveling and a safe distance from obstacles in the truck’s
path. Ensure personnel in the vicinity are aware of the truck’s movement. Travel at a safe speed for
the conditions the truck is operating in.

• Observe applicable traffic regulations. Yield right of way to pedestrians. Slow down and sound horn at
cross aisles and wherever vision is obstructed. Avoid hazardous locations.

• When leaving the truck unattended, remove the key to prevent unauthorized use.

• Start, stop, travel, steer, and brake smoothly. Slow down for turns and on uneven or slippery surfaces
that could cause the truck to slide or overturn. Use special care when traveling without a load as the
risk of overturn is greater.

• Travel with lifting mechanism as low as possible and tilted back. Always look in the direction of travel.
Keep a clear view. When the load interferes with visibility, travel with the load trailing.

• Do not handle loads that are taller than the load backrest unless secured to prevent falling.

• Do not expose truck or battery to water as there is no ingress protection.

 TABLE OF CONTENTS
INFORMATION & SPECIFICATIONS..................................................................................................................................................... 1
TRUCK COMPONENTS .................................................................................................................................................................................. 2
COMMON TOOLS ........................................................................................................................................................................................ 3
GENERAL TIGHTENING TORQUES.................................................................................................................................................................... 4
MAINTENANCE .................................................................................................................................................................................. 6
SERVICE PREPARATION ................................................................................................................................................................................ 7
WORKING CONDITIONS ............................................................................................................................................................................... 7
MAINTENANCE........................................................................................................................................................................................... 8
SERVICING AND INSPECTION ......................................................................................................................................................................... 8
LUBRICATION ........................................................................................................................................................................................... 13
DRIVING SYSTEM ............................................................................................................................................................................. 16
DRIVE WHEEL .......................................................................................................................................................................................... 17
DRIVE MOTOR ......................................................................................................................................................................................... 18
CHECKING AND TESTING U, V, W TERMINALS ................................................................................................................................................ 19
DRIVE AXLE ............................................................................................................................................................................................. 20
TRANSMISSION OIL.................................................................................................................................................................................. 21
ADD / REPLACE GEAR OIL .......................................................................................................................................................................... 21
ACCELERATOR PEDAL ................................................................................................................................................................................ 22
CHECKING AND TESTING ............................................................................................................................................................................. 23
STEERING SYSTEM ........................................................................................................................................................................... 24
REAR STEER WHEEL .................................................................................................................................................................................. 25
STEERING AXLE ........................................................................................................................................................................................ 26
STEERING CYLINDER .................................................................................................................................................................................. 28
BRAKE SYSTEM ................................................................................................................................................................................ 28
PARKING BRAKE ....................................................................................................................................................................................... 29
SERVICE BRAKE ASSEMBLY ......................................................................................................................................................................... 30
AIR DISCHARGE / ADDING BRAKE FLUID ........................................................................................................................................................ 30
HYDRAULIC SYSTEM ........................................................................................................................................................................ 31
HYDRAULIC SYSTEM OVERVIEW ................................................................................................................................................................... 32
HYDRAULIC OIL ........................................................................................................................................................................................ 32
HYDRAULIC SEALS ..................................................................................................................................................................................... 32
HYDRAULIC SCHEMATIC DIAGRAM ............................................................................................................................................................... 33
PUMP MOTOR & GEAR PUMP .................................................................................................................................................................... 34
CONTROL VALVE ...................................................................................................................................................................................... 35
HYDRAULIC CONTROL VALVE ...................................................................................................................................................................... 36
REDIRECTOR ............................................................................................................................................................................................ 37
TILT CYLINDER ......................................................................................................................................................................................... 38
CYLINDER MAINTENANCE ........................................................................................................................................................................... 41
HYDRAULIC SYMBOLS ................................................................................................................................................................................ 42
MAST ............................................................................................................................................................................................... 44
THREE-STAGE FULL FREE MAST ................................................................................................................................................................... 45
LIFTING CHAINS........................................................................................................................................................................................ 46
FORK CARRIAGE CHAINS............................................................................................................................................................................. 48
 MAST TUBING ......................................................................................................................................................................................... 50
LIFT CYLINDER.......................................................................................................................................................................................... 53
CYLINDER MAINTENANCE ........................................................................................................................................................................... 55
FULL FREE MIDDLE CYLINDER ..................................................................................................................................................................... 57
BUILT-IN SIDE SHIFTER............................................................................................................................................................................... 58
EXTERNAL SIDE SHIFTER ............................................................................................................................................................................. 59
ELECTRICAL COMPONENTS .............................................................................................................................................................. 60
CONTROLLER FUNCTIONS ........................................................................................................................................................................... 61
MAIN CONTACTOR ................................................................................................................................................................................... 61
COIL CHECKS ........................................................................................................................................................................................... 62
DC-DC CONVERTER.................................................................................................................................................................................. 63
CONTROLLER ERROR MESSAGE ................................................................................................................................................................... 65
TRACTION CONTROLLER.............................................................................................................................................................................. 65
ELECTRICAL SCHEMATIC DIAGRAMS............................................................................................................................................................ 100
CABLE WIRING DIAGRAMS ....................................................................................................................................................................... 102
WIRING HARNESS AND CONNECTORS ......................................................................................................................................................... 103
PREPARATION BEFORE TROUBLESHOOTING.................................................................................................................................................. 105
CHECK THE VOLTAGE OF BATTERY .............................................................................................................................................................. 105
TROUBLESHOOTING SOLUTIONS OF COMMON FAULTS ................................................................................................................................... 106
LITHIUM-ION BATTERY ................................................................................................................................................................... 115
TABLE OF CONTENTS .................................................................................................................................................................. CXVI
INTRODUCTION ........................................................................................................................................................................................... 1
GETTING STARTED ..................................................................................................................................................................................... 2
POTENTIAL HAZARDS .................................................................................................................................................................................. 4
PERFORMANCE DATA.................................................................................................................................................................................. 7
BATTERY INDICATOR ................................................................................................................................................................................... 8
TRANSPORTATION .................................................................................................................................................................................... 10
SERVICE ................................................................................................................................................................................................. 11
TROUBLESHOOTING & RECYCLING .............................................................................................................................................................. 13
APPENDIX A: DAILY SPOT CHECK RECORD ................................................................................................................................................... 16
APPENDIX B: BOX STRUCTURE ................................................................................................................................................................... 17
INFORMATION & SPECIFICATIONS

1
 Truck Components
13 14

12

11 15

16
10

17
9

18

2
3
4
7
6 5

Item Component Item Component

1 Drive wheel 10 Caution light
2 Safety step 11 Rear combination light
3 Battery hood 12 Overhead guard
4 Chassis 13 Steering wheel
5 Steer wheels 14 Rear mirror
6 Sling point 15 Mast
7 Towing pin 16 Headlight
8 Counterweight 17 Fork carriage
9 Driver's seat 18 Forks

2
Common Tools

Name Remark
Hex Head Sockets & Wrench 8mm~27mm One Set
Phillips Screwdriver One Piece
Flat Head Screwdriver One Piece
Volt/Ohm Meter One Set
Snap Ring Pliers One for internal and one for external
Hammer One Piece
Spreader, Crane One Pair
Cylinder Spanner Wrenches For removal and installation of cylinders
Pliers One Set including Diagonal Cutter
O-ring Picks One Set
Grease Gun One Piece
Combination Wrench One Set

3
General Tightening Torques
Screws or bolts used on the truck are of 8.8 grade
or higher performance level.
When you are conducting truck maintenance, you
can refer to Table 1.4.1 and Table 1.4.2 to select the
suitable screws or bolts for replacement.

Table 1.4.1 Screws/Bolts Performance Levels

Performance Level Material Specification (mm)

5.8 5.8 grade Low carbon steel M6 ~ M48

Quenched and tempered medium

8.8 8.8 grade M6 ~ M48
carbon steel

Quenched and tempered medium

10.9 10.9 grade M6 ~ M48
carbon alloy steel

Quenched and tempered medium

12.9 12.9 grade M6 ~ M48
carbon alloy steel

CAUTION
• Performance levels are marked on the heads of
the screws or bolts.
• Select spare parts with performance level of at
least 8.8 grade or higher level for replacement.

4
Table 1.4.2 Metric Screws/Bolts Tightening Torque Table (n•m)
Performance Level

Nominal Diameter 5.8 8.8 10.9 12.9

(mm) Proof Stress (MPa)
380 600 830 970
M6 7~8 10~12 14~17 17~20
M8 16~18 25~30 34~41 41~48
M8×1 17~20 27~32 37~43 43~52
M10 31~36 49~59 68~81 81~96
M10×1 35~41 55~66 76~90 90~106
M12 55~64 86~103 119~141 141~167
M12×1.5 57~67 90~108 124~147 147~174
M14 87~103 137~164 189~224 224~265
M14×1.5 144~170 149~179 206~243 243~289
M16 136~160 214~256 295~350 350~414
M16×1.5 144~170 228~273 314~372 372~441
M18 186~219 294~353 406~481 481~570
M18×1.5 210~247 331~397 457~541 541~641
M20 264~312 417~500 576~683 683~808
M20×1.5 294~345 463~555 640~758 758~897
M22 360~431 568~680 786~941 918~1099
M22×1.5 395~473 624~747 803~1034 1009~1208
M24 457~547 722~864 998~1195 1167~1397
M24×2 497~595 785~940 1086~1300 1269~1520
M27 669~801 1056~1264 1461~1749 1707~2044
M27×2 723~865 1141~1366 1578~1890 1845~2208
M30 908~1087 1437~1717 1984~2375 2318~2775
M30×2 1005~1203 1587~1900 2196~2629 2566~3072
M36 1587~1900 2506~3000 3466~4150 4051~4850
M36×3 1680~2011 2653~3176 3670~4394 4289~5135
M42 2538~3039 4088~4798 5544~6637 6479~7757
M42×3 2731~3269 4312~5162 5965~7141 6921~8345
M48 3813~4564 6020~7207 8327~9969 9732~11651
M48×3 4152~4970 6556~7848 9069~10857 10598~12688

5
MAINTENANCE

6
 Service Preparation
i NOTE
Regular maintenance and repair can help • Under harsh working conditions, for example, the external
ensure the continuous and reliable use of temperature is too high or too low, dusty, or is used during
the truck. multiple shifts per day, the maintenance and care
Only specially trained and qualified schedule should be shortened.
personnel are capable of maintenance and
• Clean all external parts prior to lubrication, replacement of
repair operations of the equipment. If you
filters or operating the hydraulic system. Use a clean
want to perform the maintenance and
catch container.
repair on your own, it is recommended that
on-site training be conducted for your • Only compliant lubricants must be used. See Lubricants.
maintenance personnel by an authorized
service representative.

Working Conditions

• The truck must be parked on level ground

reserved for maintenance (this area should be
clean and free of dust), block the wheels with
wooden wedges or chocks, disconnect the key
switch and the battery connections.
• Lifting tools must only be installed to fixed
positions as specified.
• When raising the truck, appropriate tools, such
as wedges, wooden blocks, or chocks, must be
used to secure the truck to prevent accidental
rolling or tipping over.

WARNING
When lifting load components, sufficiently strong
chains or safety devices must be used to secure
the truck.

CAUTION
Do not make modifications to trucks, especially to
the safety devices without written permission from
the manufacturer.

7
Maintenance
Cleaning

• Do not use liquids to clean the truck. Regular inspection and maintenance under
• Before cleaning, all necessary safety measures harsh conditions of use:
must be taken to prevent sparks (short circuit) • Dusty environment
during operation. If the truck is powered by battery,
disconnect it. • Corrosive environment

• When cleaning electrical and electronic • Cold storage environment.

components, use compressed dry air. Clean the Maintenance intervals should be shortened by
dust on the surface of components with half.
non-conductive, anti-static brush.
• Do not use a pressure washer to clean the truck.

Servicing and Inspection

Thorough and expert servicing is one of the most important requirements for the safe operation of the
truck. Failure to perform regular service may lead to truck failure and poses a potential hazard to
personnel and equipment.

The service intervals are based on single shift operation under normal operating conditions. They
must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature
fluctuations or multiple shifts.

The following maintenance checklist states the tasks and intervals when they should occur.

Maintenance intervals are defined as:

W = Every 50 service hours, at least once per week.

A = Every 250 operating hours, at least once each month and a half.

B = Every 500 operating hours, at least once per quarter.

C = Every 1000 operating hours, at least once half year.

D = Every 2000 operating hours, at least once per year.

In the run-in period (after approximately 100 service hours) or after repair work, the owner must check
the wheel nuts/bolts and retighten if necessary.

8
 Table 2.1 Inspection & Maintenance List
Interval in days/months/years 7d 60 d 90 d 6m 1y
Interval in hours 50 250 500 1000 2000
Functions and Control
Check the functions of the operation switches and
A
display
Check alarm system functions A
Check parking brake functions A
Check the emergency switch functions A
Check the steering wheel functions A
Check the cables for damage and if the terminals are
A
secure
Check the seat switch functions A
Check and tighten the controllers and contactors A
Check accelerator pedal functions A
Check fault information records and operating hours A
Power Supply & Drive System
Check the battery cables for damage and replace if
A
necessary
Check the battery charge connector A
Check if the cable connections between battery A
monomers are secure
Check battery temperature A
Check battery locking mechanism A
Check and tighten motor mounting bolts A
Check the connections of motor connectors A

A = Check/Adjust
Please refer to Inspection & Maintenance List for
regular inspection and maintenance of the vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.

9
Table 2.1 Inspection & Maintenance List (Continued)
Interval in days/months/years 7d 60 d 90 d 6m 1y
Interval in hours 50 250 500 1000 2000
Power Supply & Drive System
Check transmission oil level A
Clean or replace the gear oil Replace once every 1000 hours
Check the gearbox for abnormal noise or leaks A
Check the drive wheel and steering wheel for wear or
A
damage
Check and lubricate the wheel bearings A/L
Check the travel speed A
Hydraulic System
Check the hydraulic system functions A
Check if the hoses, pipes and interfaces are fastened
A
or sealed securely, and check if there is damage
Check the pump motor connectors A
Check and tighten pump motor mounting bolts A
Check the gear pump mount and check for leaks A
Check the cylinders for leaks A
Check the cylinders for damage and wear A
Check the oil tank mount and check for leaks A
Check the hydraulic oil level A
Replace the hydraulic oil Replace once every 2000 hours
Check and clean oil tank breather A
Replace the oil tank breather A
Check the relief pressure (2750 psi) A

A = Check/Adjust
Please refer to Inspection & Maintenance List for
regular inspection and maintenance of the vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.

10
 Table 2.1 Inspection & Maintenance List (Continued)
Interval in days/months/years 7d 60 d 90 d 6m 1y
Interval in hours 50 250 500 1000 2000
Braking System
Check the braking operation A
Check the brake fluid level A
Check the master cylinder and line connections for A
leaks
Check the release of brake pedal is normal A
Mast System
Check the mast for damage A
Clean and lubricate the rolling surface of lift mast
A/L
column with grease
Check and lubricate mast rollers A/L
Check the stability of lift mast A
Check the tubing on mast for connections and leaks A
Check the side shifter functions A
Check and lubricate the chains A/L
Check the lifting chains and chain guides for wear,
A
adjust and grease
Check the fork carriages for wear and damage A
Visual inspection of rollers, sliders and stoppers A
Check the lifting and lowering speed A
Other
Check if the decals are clear and complete A
Check the chassis for cracks or damages A
Check the connections of bolts and nuts A
Check the battery cover and lubricate the hinges A/L

A = Check/Adjust
Please refer to Inspection & Maintenance List for
regular inspection and maintenance of the vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.

11
Table 2.1 Inspection & Maintenance List (Continued)
Interval in days/months/years 7d 60 d 90 d 6m 1y
Interval in hours 50 250 500 1000 2000
Other
Check battery mounting and battery tray A
Check the seat mounting and adjustment functions A
Check the seat belt and functions A
Check the overhead guard and cabin A
Checking covers for damage A
Check if the optional features are functioning properly A

A = Check/Adjust
Please refer to Inspection & Maintenance List for
regular inspection and maintenance of the vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.

12
 Lubrication Please see Table 2.2 for the lubricants used in
this truck.
• Improper operation may be hazardous to the CAUTION
operator's health, life, and to the surrounding
environment. The use and disposal of lubricants must be
• When storing or adding lubricant, use clean carried out in strict accordance with the
containers. Do not mix different types and manufacturer's regulations.
specifications of lubricants with each other
(except for those that state they can be
mixed).

Hydraulic oil fill

Gear oil fill

Gear oil drain

Brake fluid reservoir

Fig3845-00008OM
Hydraulic oil drain

Table 2.2 Lubricants

Code Type Specification Amount Position

A Anti-wear hydraulic oil L-HM46 See Table 2.1 Hydraulic System

B Multi-purpose grease Polylub GA352P Appropriate amount Sliding surface

C Heavy duty gear oil 85W-90GL-5 6L (Align with oiling port) Drive Axle

When air within the system is

D Brake fluid DOT3 completely discharged, add to Brakes
2/3 of the oil cup

13
13
Table 2.1 Application Amount of Table 2.1 Application Amount of
Hydraulic Oil - 1 Hydraulic Oil - 2

Lifting height Lifting height

Amount Amount
Mast Series (mm) Mast Series (mm)
(L)

2300 44
3000 45
2430 44
3300 46
2610 45
3500 46
2710 45
3700 46
3000 46
3750 46
3300 46
4000 47
2-stage Mast 2-stage 3500 47
4250 47 Free Mast
3750 47
4500 48
4000 48
4750 48
4500 49
5000 49
5500 50 5000 50

6000 51 5500 51
6000 52
3920 48
4350 49
4500 49

3-stage 4700 50
Free Mast 4800 50
5000 51
5400 52
6000 53

14
Table 2.2 Sliding Surface
Lubrication Table
Code Position
L1 Steering axle
L2 Tilt cylinder connector
L3 Fork carriage
L4 Steel channel and rollers

L3 L4

L1 L2

Contact surface

15
DRIVING SYSTEM

16
 Drive Wheel • Remove the eight nuts (2) and remove the
drive wheel assembly (3).
Removal
• Turn off the truck power and remove the key. Installation
• Place the jack (1) under the chassis near the drive
wheels, secure rear tires with wheel chocks, and lift • Install in the reverse order of removal.
the drive wheels off the ground and add a block or
jack stand for added safety.

CAUTION
• Tighten the nuts by order shown and mark with
the torque: 324 –355 ft lbs., (440~480Nm).

1 Fig3850-20004SM

WARNING
Make sure the lifting equipment is solid and CAUTION
secure, and that the load capacity is greater than the After installation, check whether the tire inflation
total weight of the truck. Do not exceed a lifting reaches the specified value. After running for a
height of 4 inches to prevent the hazards to short distance, check whether the bolts are
maintenance personnel working under the truck secure.
during wheel removal and installation.

CAUTION
Replace the drive wheels when heavily worn.

The quality of tires directly affects the stability

and driving performance of the truck. If you
need to replace the factory-fitted tires, please
use original spare parts provided by the
equipment manufacturer.

Fig3218-00078OM

17
 Drive Motor
This truck obtains drive force through
AC motor.

Installation
Install in the reverse order of
Removal removal.

The drive motor (2) is mounted on the

gearbox (1).
• Power off the truck and remove the CAUTION
key. Ensure motor gear fully engages
• Remove the mat and open the with the gear inside the gearbox.
floorboard.
Rotate the gearbox. If there is no
• Remove U, V and W cables on blocking, secure it with five screws.
the drive motor.
• Disconnect the connection between
the drive motor and main wiring
cables.

CAUTION
Before the next step, secure the drive motor. Avoid
the falling of motor during removal, potentially
resulting in personal injury.

• Unscrew the five bolts (1), remove the drive

motor (2) from the gearbox (3).

The drive motor adopts an 18kW AC motor. See the table below for other parameters.

Model Rated Power kW Rated Voltage Rated Current A Rated Speed r/min Protecting Grade
JXQ-18-5A 18 54 234A 2339r/min IP54

18
Checking and Testing U, V, W Terminals
Identify if the motor windings are normal
through measuring the resistance of U-V, V-W, and
U-W respectively, if there is short circuit or
breakage refer to the following table:

CAUTION
Due to the small size of windings, use a low
resistance range with a multimeter.

Resistance
Judgment
Measurement

200m – 300m Ω Normal *

Winding internal short circuit

0Ω
(replace the motor)
Winding internal open circuit
∞Ω (replace the motor)
* The difference between the resistance values measured at
U-V, V-W and U-W shall not be greater than 2%.

Identify if there is leakage current through

measuring the resistance between U, V, W and
motor housing as shown in the following table:
Resistance
Measurement Judgment
Leakage current
0Ω
(replace the motor)
∞Ω Normal *
* For normal motor, U, V and W terminals are insulated from
motor housing.

19
Drive Axle • Unscrew the twelve bolts (7) and remove the
seal (8), then dismantle the drive axle (9).
Removal
• Power off the truck and remove the key.
• Add wheel chocks to the rear tires.
• Remove the drive wheel. See Drive Wheel
Removal.
• Remove the mast. See Three-Stage Full
Free Mast Removal section.
• Remove the floor mat and floorboard,
then remove U, V and W cables on the
drive motor.
• Remove the connection between the drive
motor and main wiring cables.
• Remove the tubing on the brake.
• Unscrew the nut (2), then remove the bolt (1).
• Unscrew the four bolts (5) and remove
the bearing cap (4), then remove the
drive assembly (6) from the chassis.
• Loosen the oil drain plug and drain all
transmission oil.

20
 CAUTION
After installing the new drive axle, please add gear
oil (see Lubrication section for specification and
filling amount).
Installation
• Transmission system installation is the opposite of removal.
• Transmission system lubrication: the axle housing is connected to the reduction box, and the
gear oil filled by the drive axle enters the reduction box.

Transmission Oil 2

Check Transmission Oil Level

• Loosen the fill port plug (1, Fig3132-
20011SM) and check the oil level.
• If oil level is level with the lower level of oiling
port, it indicates that the oil level is normal.
• If the oil level is below the lower level of the oiling
port, it is necessary to add transmission oil.

Fig3132-20011SM 1
Add / Replace Gear Oil
• Loosen the oil drain plug (3), drain the
transmission oil within the transmission.
• Install the oil drain plug (3), loosen the oil fill plug
(2) at the bottom of the drive axle and add the
3
transmission oil of same specification through
oiling port.
• Install the oil fill plug (2).

CAUTION Fig3132-20012SM

Transmission oil may damage truck parts and

contaminate the environment. When replacing the
gear oil, place a clean container under the drive
axle for discharge of gear oil.

21
Accelerator Pedal
Removal and Installation 3
• Power off the truck and remove the key.
• Remove the floor mat.
• Remove the connection between the
accelerator pedal wiring and main wiring
harness.
• Remove the two bolts (2) with wrench and
remove the accelerator pedal (3) from the
chassis.
• Install in the reverse order of removal.

Interface Description

Pin Description Color Remark

A Pedal power supply Red 13-15Vdc
B Output signal White 0.2±0.1~8±0.3VDC
C Pedal signal grounding Black -
D Pedal Switch - Positive Electrode Green Switch output
E Pedal switch output Grey Switch output

22
 Checking and Testing • Press the accelerator pedal.
Checking • Measure the voltage between the interfaces
with a multimeter.
• Check if the accelerator is in the off position,
its wiring harness is free of damage, in good Refer to the following table:
condition, and if the connectors are
connected securely.
Press the accelerator pedal:
Testing
Connection
Voltage Measurement
interface
• Press the accelerator pedal, if the accelerator
information on the display does not change, it A-C 13 V
indicates there is failure with the accelerator
Changing within the range of 0V to
pedal or its circuit. A-B
9V with the level of pressing
• Turn off the vehicle to check the accelerator
pedal and its wiring harness. (See Fig3131- A-E -
50017SM)
B-C 0V
• Provide a voltage of 13V between accelerator
pedal harness connectors (A) and (C), check
the voltage at each port of the wiring harness
with a multimeter.
• Place the accelerator pedal at its original
position.
• Measure the voltage between the interfaces
with a multimeter.

Refer to the following table:

Accelerator pedal at original position:

Connection
Voltage Measurement
interface
A-C 13V
A-B 0V
A-E -
B-C 0V

23
STEERING SYSTEM

24
Rear Steer Wheel • Remove the eight nuts (2) on the steer
wheel assembly (3).
Removal • Remove the steer wheel assembly (3)
from the steering axle (4).
• Turn off the truck power and remove the
key.
• Ensure the parking brake is set.
• Place the jack (1) under the chassis near
steering wheels, lift the wheel off the
ground and add a block or jack stand for
added safety.

2 3 Fig3845-00012OM

Installation and Commissioning

Install in the reverse order of removal.
1

CAUTION
WARNING Install the eight nuts as shown in Fig3132-
70002SM.
Make sure the lifting equipment is solid and
secure, and that the load capacity is greater than Tighten the nuts by order and mark with the
the total weight of the vehicle. Lifting height of not torque: 152-180 ft lbs., (206-243Nm).
more than 4 inches and put a block under the
chassis for support, to prevent the hazards to the
maintenance personnel working under the
vehicle for wheel removal and installation.

25
 WARNING
Be sure that the truck is secure and won't move or
tilt when replacing wheels.

• Run the truck to see if the steering wheel is

functioning properly. If there is blocking or
noise, check if the wheel bearings are • Unscrew the four bolts (2), then dismantle
functioning properly. the steering axle (3) from the chassis (4).

CAUTION
Quality of tires directly affects the stability and
driving performance of the device.

If you need to replace the factory-fitted tires,

please use original spare parts provided by the
equipment manufacturer.

Steering Axle
Removal Installation
• Turn off the truck power and remove the key. Install in the reverse order of removal.
• Ensure that the parking brake is set.
• Dismantle the rear steer wheels (see Rear CAUTION
Steer Wheels).
When removing the tubing and steering axle,
• Remove the two tubes (1) from the steering
the system will lose some hydraulic oil.
axle (3).

CAUTION
Hydraulic oil may damage truck parts and
contaminate the environment. When removing
joints or tubing, place a clean container under it for
discharge of hydraulic oil.

CAUTION
Before proceeding to the next step,
stabilize the steer axle to avoid it
falling during removal which may result
in personal injury.

26
Steering Axle

Please add grease

27
Steering Cylinder Steering Cylinder Maintenance

Removal CAUTION
• Turn off the truck power and remove the key. Use suitable hose clamps to avoid cylinder
• Dismantle the steering. deformation caused by severely tight
hose clamp.
• Unscrew the four bolts (23, Fig3850-
70005SM). • Carry out the maintenance work in a
• Unscrew the two bolts (32), knock out the clean environment to prevent impurities
pin (36), dismantle the steering cylinder from entering cylinder, causing cylinder
(18) from the steer axle (17). damage.
• During installation, hydraulic oil of
Installation the same specifications must be
used for cleaning or lubrication.
Install in the reverse order of removal.
• Secure the cylinder to hose clamp and
gently clamp the cylinder middle.
CAUTION • Unscrew the cylinder cap (1, Fig3850-
70006SM) from side with cylinder
When removing the steering cylinder, the wrench.
system will lose some hydraulic oil.
• Remove the collar (6), snap ring (13 &
12 & 9), ring (4), O-ring (11 & 10), dust
seal (8) and seal (7) from the cylinder
cap.
• Pull out the piston rod (3) from cylinder
block (2).
• Separate the piston (5) from the piston
rod.
• Remove the back-up ring (19), ring
(18), O-ring (16) and balls (17) from the
piston.
• Clean with hydraulic oil of the same
specifications.
• Replace the problem parts and
BRAKE SYSTEM assemble in reverse order.

CAUTION
If the piston rod or cylinder tube is
damaged, replace the entire cylinder.
If the seals are aged or damaged, replace
the complete set of seals.
When replacing or repairing the cylinder,
refill the lubricant through the grease
nipples at both ends of the cylinder.
Fig3850-70006SM

28
 Parking Brake Adjustment

Removal and Installation CAUTION

• Turn off the truck power and remove the key. Prior to parking brake adjustment, use triangle
• Use chocks to fix the wheels. wooden wedges to secure the wheels.
• Remove the connection between the brake
switch (1, Fig3127-10001SM) on the parking
brake (4) and the main wiring harness.
• Remove left / right brake cable on the parking
brake.
• Loosen the bolts (3), remove the parking
brake (4).
• Install in the reverse order of removal.
Ensure the parking brake switch deactivates
the travel circuit.

• Press and hold the button (1), push the parking

brake lever (2) from A position (braking) to B
position (released).
• Bolt (3) is used to adjust the operating torque for
pulling the brake lever (2) from B position to A
position.
• Operating torque: 147~196 Nm
• Adjust parking brake so it can hold truck rated
capacity on a 15% grade

29
 Service Brake Assembly Installation
• Install in the reverse order of removal.
Removal
• Turn off the truck power and remove the key. • Add brake fluid into the brake reservoir until it
fills 2/3 of the cup. Please apply as specified
• Remove the mat and open the floorboard. (see the Lubrication section for
• Use wedges or chocks to fix the wheels. specifications).
• Remove the hydraulic tubing (1, 2) from
the master pump cylinder (5).
CAUTION
• Remove the cotter pin (3) on the pin shaft (4),
then knock out the pin shaft (4) from side. After replacing the brake master cylinder or
tubing, the air within the entire brake pipeline
• Unscrew the two bolts (6), then remove the
must be discharged.
brake master cylinder (5) from the chassis.

Air Discharge / Adding Brake Fluid

• Fill the oil cup with brake fluid.
• Press the brake pedal repeatedly until you
feel pressure.
• Open the bleeder screw on brake cylinder
of drum brake, press the brake pedal
pressure to the bottom, discharge the
residual air from the vent.
• When there is flow of fluid running out of
the vent, it indicates that the air discharge is
completed, release the brake pedal and close
the vent.

CAUTION
CAUTION
When removing the tubing and brake pump, the During the entire process of operation, there
system will lose some brake fluid. must always be brake fluid in the oil cup.

30
HYDRAULIC SYSTEM

31
Hydraulic System Overview Hydraulic Oil
Hydraulic oil specifications:
• Lower the mast to the ground, observe the oil
level with the oil dipstick. When adding hydraulic Anti-wear Hydraulic Oil L-HM46.
oil, use hydraulic oil of the same specifications.

• When the mast occasionally jitters, it may

indicate leaks in the cylinder, or there could be Hydraulic Seals
leaks on the valve body. Dismantle and clean
(to clean with hydraulic oil of the same The seals installed within the cylinder are
specifications) the valve on the valve body, made of rigid polyurethane. The deformation
discharge the foreign bodies within the valve during assembly due to compression will not
body through repeatedly lifting and lowering of be permanent.
the mast. When assembling, pay attention to prevent
the seals from being broken, rolled and
• If hydraulic oil is decreasing, thoroughly check undercut.
the system for leaks.

• Disassembly of cylinder needs to be

performed in a clean environment. Before Assembly Instructions
removing the cylinder, wipe it clean. Carefully The tools used to install the seals must be
remove the piston rod to prevent the cylinder made of soft metal or suitable plastic,
wall from being scratched by its end surface or without burrs and sharp edges on surfaces.
damaged part. Every time cylinder is replaced, It is prohibited to use the tools that can
replace all the cylinder seals. easily damage the surface of seals, such as,
screwdriver or other similar tools with hard
front edges.
The area where the hydraulic seals are to be
installed should be free of burrs, sharp edges
and cracks. If the installation of seals needs
to cross sharp edges, grooves or cuts,
protective devices must be used. Before
installation, lubrication should be applied to
the seals and the mounting positions.

CAUTION
The lubricant used during assembly must be
of the same specifications as the hydraulic
oil used in the truck.

32
Hydraulic Schematic Diagram

33
 Pump Motor & Gear Pump
This truck obtains hydraulic power through the AC
pump motor.

Removal
• Turn off the truck power and remove the key.
• Remove the AMP connector on the pump motor
and remove the cables U, V and W from the
pump motor.
• Loosen the tubing connector (1) with a wrench,
and then remove the tubing (2) from the gear
pump (7).
• Loosen the tubing connector (5), remove the
clamp (10) and pipe (3) from the gear pump (7).
• Unscrew the four bolts (4) and (9) remove the
pump motor & gear pump assembly from the
chassis.
• Unscrew the two bolts (6) and remove the gear
pump (6) from the pump motor (8).

CAUTION
When removing the tubing and pipe, the system
will lose some hydraulic oil.

Installation
Install in the reverse order of removal.

34
Control Valve
The valve rod is driven by lever to switch the ON
and OFF of tubing within the valve body, which
controls the Lifting - Lowering, Forward Shifting
- Retract, Tilting Forward - Tilting Backward and
Left Shifting - Right Shifting of the vehicle.

Removal (Fig3850-40012SM) Installation

• Turn off the truck power and remove the key. Install in the reverse order of removal.
• Remove the mat and open the floorboard.
• Remove the tubing on the multi-way valve (1) CAUTION
and remove the connection between the
control switch (2) and main wiring harness. Some hydraulic oil will be lost when
removing the manual multi-way valve. Add an
appropriate amount of hydraulic oil after the
CAUTION replacement is completed.

Hydraulic oil may damage truck parts and

contaminate the environment. When
removing joints or tubing, place a clean
container under it for discharge of hydraulic oil.

• Remove the cotter pin (3) on pin shaft (4),

remove the connecting rod (5) from the multi-way
valve.
• Unscrew the three bolts (6), then remove the
multi-way valve (5) from the mounting plate (7).
• Remove the rubber cover (8) and unscrew the
bolt (9), then remove the bracket (10) from the
multi-way valve.

35
Hydraulic Control Valve

Connection Interface
Item Interface Function
Terminals Size
A1 Lifting, lifting / lowering solenoid valve controls Lift Cylinder M30
A2 Backward tilting, backward tilting solenoid valve controls Tilt Cylinder M30
B2 Forward tilting, forward tilting solenoid valve controls Tilt Cylinder M30
A3 Right shifting, right shifting solenoid valve controls Side-Shift Cylinder M30
B3 Left shifting, left shifting solenoid valve controls Side-Shift Cylinder M30
A4 Attachment Reach Cylinder M30
B4 Attachment Reach Cylinder M30
P Oil Inlet Redirector G3/4
T Drainback Tank M33×2

36
 Redirector

4
1

• Unscrew the four bolts (3), dismantle the

redirector (4).
• Install in the reverse order of removal.

Removal and Installation

• Turn off the truck power and remove the CAUTION

key.
As some hydraulic oil will be lost when
• Remove the mat and open the floorboard. removing the redirector, add an appropriate
• Loosen the joint (1) and remove the amount of hydraulic oil after the replacement is
tubing (2) on the redirector (4). completed.

CAUTION
Hydraulic oil may damage truck parts and
contaminate the environment. When
removing joints or tubing, place a clean
container under it for discharge of hydraulic oil.

Symbol Interface Function Connection Terminals Interface Size

T Drainback Tank M18×1.5
P Oil Inlet Gear Pump M20×1.5
L Left turning, steering wheel controls Steer axle M18×1.5
R Right turning, steering wheel controls Steer axle M18×1.5
EF Port, to the Port P of multi-way valve Multi-way Malve M20×1.5

37
Tilt Cylinder • The use of sharp tools should be avoided, so as
not to stab the seals. For the seals that are
Cylinder Removal Precautions difficult to remove, soak them with boiling water,
remove them when softened.
• Before removing the cylinder, be sure to
relieve the hydraulic circuit first, which is to • Before removing, try to create conditions to
lower the lifting mast to the ground. Move the prevent the cylinder parts from being
tilt hydraulic lever to its maximum range in contaminated by the surrounding dust and
each direction. Support the mast with a impurities.
chain or strap to the overhead guard to • For the cylinder which is found with internal or
prevent the mast from tipping forward. When external leakage during use, if the piston rod or
removing the tubing connected with the cylinder tube is not scratched, they may leak due
cylinder, the pressured hydraulic oil within the to worn or aged seals.
circuit may be sprayed out at high speed
along with the tubing, and there is risk of
personal injury. CAUTION
When the seals need to be replaced, replace
• Turn off the power source, so that the entire
them with the complete set of seals in the
hydraulic system will stop functioning, then
cylinder repair kit.
the connecting tubing can be loosened, to
avoid the residual pressure within the circuit,
the tubing joint should be loosened slowly. • Pay special attention to the cylinder tube, piston
Loosen the joint by half and shake the tubing rod and other moving parts for bumps and
to see if there is overflow of pressured oil, scratches. If only minor damage, sand the edge
and then go on with the removal. point around the damaged part with fine stone
and then polish the part smooth with
• Cylinder is the powered actuator in hydraulic
system. Before removing the cylinder from metallographic sandpaper.
the equipment, the connection part must be
secured to prevent personal injury or damage
to the truck.
• Prior to disassembly of the cylinder, you
should be familiar with its main structure.
Due to the different size, structure, and
purpose of the cylinders, the sequences and
methods used for removal are also different.
• When removing each part, do not hammer
forcefully. If it cannot be avoided, use a
copper rod to avoid damage to the parts.
To loosen fine threaded cylinder caps, use
cylinder wrench with even force as to not
damage the threads.
• Upon removal, damage to cylinder threads, oil
port threads, cylinder cap threads, piston rod
surface and inner cylinder wall should be
prevented.
• To prevent piston rod from bending or
deformation, support it wooden block when
placing.

38
 Cylinder Cap CAUTION
O-ring is quite flexible and easy to
install, but it must not be stretched to
the extent of permanent deformation,
rolled while installing.
Cylinder Wrenches
• Y-ring or X-ring needs to be identified if it is for
shaft or hole to avoid misplacement.
Piston Rod • The removed O-rings and dust rings should be
replaced with new ones.
• Cylinder parts must not be arbitrarily replaced, the
original products provided by the manufacturer
should be used.
Cylinder Tube
• After maintenance and assembly of the cylinder is
completed, pressure leak testing must be carried
out before it can be put operation once again.
• Before testing, discharge the air within the cylinder,
run the cylinder in a small range of movement
several times.
* See Lift Cylinder for the removal and • Note: If the cylinders are drifting down or have
installation of lift cylinder and side shift uneven movement/resistance, raise the pressure
cylinder. slowly and carefully observe for leaks.
* See Steering Cylinder for the removal and
installation of steering cylinder.

Cylinder Installation Precautions

• All parts should be cleaned up before assembly,
then assembled after being dried.
• During assembly, apply appropriate amount of
hydraulic oil for lubrication.
• The tools used to install the seals must be made
of soft metal or suitable plastic, without burrs and
sharp edges on surfaces. It is prohibited to use
tools that can easily damage the surface of
seals, such as a screwdriver or other similar
tools with hard front edges.
• Before installing, lubrication should be performed
to the seals and the mounting positions first with
hydraulic oil.

39
Removal and Installation
Tilt cylinder is installed on the chassis and outer CAUTION
mast.
Hydraulic oil may damage truck parts and
• Secure the mast, block the truck wheels contaminate the environment. When
with wooden wedge, press the emergency removing joints or tubing, place a clean
stop switch and turn off the key switch. container under it for discharge of hydraulic oil.
• Unscrew the two nuts (1) and remove the
two tubes (2) from the tilt cylinder (3). • Pull out the emergency stop switch and turn on
the key switch.
• Unscrew the anchor bolt (6) from the outer
mast with socket wrench and pull out the • Repeat tilt cylinder to discharge the air within the
pin shaft (7). tubing and cylinder.
• Unscrew the anchor bolt (4) from the • Check the hydraulic oil level and make sure that
chassis with socket wrench and pull out the the liquid is at standard level.
pin shaft (5).
• Remove the tilt cylinder (3).
• Replace with new cylinder and install in
reverse order.
• Add hydraulic oil of the same
specifications into the tank, see the
Lubrication Section.
3

40
Cylinder Maintenance

CAUTION
Use suitable hose clamps to avoid
cylinder deformation caused by severely
tight hose clamp.
Carry out the maintenance work in a
clean environment to prevent impurities
from entering cylinder, causing cylinder
damage.
During the installation, hydraulic oil of
the same specifications must be used
for cleaning or lubrication.

• Secure the cylinder to hose clamp and gently

clamp the cylinder bottom.
• Unscrew the nut (4, Fig3530-40004SM) and
bolt (3), then remove the clevis (2) from the
piston rod (18).
• Unscrew the cylinder cap (13) with cylinder
wrench.
• Remove the dust ring (8), retainer ring (7),
rubber ring (9), and seal ring (10) from the
cylinder cap (13).
• Remove the bearing (14), support ring (6)
rubber ring (11) and O-ring (12) from the
cylinder cap (13). CAUTION
• Pull out the piston rod (18) from cylinder block If the piston rod or cylinder tube is damaged,
(15). replace the entire cylinder.

• Remove the seal (16) and support ring (17) If the seals are aged or damaged, please
from the piston rod. replace the complete set of seals.

• Clean with hydraulic oil of the same When replacing or repairing the cylinder,
specifications. please refill the lubricant through the grease
nipples at both ends of the cylinder.
• Replace the problem parts and assemble in
reverse steps.

41
Hydraulic Symbols

42
43
MAST

44
Three-stage Full Free Mast • Unscrew the bolts (3) and remove the fixed
plate (4) between the outer mast and
chassis (C and D).
Removal
• Remove the mast from the truck.
• Remove the connections between lifting -
lowering tubing, left shifting tubing and right
shifting tubing and mast tubing.
Installation
• Wrap the sling (1) around the upper beam of
inner and outer masts, slightly lift the mast Install in the reverse order of removal.
with crane.
WARNING
• Remove the shafts (2) between the outer
mast and tilt cylinders (A and B). Make sure the lifting equipment is solid and
secure, and the load capacity should be greater
than the total weight of the vehicle.

45
Lifting Chains CAUTION
Chain Adjustment When the adjustment is completed,
there should be an adjustable distance
• Lower the mast to the ground. of at least three pitches over the chain
bolts.
• Press the emergency stop switch and
disconnect the key switch. • Pull out the emergency stop switch and turn on
the key switch.
CAUTION • Repeatedly lift/lower the mast to test if the
Switch off the power supply before chain is tense. If the chain is still loose, repeat
any adjustments or operations the steps above.

• Loosen the upper lock nut (1, Fig 3850-

60004SM) and the lower lock nut (2) on
chain bolt.

• By screwing upward, the adjusting nut

(8) in the middle, the chain will slowly tension.

• When the chain is adjusted to be tensioned

with no obvious loosening, fasten the upper and
lower lock nuts.

46
Chain Replacement
Mast Chains

• Block the truck wheels with wooden wedges,

raise the inner mast (2, Fig3850-60008SM)
for 20 in or 500mm, insert wooden block
between inner mast and the ground for
support.

CAUTION
Place support under the inner mast to prevent it
from falling, resulting in personal injury.
• Remove the cotter pin (7, Fig3850-60004SM),
then unscrew the jam nuts (2 & 8) and from the
chain joint (1) and chain joint (6).
• Remove the cotter pin (3), pull out the pin
shaft (4), separate the chains (5) from the
chain joint (1) on outer mast.
• Remove the chain assembly from the chain
sprocket.
• Replace with new chains and hang the new
chain assembly onto the chain sprocket.
• Put the chain connector (6) through the inner
mast chain-hanging plate, screw the jam nut
(2).
• Put the chain connector (1) through the outer
mast chain-hanging plate, screw the jam nut
(2).
• Adjust the chains according to the Lifting
Chain Section.

47
Fork Carriage Chains
• Block the truck wheels with wooden wedges, raise
the fork carriage 20 inches or 500mm, insert
wooden block between inner mast and the ground
for support.

CAUTION
Place support under the inner mast to prevent it
from falling, resulting in personal injury.

• Remove the cotter pin (7, Fig3850-60006SM), then

unscrew the jam nuts (2 & 8) and from the chain
joint (1) and chain joint (6).
• Remove the cotter pin (3), pull out the pin shaft (4),
separate the chains (5) from the chain joint (1) on
full free cylinder.
• Remove the chain assembly from the chain
sprocket.
• Replace with new chains and hang the new chain
assembly onto the chain sprocket.
• Put the chain connector (6) through the fork
carriage chain-hanging plate, screw the jam nut (2).
• Put the chain connector (1) through full free cylinder
plate, screw the jam nut (2).
• Adjust the chains according to the Lifting Chain
Section.

48
49
Mast Tubing

HYDRAULIC SYSTEM OF LIFT SYSTEM

Code Description
A1 Lifting / Lowering Mast Tubing

50
HYDRAULIC SYSTEM OF THIRD PIPELINE

Code Description
A3 Right Shift Mast Tubing
B3 Left Shift Mast Tubing

51
HYDRAULIC SYSTEM OF FOURTH PIPELINE

Code Description
A4 Attachment
B4 Attachment

52
Lift Cylinder CAUTION
Hydraulic oil may damage truck parts and
Left Cylinder Removal (with mast down) contaminate the environment. When removing joints
• Remove the mast from the chassis according or tubing, place a clean container under it for
to the Three Stage Full Free Mast Section. discharge of hydraulic oil.
• Lay down the mast with lifting tools (with • Unscrew the hose clamp (21) and remove the
outer mast underneath the inner mast), place hose (10).
sleepers at both ends for supporting.
• Loosen the connector (7, Fig3850-60017SM) CAUTION
and remove pipe (16, Fig3850-60017SM).
Before going on with the next step, secure the
• Unscrew the hose clamp (19) and remove the
cylinder properly first. Be sure to avoid the falling of
hose (10).
cylinder during removal, resulting in personal injury.

CAUTION • Unscrew the mounting bolt (8) from the bottom

of the cylinder.
Hydraulic oil may damage truck parts and
contaminate the environment. When removing • Unscrew bolt (3) and remove the cylinder (5)
joints or tubing, place a clean container under from the mast.
it for discharge of hydraulic oil.
Full Free Middle Cylinder
(with mast on the vehicle)
• Unscrew the bolt (6), remove the support
• Lower the mast to the bottom, press the
plate (17, Fig3850-60008SM) and loosen the
emergency stop switch and disconnect the key
nut (18, Fig3850-60008SM) and remove the
switch.
cylinder U Bolt - Side (7).
• Remove load backrest (see Side Shifter
CAUTION Removal).

Before the next step, secure the cylinder • Block the truck wheels with wooden wedges,
properly. Be sure to avoid the falling of cylinder raise the fork carriage to 20 inches (500mm)
during removal, resulting in personal injury. with lifting tools, insert wooden block between
it and the ground for supporting.

CAUTION
Hydraulic oil may damage truck parts and
• Unscrew the mounting bolt (8) from the
contaminate the environment. When removing joints
bottom of the cylinder.
or tubing, place a clean container under it for
• Unscrew bolt (3) and remove the cylinder (4) discharge of hydraulic oil.
from the middle mast.
Right Cylinder Removal (with mast down)
• Remove the mast from the chassis according
to Three Stage Full Free Mast Section.
• Lay down the mast with lifting tools (with outer
mast underneath the inner mast), place
supports at both ends for supporting.
Disconnect the hose (4) between three-pass
assembly (15, Fig3850-60017SM)

53
• Loosen the joints (4, Fig3850-60017SM) to
separate the middle cylinder and rigid pipe
assembly (2).
• Unscrew bolt (20, Fig3850-60018SM) and
remove the middle cylinder roller guard (25).
• Disconnect the connections between the
tubing (17, Fig3850-60018SM) around the
middle cylinder roller and rigid pipe assembly
(16).
• Remove the fork carriage chains according to
the Chain Replacement Section.

54
• Unscrew the bolt (22) and remove the middle
cylinder fixing plate (21) and sprocket seat
(22) from the cylinder (14, Fig3850-60008SM).
• Unscrew the bolt (15) and (16) and separate the
cylinder (14) from the inner mast (2)
• Remove the cylinder (14) from the truck.

CAUTION
Before the next step, secure the cylinder properly.
Be sure to avoid the falling of cylinder during
removal, possibly resulting in personal injury.

Cylinder Maintenance
Lifting Side Cylinder

CAUTION
Use suitable hose clamps to avoid cylinder
deformation caused by severely tight hose
clamp.
Carry out the maintenance work in a clean
environment to prevent impurities from entering
the cylinder, causing cylinder damage.
During the installation, hydraulic oil of the same
specifications must be used for cleaning or
lubrication.

• Secure the cylinder to hose clamp and gently • Remove the cushion collar (10), steel cable
clamp the cylinder bottom. baffle ring, (11) and steel cable baffle ring (9)
• Unscrew the cylinder cap (5) with cylinder and from the piston.
wrench. • Remove the backup ring (12) and seal (13) strip
• Remove the dust ring (2), seal (3), O-ring (4) and (14) from the piston.
bearing (6) from the cylinder cap. • Clean with hydraulic oil of the same
• Pull out the piston rod (1) from the cylinder tube specifications.
(7). • Replace the worn parts and reassemble in
• Remove the piston (8) from the piston rod. reverse order.
• Use the same method to remove the right
cylinder.

55
 Right Lifting Cylinder

No. Name No. Name

1 Piston rod 11 Steel ring
2 Dust ring 12 Support ring
3 Seal 13 Seal
4 O-ring 14 Cylinder stopper
5 Cylinder cap 15 Pin
6 Bearing 16 O-ring
7 Cylinder tube 17 Bushing
8 Piston 18 Spring
9 Steel ring 19 Valve
10 Cushion collar

56
 CAUTION
If the piston rod or cylinder tube is damaged,
replace the entire cylinder.
If the seals are aged or damaged, replace the
complete set of seals.

Full Free Middle Cylinder

• Secure the cylinder to hose clamp and gently
clamp the cylinder bottom.
• Unscrew the cylinder cap (5) with cylinder wrench.
• Remove the dust ring (2), retaining ring (4),
seal (3), O-ring (6), bearing (7), O-ring (8) from
the cylinder cap.
• Pull out the piston rod (1) from the cylinder tube (11).
• Remove the support ring (14) and seal (15),
retaining ring (16) from the piston (13).

CAUTION
If the piston rod or cylinder tube is damaged,
replace the entire cylinder.
If the seals are aged or damaged, replace the
complete set of seals.

57
 Cylinder Installation
• Install in the reverse order of removal.
• Add hydraulic oil of the same specifications into
the tank, see the Lubrication Section.
• Pull out the emergency stop switch and turn on
the key switch.
• Repeat Lift - Lower cylinder to discharge the air
within the tubing and cylinder.

• Check the hydraulic oil level and make sure that

the liquid is at standard level.

Built-in Side Shifter

Side Shifter Removal
• Lower the mast to the ground, press the
emergency stop switch and disconnect the key
switch.
• Block the truck wheels with wooden wedge.
• Unscrew the four bolts (1, Fig3530-60003SM),
remove the load backrest (2) from the built-in
side shifter (3).

CAUTION
Hydraulic oil may damage truck parts and
contaminate the environment. When removing
joints or tubing, place a clean container under it
for discharge of hydraulic oil.
• Remove the right shifting tubing and left shifting
tubing from the built-in side shifter.

CAUTION
Before the next step, secure the side
shifter properly. Be sure to avoid the
falling of side shifter during removal,
which may result in personal injury.
• Remove the chain assembly and remove the
side shifter from the inner mast.

58
Side Shifter Installation
• Install the side shifter according to the reverse
order of removal according to the Side Shift
Removal Section.
• Add hydraulic oil of the same specifications into 1
the tank, see the Lubrication Section.
• Pull out the emergency stop switch and turn on
the key switch.
• Repeat left shifting - right shifting operations to
discharge the air within the tubing and side shift
cylinder.
• Check the hydraulic oil level and make sure that
the liquid is at standard level. 3

4
External Side Shifter
Side Shifter Removal
• Lower the mast to the ground, press the
emergency stop switch and disconnect the key
switch.
• Block the truck wheel with wooden wedge.
• Unscrew the four bolts (3, Fig3530-60004SM),
remove the load backrest (1) from the external
side shifter (2).
2
CAUTION 7
Hydraulic oil may damage truck parts and
contaminate the environment. When
removing joints or tubing, place a clean 8
container under it for discharge of
hydraulic oil.
• Remove the right shifting tubing (8, Fig3131- Side Shifter Installation
60005SM) and left shifting tubing (7) from the
• Install the side shifter in the reverse order of
built-in side shifter. • Install the side shifter according to the
removal according to 8.1.6.1.
reverse order of removal according to Side
Shift Removal Section.
CAUTION
• Add hydraulic oil of the same specifications
Before the next step, secure the side into the tank, see Lubrication Section.
shifter properly. Be sure to avoid the side • Pull out emergency stop switch and turn on
shifter falling during removal, resulting in the key switch.
personal injury.
• Repeat left shifting - right shifting
• Remove the external side shifter (2, Fig3530- operations to discharge the air within the
60004SM) from fork carriage (4). tubing and side shift cylinder.
• Check the hydraulic oil level and make
sure that the liquid is at standard level.

59
ELECTRICAL COMPONENTS

60
 Controller Functions Main Contactor
Electrical control of this truck is mainly driven
by traction controller.

Fuse Fuse Main Contactor

Removal and Installation

Traction Controller • Turn off the key switch and remove the key,
press the emergency stop switch.
Pump Controller Fuse box
• Open the battery hood.
• Controller: • Disconnect the wirings (2) from the main
contactor (1).
Traction controller: mainly used for the control
of drive motor and pump motor • Unscrew the four bolts (3), dismantle the
main contactor (1) from the mounting plate.
• Other: • Install in the reverse order of removal.
Main Contactor, fuse box, DC-DC converter,
seat switch, etc.

Removal and Installation

• Turn off the key switch and remove the key,

press the emergency stop switch.
• Open the battery hood.
• Remove all the cables, wirings and strips
from the controller, unscrew the fixing screws
and remove the controller from the electrical
mounting plate.
• Install in the reverse order of removal.

61
 3

Checking and Testing Visual Inspection

• Visually check the surface of contactor for
scratches, damages and stains. Contact Checks
• If any of the above is found, replace with a new • Check if the surface of contact surface is
contactor. smooth and symmetrical.
• Separately provide the contact with a voltage
Coil Checks of 80V to observe if the contact can absorb.
• Disconnect the cables on the contactor. • If the surface is uneven or the contact does
• Check the resistance of the coil with a multi-meter not absorb, replace the main contactor.
measurement method as shown in Fig1221-
50009SM.
• Identify if the contactor is normal according to the
readings of resistance on the multimeter.

As shown in the following table:

Resistance
Judgment
Measurement
Approx. 160 Ω Normal
Coil shorting
0Ω
(replace the contactor)
Coil breaking
∞Ω (replace the contactor)

62
DC-DC Converter Checking and Testing
DC-DC converter provides converted voltage Checking
for lights, horn and buzzer. • Check if the appearance of converter and its
Working performance: 80V DC to 12V wiring harness are in good condition, and if the
connectors are connected securely.
Removal and Installation Testing
• Switch off the key switch and remove the • Check if the converter circuit is conductive.
key, press the emergency stop switch. • Provide a voltage of 80V between converter
• Open the battery hood. interfaces 3 and 18.
• Remove the connection between the • If there is voltage output of 12V between
converter wiring and main wiring harness. interfaces 4 and 17, the converter is working
• Unscrew the four screws (2) and remove properly.
the converter (3) from the battery box. • If the output voltage is not 12V, the converter
• Install in the reverse order of removal. needs to be replaced.

63
Fuse
The entire vehicle is installed with six fuses altogether. When there is fuse failure, the truck may not
be able to run properly due to that.
Status
Function Main Main
Fuse 1 Fuse 2 Fuse 3 Fuse 4
Fuse 1 Fuse 2
Fuse 1 10A × Ο Ο Ο Ο Ο
Fuse 2 10A Ο × Ο Ο Ο Ο
Fuse 3 10A Ο Ο × Ο Ο Ο
Fuse 4 10A Ο Ο Ο × Ο Ο
Main Fuse 1 400A Ο Ο Ο Ο Ο ×
Main Fuse 2 400A Ο Ο Ο Ο × Ο
1 Drive × Ο Ο Ο × ×
2 Hydraulic Action × Ο Ο Ο × ×
3 Steering × Ο Ο Ο × ×
4 Instrument × Ο Ο Ο Ο Ο
5 Left/Right Turn Light Ο Ο × Ο Ο Ο
6 Warning Light Ο Ο × Ο Ο Ο
7 Horn Ο Ο Ο × Ο Ο

8 Headlight/Rear Ο × Ο Ο Ο Ο
Combination Light
Reverse Light/Reverse
9 Ο Ο Ο × Ο Ο
Buzzer
10 Brake Light Ο Ο Ο × Ο Ο

× : Failure
Location of Fuses Ο : Normal
Fuse 1: installed on controllers
Fuse 2-5: installed in fuse box
★ Fuse position in electrical schematic diagram

64
Controller Error Message
Electrical faults are mainly caused by electrical While the when the components failures which
components failure or electrical circuit failure. may affect the ON/OFF of control circuit occur to
Wherein, when some components failures which the electrical circuit, the controller will alarm for
may not affect the ON/OFF control circuit occur, error, and fault information will be displayed.
the instrument won't display fault code.

Traction Controller

Code Error Text Explanation Troubleshooting

This is a safety
related test.
It is a self-
diagnosis test that This alarm could be caused by a CAN bus malfunctioning,
8 WATCHDOG involves the logic which blinds master-supervisor communication.
between master
and supervisor
microcontrollers.

A hardware
problem in the
logic board due
to high currents
LOGIC (overload). An The failure lies in the controller hardware. Replace the
17 overcurrent
FAILURE#3 controller
condition is
triggered even if
the power bridge
is not driven.

Fault in the
hardware section
LOGIC of the logic board The failure lies in the controller hardware. Replace the
18
FAILURE#2 which deals with controller.
voltage feedback
of motor phases.
1-Fault can be caused by a key input signal characterized
This fault is
by pulses below the undervoltage threshold, possibly due to
displayed when
external loads like DC/DC converters starting-up, relays or
the controller
contactors during switching periods, solenoids energizing or
detects an
de-energizing. Consider to remove such loads.
undervoltage
LOGIC condition at 2- If no voltage transient is detected on the supply line and the
19
FAILURE#1 the KEY input. alarm is present every time the key switches on, the failure
Undervoltage probably lies in the controller hardware. Replace the logic
threshold depends board.
on the nominal
voltage of the 3- If the alarm occurs during motor acceleration or when there
controller is a hydraulic-related request, check the battery charge, the
battery health and power-cable connections.

65
 Error
Code Text Explanation 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 motor connection is OK, the problem is
inside the controller.
B) If the problem occurs after closing the LC (the LC
closes and then opens back again), check:
- Motor internal connections;
The pump motor output - If motor windings/cables have leakages towards
PUMP
is lower than expected, truck frame.
28 VMN - If no problems are found on the motors, the
considering the PWM duty
LOW cycle applied. problem is inside the controller.
C) If the alarm occurs during motor running, check:
- Motor internal connections;
- If motor windings/cables have leakages towards
truck frame.
- That the LC power contact closer properly, with a
good contact.
- If no problem is found on the motors, the problem
is inside the controller, it is necessary to replace the
logic board.

This test is carried out when -Motor internal connections

the pump motor is turning -If motor windings/cables have leakages towards
PUMP
(PWM applied). The pump truck frame.
29 VMN
motor output is higher than -If no problem is found on the motors, the problem
HIGH expected, considering the is inside the controller, it is necessary to replace the
PWM applied. logic board.

Start-up test. Before switching

the LC on, the software checks
the power bridge: it turns on
If the problem occurs at start up (the LC does not
alternatively the high-side
close at all), check:
power MOSFETs and expects
- Motor internal connections (ohmic continuity).
the phase voltages increase
- Motor power-cables connections.
toward the positive rail value.
- If the motor connections are OK, the problem
If one phase voltage is lower
is inside the controller; replace it.
than a certain percentage of
the rail voltage, this alarm
VMN If the alarm occurs while the motor is running, check:
30 occurs.
LOW - Motor connections.
Motor running test. When the
- That the LC power contact closes properly, with
motor is running, the power
a good contact.
bridge is on, and the motor
- If no problem is found, the problem is inside
voltage feedback tested; if it is
the controller. Replace it.
lower than expected value (a
range of values is
considered), the controller
enters in fault state.

66
Code Error Text Explanation Troubleshooting

Before switching the LC on,

the software checks the power
bridge: it turns on alternatively
the low-side power MOSFETs A）If the problem occurs at start-up (the
and expects the phase LC does not close), check:
voltages decrease down to -B. - Motor internal connections (ohmic
If the phase voltages are continuity).
higher than a certain - Motor power cables connections.
percentage of the nominal - If the motor connections are OK, the
battery voltage, this alarm problem is inside the controller. Replace
31 VMN HIGH occurs. it.
This alarm may also occur
when the start-up diagnosis B) If the alarm occurs while the motor is
has succeeded and so the running, check:
LC has been closed. In this - Motor connections.
condition, the phase voltages - That the LC power contact
are expected to be lower than closes properly, with a good
half the battery voltage. If one contact.
of them is higher - If no problem is found, the problem is
than that value, this alarm inside the controller. Replace it.
occurs.

Before driving the LC coil,

the controller checks if the
contactor is stuck. The
controller drives the power
bridge for several dozens of It is suggested to verify the power contacts
CONTACTOR
37 milliseconds, trying to of LC; if they are stuck, is necessary to
CLOSED discharge the capacitors bank. replace the LC.
If the capacitor voltage does
not decrease by more than a
certain percentage of the key
voltage, the alarm is raised.

The LC coil is driven by the

controller, but it seems that
the power contacts do not
close. To detect this condition,
the controller injects a DC
CONTACTOR LC contacts are not working. Replace the
38 current into the motor and
OPEN checks the voltage on power
LC.
capacitor. If the power
capacitors get discharged it
means that the main
contractor is open.

67
Code Error Text Explanation Troubleshooting

1-Check the motor connection, that there is

continuity. If the motor connection is opened, the
While the pump motor is
current cannot flow, so the test fails and the
PUMP I=0 running, the current
error code is displayed.
52 EVER feedback is constantly stuck to
zero.
2-If everything is ok for what it concerns the
motor, the problem could be in
the current sensor or in the related circuit.

In standby, the sensor detects The current sensor or the current feedback
STBY I
a current value different from circuit is damaged. Replace the
53 HIGH zero. controller.

68
Code Error Text Explanation Troubleshooting

When the key is 1-Check if an external load in parallel to the

switched on, the inverter capacitor bank, which sinks current from the
tries to charge the power capacitors-charging circuit, thus preventing
capacitors through the the caps from charging well. Check if a lamp
series of a PTC and or a dc/dc converter or an auxiliary load is
a power resistance, placed in parallel to the capacitor bank.
checking if the capacitors
CAPACITOR are charged within a 2- The charging resistance or PTC may be
60 certain timeout. If the
CHARGE broken. Insert a power resistance across
capacitor voltage results line-contactor power terminals; if the alarm
less than a certain disappears, it means that the charging
percentage of the resistance is damaged.
nominal battery voltage,
the alarm is raised, and 3- The charging circuit has a failure or there
the main contactor is not is a problem in the power
closed. section. Replace the controller.

It is necessary to improve the controller

cooling. To realize an adequate cooling
in case of finned heat sink important
The temperature of the factors are the air flux and the
controller base plate cooling-air temperature. If the thermal
is above 85 °C. The dissipation is realized by applying the
maximum current is controller base plate onto the truck frame, the
TH.
62 proportionally decreased important factors are the thickness of the
PROTECTION with the temperature frame and the planarity and roughness of its
excess from 85 °C up surface.
to 105 °C. At 105 °C the If the alarm occurs when the controller is
current is limited to 0 A. cold, the possible reasons are a
thermal-sensor failure or a failure in the logic
board. In the last case, it is
necessary to replace the controller.

69
Code Error Text Explanation Troubleshooting
1- Check the temperature read by the thermal
sensor inside the motor through the MOTOR
This warning occurs TEMPERATURE reading in the TESTER
when the temperature function.
sensor is open (if digital)
or if it has overtaken the 2- Check the sensor ohmic value and the sensor
MOTOR
65 MAX. MOTOR TEMP. wiring.
TEMPERAT.
threshold (if analog) (see 3- If the sensor is OK, improve the cooling of the
paragraph Mast Tubing motor.
Section).
4- If the warning is present when the motor is cool,
replace the controller.
1- Check the battery charge and charge it if
Parameter BATTERY necessary
CHECK is other than
0 (SET OPTION) 2- If the battery is charged, measure the battery
and battery charge is voltage through a voltmeter and compare it with
BATTERY evaluated to be lower the BATTERY VOLTAGE reading in the TESTER
66
LOW than BATT.LOW function. If they are different, adjust the ADJUST
TRESHLD BATTERY parameter (ADJUSTMENTS list) with
(ADJUSTMENTS). the value measured through the voltmeter.
3- If the problem is not solved, replace the logic
board.

1- Check if there is a short or a low impedance pull-

down between NMC (A12) and -B.
The driver of the LC coil
DRIVER 2- The driver circuit is damaged; replace the logic
74 is shorted.
SHORTED board.
3-The SET POSITIVE PEB parameter is not correct

The LC coil driver is not This type of fault is not related to external
able to drive the load. components; replace the logic
CONTACTOR The device itself or its board.
75
DRIVER driver circuit is
damaged.

70
 At key-on and
immediately after that, 1- Check the wirings.
the travel demands
have been turned off.
This alarm occurs if the
2- Check the mechanical calibration and the
functionality of the accelerator potentiometer.
ACCELERATOR
VACC NOT reading (in TESTER
78 3- Acquire the maximum and minimum
OK function) is above the potentiometer value through the
minimum value PROGRAM VACC function.
acquired during the
PROGRAM VACC 4- If the problem is not solved, replace the logic
procedure. board.

71
Code Error Text Explanation Troubleshooting

1- Check wirings.
Incorrect starting sequence.
Possible reasons for this alarm 2- Check microswitches for failures.
are: 3- Through the TESTER function, check the
INCORRECT
79 1- A travel demand active at states of the inputs are coherent with
START key-on. microswitches states.
2- Man-presence sensor active 4- If the problem is not solved, replace the
at key on. logic board.

1- Check that travel requests are not

active at the same time.

This alarm occurs when both 2- Check the FW and BW input states
FORW + the travel requests (FW and through the TESTER function.
80
BACK BW) are active at the same
3- Check the wirings relative to the FW and
time.
BW inputs.
4- Check if there are failures in the
microswitches.
5- If the problem is not solved, replace the
logic board.

1- Check the electrical and the mechanical

functionality of the encoder and the wires
crimping.
This fault occurs when the
frequency supplied to the 2- Check the mechanical installation of the
motor is higher than 30 Hz and encoder, if the encoder slips
ENCODER the signal feedback from the inside its housing it will raise this alarm.
82 encoder has a too high jump
ERROR 3- Also, the electromagnetic noise on the
in few tens of milliseconds. sensor can be the cause for the alarm. In
This condition is related to an these cases, try to replace the encoder.
encoder failure.
4- If the problem is still present after
replacing the encoder, the failure is in the
controller.

100 FROM E CAN Alarm received from E-CAN /

Present when altitude

WAIT measure is active. Is set if
103 HEIGHT the initialize sequence has /
ACQ. not been performed

72
Code Error Text Explanation Troubleshooting

MAXIMUM HEIGHT M" parameter

SHELF WR. Adjust this parameter into allowed range
104 out of range (under 1m or above
IN:100 25.5m)
values

PLC device has opened the Main

AGV PLC Contactor and the Electric Brake
105 This problem is due to PLC device (MIR)
E-STOP coils (and the A19-DI5 input is
closed to key)

Zapi controller is waiting the right

behavior of the A19-DI5 input
(driven by the PLC) to close the
Main Contactor:
""XX"" = 1 --> From the key on
event to ""BOOT TIME A19 LO""
the controller checks if the A19-DI5
input is open to key.
""XX"" = 2 --> From the end of
the above check the controller
wait ""BOOT TIME TOL LO"" the
closing to key of the A19-DI5 input;
AGV WAIT
106 ""XX"" = 3 --> From the end of the This problem is due to PLC device (MIR)
BOOT XX above check the controller check if
the A19-DI5 input is closed to key
for at least ""BOOT TIME A19 HI""
;
""XX"" = 10 --> A19-DI5 input
closed to key at the key on event;
""XX"" = 11 --> Check failed on
point ""XX"" = 1;
""XX"" = 12 --> Check failed on
point ""XX"" = 2;
""XX"" = 13 --> Check failed on
point ""XX"" = 3;

The controller is waiting the

AGV WAIT traction requests to allow a This problem is due to AGV master
107
RELEASE state transition between "AGV device (MIR)
mode" and "MANUAL mode"

Missed or wrong at least one of

AGV CAN the AGV messages (with ID This problem is due to AGV master device
108
BUS KO 0x208, 0x218) from "AGV (MIR)
master device" (MIR)

73
Code Error Text Explanation Troubleshooting

With ""AGV CHECK LEVEL"" = 0 -->

Alarm disabled and ""AGV mode""
request wired (A31-DI4) not evaluated
for mode transitions.
With ""AGV CHECK LEVEL"" = 1 -->
Mismatch of CAN and wired (A31-DI4)
AGV SIGNAL This problem is due to AGV master
109 ""AGV mode"" requests.
MISM. With ""AGV CHECK LEVEL"" = 2 -->
device (MIR)
Mismatch of CAN and wired (A31-DI4)
""AGV mode"" requests or mismatch
of CAN ""AGV mode"" requests on
messages ID 0x208 (traction) and
0x218 (EPS)

AUX OUT OF
110 Aux pot out of the normal range
RNG

VACC AUX The output of aux pot is present, but the

111
NOTOK enable switch is not active

Done the wrong way of aux pot

ALL ACQU.
112 teaching
AUX

‘DIAG ENC ERROR’ ） Encoder error

diagnosis. Activates ‘HEIGHT ENC
HEIGHT ENC ERROR’ alarm in case of fork height
113
ERROR delta over ‘ENC ERROR TH. MM’ in less
of ‘ENC ERROR MS’.

74
Code Error Text Explanation Troubleshooting

SHELF
Height request under ‘0-SENSOR POS
114 WRONG
MM’
REQ.

Shelf selector activation request before the release shelf selector request
SHELF WAIT and check the height
115 initialization of the height measurement
HEIG. measurement system

SHELF WR. INP: xx’ ） Bit 0 of xx: pick and

place request bits both active or both not
active.
‘SHELF WR. INP: xx’ ） Bit 1 of xx: Changed
pick and place request bits or ‘height
request’ during the state machine sequence;
‘SHELF WR. INP: xx’ ） Bit 2 of xx: ‘HEIGHT
OFFS A MM’ higher than ‘HEIGHT OFFS B
MM’;
‘SHELF WR. INP: xx’ ） Bit 3 of xx: ‘HEIGHT
SHELF WR. OFFS A MM’ out of range.
116
INP: ‘SHELF WR. INP: xx’ ） Bit 4 of xx: ‘HEIGHT
OFFS B MM’ out of range.
‘SHELF WR. INP: xx’ ） Bit 5 of xx: ‘SHELF
CUTBACK MM’ out of range.
‘SHELF WR. INP: xx’ ） Bit 6 of xx: ‘SHELF
CUTBACK SP’ out of range.
‘SHELF WR. INP: xx’ ） Bit 7 of xx: ‘HEIGHT
TOLER. MM’ out of range or higher than
(‘HEIGHT OFFS B MM’ - ‘HEIGHT OFFS A
MM’) / 2;

CAN message timeout of the shelf selector

CAN SHELF Check can wiring
117 messages between traction and pump
SELEC. controller.

Bit 0 of xx: height region 3 is not

present. There is a tolerances
HEIGHT WR. intersection.
118 Bit 1 of xx: height region 0 is not present.
TOL
The lower ‘FREE LIFT TOL.’ border goes
under zero millimeters

75
Code Error Text Explanation Troubleshooting

DIAG UNDER MIN.’ ） Under minimum

diagnosis. Activates the bit 0 of xx of the
‘HEIGHT ZERO xx’ alarm in case of under
zero millimeters forks height detection;
‘DIAG Z.SW LEVEL’ ） Switch level
diagnosis. Activates the bit 1 of xx of the
‘HEIGHT ZERO xx’ alarm in case of switch
excited on height regions 0, 1, 2, 3. Activates
the bit 4 of xx of the ‘HEIGHT ZERO xx’
alarm in case of switch not excited on height
HEIGHT region 6. This problem is due to AGV
119 ‘DIAG Z.SW VS SPD’ ） Zero switch vs
ZERO master device (MIR)
encoder speed diagnosis. Checks if the zero
switch edges matches with encoder speed.
Activates the bit 2 of xx of the ‘HEIGHT
ZERO xx’ alarm in case of zero switch
positive edge and negative encoder speed.
Activates the bit 3 of xx of the ‘HEIGHT
ZERO xx’ alarm in case of zero switch
negative edge and positive encoder speed.
This diagnosis is made on height regions 4,
5.

Encoder locked diagnosis. Active on forks

height regions 3, 4, 5, 6. Activates ‘HEIGHT
ENC LOCK.’ alarm in case of height not
increased over the value of ‘MOVING
HEIGHT THRES. MM’ for more than ‘MAX STILL
120 ENC T. MS’ and lift function active over ‘PUMP
LOCK. SPD THRES.’ speed or in case of height
not decreased over the value of ‘MOVING
THRES. MM’ for more than ‘MAX STILL T.
MS’ and lower function active.

CAN ENC
121 Can Encoder in alarm
IN ALARM

Wrong/failed can encoder setting ‘CAN

ENC SDO xx’ ） xx bit 0: CAN
ENCODER has not responded to 10
attempt to set the configuration #5; ‘CAN
CAN ENC ENC SDO xx’ ） xx bit 1: CAN
122 ENCODER has a wrong configuration.
SDO
‘CAN ENC SDO xx’ ） xx bit 7: Traction
SDO state machine for CAN ENCODER
management in error

76
Code Error Text Explanation Troubleshooting

Check the lift limit switch perform a reset of the switch

LIFT LIMIT Limit SW in alarm (lift above the SW and lower below the SW)
123
ERROR

FROM
Alarm received from EP
124 REMOTE remote device
DEV

Model TYPE and Inverter Check the coherence between the HW and the
WRONG INV. Type do not match with parameter settings
125
MODEL the HW

POT -
128 -
MISMATCH

1-Check the parameter controller type in

Wrong set of controller "special adjustment" menu
WRONG type and model type
129 2-Check the parameter model type in "special
CONFIG
adjustment" menu

1-Do the teaching again

REACH OUT Reach pot out of the
130 normal range 2-Check the wiring of the reach pot
OF RNG

77
Code Error Text Explanation Troubleshooting

VACC The output of reach pot

1-Check the reach pot
131 REACH is present, but the
NOTOK enable switch is not 2-Check the wiring
active

ALL ACQU. Do the wrong way

132 Perform calibration correctly
REACH of reach pot
teaching

"TLT OUT OF
RANGE Tilt pot out of the 1-Perform calibration correctly
133
TILT OUT OF normal range
2-Check the wiring of the tilt pot
RNG"

the output of tilt pot is 1-Check the tilt pot

VACC TILT present, but the enable
134 switch is not active 2-Check the wiring
NOT OK

"SFT OUT OF Side shift pot out of the 1-Perform calibration correctly
RANGE normal range
135 2-Check the wiring of the side shift pot
SHIFT OUT
OF RNG"

78
Code Error Text Explanation Troubleshooting

The output of side shift

VACC SHFT 1 - Check the side shift pot
136 pot is present, but the
NOT OK enable switch is not 2- Check the wiring
active

Do the wrong way of Perform calibration correctly

ALL ACQU.
137 tilt pot teaching
TILT

Do the wrong way of Perform calibration correctly

ALL ACQU.
138 side shift pot
SHIFT teaching

The controller lost the

"NO CAN communication with EP 1-Check the wiring of can cable
TILL EP tiller at least once, when
139 2-Try to replace the EP tiller
NO CAN the truck is using
TILLER EP" 3-Replace the controller

"WAIT TILL Wait the EP tiller CAN- 1-Check the wiring of can cable
EP BUS communication
140 when key-on 2-Try to replace the EP tiller
WAIT TILLER
EP" 3-Replace the controller

79
Code Error Text Explanation Troubleshooting

If set the PEDAL BRK 1-Check the wiring of can-brake

TYPE is option#1, but
NO CAN 2-Check if the can-brake is broken
141 the controller can't get
BRAKE EP the can message from
brake, the alarm 3-Try to set the PEDAL BRK TYPE=NONE
occurs.

If download a SW with
activation function, but Do activation with EP TOOLS.
WAIT
142 haven't do any activation
ACTIVATION
before, the alarm occurs.

If the EP PASSWORD
function is active but 1-Enter the correct password
WRONG
143 haven't enter the correct
PASSWORD password, the alarm
2-Disable the password function
occurs

When the truck is

running, if the
DISPLAY TYPE=5, but 1-Check the communication wiring between EP
NO CAN the controller loses DISPLAY and controller
144
DISP EP communication with EP
2-Check if the EP DISPLAY is broken
DISPLAY, this alarm
occurs

If the DISPLAY 1-Check the communication wiring between EP

TYPE=5, but the DISPLAY and controller
controller can't get
WAIT DISP message from EP 2- Check if the EP DISPLAY is broken
145 DISPLAY when the
EP 3- Try to set the DISPLAY TYPE into a correct
truck starts, this alarm
value
occurs

80
Code Error Text Explanation Troubleshooting

If the rental function is

RENTAL active, but the rental 1-Check the rental hour left in TESTER menu
146
TIMEOUT enable time is run
out, this alarm occurs 2-Use EP TOOLS to disable the rental function

If the communication 1-Check the communication wiring between

BMS and controller
NO CAN BMS between BMS and
147 controller is out of
EP
time, this alarm
occurs 2-There's a fault on BMS can device, replace the
BMS

If the battery charge level

1-Check the battery charge level
EP BMS MC is too low, the BMS
148
OPEN require the main contactor 2-Check if the battery is ok
open, this alarm occurs
3-Replace the BMS

If the battery charge

level is too low, the BMS 1-Check the battery charge level
EP BMS require the controller to
149 reduce the traction 2-Check if the battery is ok
TRAC CTB
speed, this alarm occurs
3-Replace the BMS

If the battery charge

level is too low, the 1-Check the battery charge level
BMS require the 2-Check if the battery is ok
EP BMS LIFT controller to stop the lift
150 3-Replace the BMS
STOP function, this alarm
occurs

81
Code Error Text Explanation Troubleshooting

If the battery charge level 1-Check the battery charge level

is too low, the BMS
EP BMS 2-Check if the battery is ok
151 require the controller to
TRAC STOP stop the traction function, 3-Replace the BMS
this alarm occurs

IIC BUS
152 For DualACE2 NG
ERROR

It is necessary to acquire
the offset angle between
the stator and the speed
OFFSET sensor, i.e. they mutual Perform the teaching procedure: in OPTIONS,
153 angular misalignment. An select ABS SENS. ACQUIRE.
SPD.SENS.
automatic function is
dedicated to this
procedure.

SIXSTEP
154 - -
ERROR

The controller is waiting

for the motor to stop
WAIT rotating. This warning
155 MOTOR can only appear in
STILL controllers for brushless
motors.

82
Code Error Text Explanation Troubleshooting

- This problem is due to AGV master device

156 REMA T. ALARM (MIR)

INPUT For DualACE2 NG

157
MISMATCHXX

NOT RDY DRV. -

158
POW.

Wrong voltage detected

by feedback circuit on
STEERING the steering contact.
159
CONTACT Examinate the wiring.

SENS BAT TEMP -

160
KO

Incorrect start
INC. START sequence related to the
161
GEAR gear switch (only in
ECB configuration)
Active if battery
BATTERY charger input is high
162 (only in ACEX NG
CHARGER
pedestrian truck)

ED SLIP
163
MISMATCH

164 TH. PROT. PUMP

83
Code Error Text Explanation Troubleshooting

SPEED For DualACE2

168 This problem is due to AGV master device (MIR)
FB.ERR. XX NG

SP
For DualACE2
169 MISMATCH
NG
XX
1- Check if the SET KEY VOLTAGE parameter in the
ADJUSTMENTS list is set in accordance with the key
The measured
voltage.
key voltage is not
WRONG KEY
170 the right one for
VOLT. 2- Check if the key voltage is ok using a voltmeter, if not
the inverter.
check the wiring.

3- In case the problem is not solved, replace the logic

board.
ACQUIRING
171 A.S. - -
ACQUIRE
172 - -
ABORT
ACQUIRE
173 - -
END
SPEED FB.
175 - -
ERROR
INT. For DualACE2 NG
176
CANBUSKO

1- Check the connections between the controller

outputs and the loads.

This alarm 2- Collect information about characteristics of the coil

occurs when an connected to the driver and ask for assistance to an EP
overload of the technician to verify that the maximum current that can be
COIL SHOR. supplied by the hardware is not exceeded.
177 EB driver
EB.
occurs.
3- In case no failures/problems have been found, the
problem is in the controller, which must be replaced."

1- Check the temperature read by the thermal

sensor inside the motor through the MOTOR
The temperature
TEMPERATURE reading in the TESTER function.
sensor has
MOTOR overtaken
178 2- Check the sensor ohmic value and the sensor
TEMP. STOP the threshold
defined by STOP wiring.
MOTOR TEMP. 3- If the sensor is OK, improve the cooling of the
motor.

4- If the warning is present when the motor is cool,

replace the controller.

84
Code Error Text Explanation Troubleshooting

The voltage read by the 1- Acquire the maximum and minimum values coming
microcontroller at the from the steering potentiometer through the STEER
steering-sensor input is ACQUIRING function. If the alarm is still present,
not within the STEER check the mechanical calibration and the functionality
STEER RIGHT VOLT of the potentiometer.
179 ÷ STEER LEFT VOLT
SENSOR KO 2- If the problem is not solved, replace the logic
range, programmed
through the STEER board.
ACQUIRING function

The motor current has If the alarm condition occurs again, ask for
overcome the limit fixed assistance from an EP technician.
180 OVERLOAD
by hardware. The fault condition could be affected by wrong
adjustments of motor parameters.

Mismatch between
WRONG ENC parameters ENCODER Set the two parameters with the same value,
181 according to the adopted encoder
SET PULSES 1 and
ENCODER PULSES 2

No load is connected
1- Check the EVP2 condition.
between the EVP2
EVP2 COIL output and the electro 2- Check the EVP2 wiring.
182
OPEN valve positive terminal.
3- If the problem is not solved, replace the logic
board.

1- Check if there is a short circuit or a low-

impedance conduction path between the
negative of the coil and -B.
1- The EVP2 driver is
shorted. 2- Collect information about:
• the voltage applied across the EVP2 coil.
2- The microcontroller • the current in the coil.
EVP2 DRIV. detects a mismatch • features of the coil.
183
SHORT between the valve set- Ask for assistance from EP to verify that the
point and the feedback of software diagnoses are in accordance with the type
the EVP2 output of coil employed.

3- If the problem is not solved, it could be necessary

to replace the
controller.

The EVP2 driver is not

EVP2 able to drive the EVP2 This fault is not related to external components.
184 DRIVER coil. The device itself or Replace the logic board.
OPEN its driving circuit is
damaged.

TILLER
185 - -
ERROR

85
Code Error text Explanation Troubleshooting

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 because the
motor connected to -P is not still.
For this reason, the software 1- If the motor connected to -P is still
waits 30 seconds for the voltage moving, just wait for it to be still.
to be at the “steady state” value
WAIT MOT.P 2- If not, in 30 seconds the alarm PUMP
186 (and for the pump motor to
STILL be still). After this time, the VMN NOT OK will appear.
software assumes that the
problem is not because the pump
motor is not still and show the
PUMP VMN NOT OK alarm.

1-Check the microswitches status

If there's more than one pump
MANY PUMP 2-Check the wiring of pump functions
187 function request, e.g. lift+tilt, the
REQ. alarm occurs 3-Disconnect the wire on the controller
side
4-If the problem is not solved, replace the
logic board.

1-It is suggested to repeat the acquiring

The minimum voltage of the lift procedure of MIN LIFT and MAX LIFT
PUMP VACC potentiometer is not correctly set.
188
NOT OK 2-Check the wiring of the lift pot
3-Check if it's the lift pot fault

1- Check wirings.

Man-presence switch is not 2- Check microswitches for failures.

PUMP INC enabled at pump request
189 3- Through the TESTER function,
START check the states of the inputs are
coherent with microswitches states.
4- If the problem is not solved, replace the
logic board.

86
Code Error Text Explanation Troubleshooting
1- The motor connected to -P must be
Switching the LC on, the completely still before this alarm occurs. The
software checks the software waits 30 seconds before showing this
output voltage on -P alarm. During this time, it shows the WAIT
connector and expects MOTOR STILL warning.
PUMP VMN that it is at a “steady
190 state” value (if DC PUMP 2- Motor internal connections
NOT OK
option is set to ON, see 3- Motor power cables connections
HYDRO SETTINGS).
If the voltage is too low, 4- Motor leakage to truck frame
this alarm occurs.
5- If the motor connections are ok, the problem is
inside the controller it is necessary to replace the
logic board.
In standby condition
(pump motor not driven),
the feedback coming
from the current sensor This type of fault is not related to external
PUMP I NO components; replace the
191 in the pump chopper
ZERO gives a value out of controller.
a permitted range,
because the pump
current is not zero.

For COMBIAC0 and

COMBIACX）it means
PUMP VACC the output of lift pot
192
RANGE is out of the normal
range

1- Verify that the EB coil is connected correctly

between pin A2 and pin A4.

There is a hardware 2- Verify that the parameter POSITIVE E.B.is set

problem in the smart in accordance with the actual configuration (see
driver circuit. The driver paragraph 8.2.5). The software, in fact,
SMARTDRIVER is set to be ON, but the depending on specific parameter value,
193 makes a proper diagnosis, a wrong configuration
KO output voltage does not
increase of this parameter could generate a false fault.

3- In case no failures/problems have been

found, the problem is in the
controller, which must be replaced.

87
Code Error Text Explanation Troubleshooting

For the versions where the smart driver is

not installed (36/48V and 80V), it is
possible to decide where the positive
supply for pin A2 comes from by choosing
a dedicated hardware configuration. The
parameter POSITIVE E.B. has to be set
in accordance with the hardware
configuration, because the software 1- Verify that the parameter
makes a proper diagnosis depending on POSITIVE E.B. is set in
the parameter; a wrong setting could accordance with the
generate a false fault. The available actual coil positive supply
choices are: (see the Built-In Side Shifter
- 0 = PEB is managed by the smart driver Section)
AUX BATT. (available for 24V version only).
194 2- In case no failures/
SHORT. - 1 = PEB comes from the TILLER
problems have been found, the
input (A1).
problem is in the controller,
- 2 = PEB comes from PEV (A3). PEV which must be replaced.
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."

1- Verify that the parameter

POSITIVE E.B. is set in
accordance with the
actual coil positive supply
The voltage on pin A2 is high even if the 2- Check if there is a short or
POS. EB. smart driver is turned OFF a low impedance path
195 between pin A2 and of
SHORTED
the +B. In case no failures/
problems have been found, the
problem is in
the controller, which must be
replaced.

88
Code Error text Explanation Troubleshooting

1- Verify the motor phases

connection on the motor side.
Short circuit between two motor phases.
The hexadecimal value “XX” identifies the 2- Verify the motor phases
shorted phases: connection on the inverter side.
MOT.PHASE 36: U – V short circuit 37:
196
SH. U – W short circuit 38: V– W 3- Check the motor power
short circuit cables.

4- Replace the controller.

5- If the alarm does not

disappear, the problem is in the
motor. Replace it.

WRONG Wrong software version on supervisor uC. Upload the correct software
197 version
SLAVE VER.

At start-up there is a mismatch in the

M/S PAR parameter checksum between the Restore and save again the
198 master and the supervisor parameters list.
CHK MISM
microcontrollers.

Wait until the end of the

Master uC is transferring parameters to procedure. If the alarm remains
PARAM
199 the supervisor. longer, re-cycle the key.
TRANSFER

1- Check that the battery has the

The logic board measures a voltage same nominal voltage of the
value across the DC-link that is inverter.
VDC OFF constantly out of range, above the
200 maximum allowed value 2- Check the battery voltage, if
SHORTED
it is out of range replace the
battery.

3- If the battery voltage is ok,

replace the logic board.

TORQUE Check in the HARDWARE

There is an error in the choice of the SETTINGS list the value of those
201 PROFILE torque profile parameters. parameters.

89
Code Error Text Explanation Troubleshooting

This fault is displayed when the

controller detects an overvoltage
condition. Overvoltage threshold
depends on the nominal voltage of
the controller.
Nominal voltage 24V 36/48V 72/80V
96V
Overvoltage threshold 35V 65V 115V If the alarm happens during the
130V brake release, check the line
VDC LINK As soon as the fault occurs, power contactor contact and the battery
202 bridge and MC are opened. The
OVERV. power- cable connection.
condition is triggered using the same
HW interrupt used for undervoltage
detection, uC discerns between the
two evaluating the voltage present
across DC-link capacitors:
- High voltage Overvoltage
condition
- Low/normal voltage Undervoltage
condition

The Mcu and the Scu check the This type of fault is related to internal
HW FAULT status of the main contactor is components. Replace the logic
203
MC different from each other. board.

1- Check the mechanical calibration

and the functionality of the brake
The CPOT BRAKE input read by the potentiometer.
microcontroller is out of the range
BRAKE RUN 2- Acquire the minimum and
204 defined by parameters SET PBRK.
OUT MIN and SET PBRK. MAX maximum potentiometer values.

3- If the alarm is still present,

replace the logic board.

The controller receives from EPS

EPS RELAY information about the safety Verify the EPS functionality
205
OPEN contacts being open.

Before closing the LC, the software 1- Check the motor power cables.
checks the power-bridge voltage
without driving it. The software 2- Check the impedance between U,
expects the voltage to be in a V and W terminals and -B terminal of
“steady state” value. If it is too high, the controller.
this alarm occurs. The hexadecimal 3- Check the motor leakage to
INIT VMN value “XX” identifies the
206 truck frame.
HIGH faulty phase: 81:
phase U 4- If the motor connections are OK
82: phase V and there are no external low
83: phase W impedance paths, the problem is
inside the controller. Replace it.

90
Code Error Text Explanation Troubleshooting

Before closing the LC, the software 1- Check the motor power cables.
checks the power-bridge voltage
2- Check the impedance between U,
without driving it. The software
V and W terminals and -B terminal of
expects the voltage to be in a
the controller.
“steady state” value. If it
is too low, this alarm occurs. The 3- Check the motor leakage to
INIT VMN hexadecimal value “XX” identifies
207 truck frame.
LOW the faulty phase: 01: phase U
02: phase V 4- If the motor connections are OK
03: phase W and there are no external low
impedance paths, the problem is
inside the controller. Replace it.

This type of fault is related to internal

The connection of the EEPROM is components. Replace the logic
208 EEPROM KO not ok board.

The controller has restored the

1- A travel demand or a pump
default settings. If a CLEAR
request does cancel the alarm.
PARAM EEPROM has been made before the
209 last key re-cycle, this warning 2- If the alarm appears at key-
RESTORE
informs you that EEPROM was on without any CLEAR EEPROM
correctly cleared. performed, replace the controller.

The algorithm implemented to check

the main RAM registers finds wrong Try to switch the key off and then on
WRONG contents: the register is “dirty”. This again, if the alarm is still present
210
RAM MEM. alarm inhibits the machine replace the logic board.
operations.

1- Check the encoder condition.

2- Check the wiring.
The traction rotor is stuck, or
STALL the encoder signal is not 3- Through the TESTER function,
211 correctly received by the
ROTOR check if the sign of FREQUENCY and
controller ENCODER are the same and if they
are different from zero during a
traction request.
4- If the problem is not solved, replace
the logic board.

Ask for assistance to an EP

The error between the power setpoint technician about the correct
POWER
212 and the estimated power is out of adjustment of the motor
MISMATCH range. parameters.

91
Code Error Text Explanation Troubleshooting
1- Verify LC coil is properly connected.

2- Verify CONF. POSITIVE LC parameter is set in

accordance with the actual coil positive supply (see
The positive voltage of the Built-in Side Shifter Section). Software,
POSITIVE LC is different from depending on the parameter value, makes a proper
213 expected.
LC OPEN diagnosis; a mismatch between the hardware and
the parameter configuration could generate a false
fault.

3- In case no failures/problems have been found, the

problem is in the controller, which must be replaced.
No load is connected
1- Check the EVP condition.
between the EVP
EVP COIL output (A24) and the
214 2- Check the EVP wiring.
OPEN electro valve positive
terminal.
3- If the problem is not solved, replace the logic
board.
1- Check if there is a short circuit or a low-
impedance conduction path
1- The EVP driver
between the negative of the coil and -B.
(output A24) is
shorted.
2- Collect information about:
2- The microcontroller
• the voltage applied across the EVP coil.
EVP DRIV. detects a mismatch
215 • the current in the coil.
SHORT. between the valve set-
• features of the coil.
point and
Ask for assistance to EP to verify that the software
the feedback of the
diagnoses are in accordance with the type of coil
EVP output.
employed.
If the problem is not solved, it could be necessary to
replace the controller.
This fault appears 1- Check the EB coil.
when no load is
EB. COIL connected between 2- Check the wiring.
216 the NEB output (A4)
OPEN
and the EB positive 3- If the problem is not solved, replace the logic
terminal PEB (A2). board.

Terminal PCOM is
not connected to the
battery, or the
voltage is different
from that defined by 1- Check PCOM terminal: it must be connected to
parameter SET the battery voltage (after the main contactor).
POSITIVE PEB (see
PEV NOT the ADJUSTMENTS
217 list, paragraph 8.2.3). 2- Set the nominal PCOM voltage in parameter
OK
This alarm can occur if SET POSITIVE PEB in ADJUSTMENTS list (see
output NAUX1 is present the Mast Tubing Section).
(and the related setting
is active) or the AUX
OUT function is active.

92
Code Error Text Explanation Troubleshooting
1- Check if the resistance of the sensor is what
expected measuring its resistance.
The output of the motor
SENS MOT thermal sensor is out of
218 2- Check the wiring.
TEMP KO range.
3- If the problem is not solved, replace the logic
board.

Only for AC3 and 1- Check PCOM terminal: it must be connected to

ACE3）the PEB and the battery voltage (after the main contactor).
PEB-PEVP PEV voltage is not
219 2- Set the nominal PCOM voltage in parameter
NOT OK match the parameter
SET POSITIVE PEB in ADJUSTMENTS list.
setting

At key-on, the logic

board measures 1- Check that the battery has the same nominal
a voltage value of voltage of the inverter.
the KEY input that is
VKEY OFF 2- Check the battery voltage, if it is out of range
constantly out of
220 replace the battery.
SHORTED range, below the
minimum allowed 3- If the battery voltage is ok, replace the logic
value. board.

1- Check that the handbrake is not active by

mistake.
2- Check the SR/HB input state through the
Handbrake input is TESTER function.
221 HANDBRAKE active. 3- Check the wirings.
4- Check if there are failures in the
microswitches.
5- If the problem is not solved, replace the logic
board.
This alarm can appear
only in a Traction +
Pump configuration or in 1- Check if there are wrong connections in the
a multimotored one. external wiring.
There is an input
2- Using the TESTER function, verify that the seat
SEAT mismatch between the
222 traction controller and
inputs are in accordance with the actual state of
MISMATCH the external switch.
the pump controller
relatively to the 3- In case no failures/problems have been found, the
TILLER/SEAT input (A1): problem is in the controller, which must be replaced.
the two values recorded
by the two controllers are
different.

93
Code Error Text Explanation Troubleshooting

1- Check the connections between the

controller outputs and the loads.
MC-EF COIL
SHOR.(For 2- Collect information about characteristics of the
ACE2, ACE3) This alarm occurs when coil connected to the driver and ask for assistance
MC-EB an overload of the MC to a EP technician in order to verify that the
223
driver maximum current that can be supplied by the
COIL SHOR.
hardware is not exceeded.
(For ACE2,
ACE3) 3- In case no failures/problems have been
found, the problem is in the controller, which
must be replaced.

1- Check the connections between the

controller outputs and the loads.

COIL SHOR. This alarm occurs 2- Collect information about characteristics of the
MC (For when an overload of coil connected to the driver and ask for
223 Combi AC0/ the MC driver assistance to a EP technician in order to verify that
Combi ACX the maximum current that can be supplied by the
and ACE4) hardware is not exceeded.
3- In case no failures/problems have been
found, the problem is in the controller, which
must be replaced.
The controller receives
from the CAN bus the
message that another
controller in the net is in
fault condition;
consequently, the Check if any other device on the CAN bus is in
WAITING controller itself cannot fault condition.
224 enter into an operative
FOR NODE
status, but it has to wait
until the other node
comes out from the fault
status.

the current sensor of

CURRENT the controller cannot be
This type of fault is related to internal
225 components. Replace the logic board.
SENS. KO driven or always 0

94
Code Error Text Explanation Troubleshooting

1- The CPOT
input read by the
1- Acquire the maximum and minimum
microcontroller is not
potentiometer values through the PROGRAM
within the MIN VACC
VACC function. If the alarm is still present, check
÷ MAX VACC range,
the mechanical calibration and the functionality of
programmed through
VACC OUT the PROGRAMM
the accelerator potentiometer.
226
RANGE VACC function. 2- If the problem is not solved, replace the logic
board.
2-The acquired
values MIN VACC
and MAX VACC are
inconsistent.
At start-up, some
hardware circuit
intended to enable
and disable the power
bridge, or the LC This type of fault is related to internal
driver (output A12) is components. Replace the logic board.
227 HW FAULT found to be faulty. The
hexadecimal value
“XX” facilitates EP
technicians debugging
the problem.

1- Activate the tiller/seat input.

2- Check the tiller/seat input state through the
Tiller/seat input has TESTER function.
TILLER been inactive for more
228 than 120 seconds. 3- Check the wirings.
OPEN
4- Check if there are failures in the microswitches.
5- If the problem is not solved, replace the logic
board.
At start-up, the
hardware circuit
dedicated to enable
and disable the EB This type of fault is not related to external
driver (output A4) is components. Replace the logic
HW FAULT
229 found to be faulty. The board.
EB. hexadecimal value
“XX” facilitates EP
technicians debugging
the problem.

This fault appears

when no load is 1- Check the wiring, to verify if LC coil is connected to
connected between the right connector pin and if it is not interrupted.
LC COIL the NMC output
230 2- If the alarm is still present, then the problem is
OPEN A12 and the positive
inside the logic board; replace it.
voltage (for example
the KEY voltage).

95
Code Error Text Explanation Troubleshooting

CONT. DRV. AUX valve driver is not The device or its driving circuit is damaged. Replace
232
EV able to drive the load. the controller.

1- Check that motor phases are correctly connected.

The DC-link voltage 2- Check that there is no dispersion to ground for

POWERMOS drops to zero when a every motor phases.
233
SHORTED high-side or low-side 3- In case the problem is not solved, replace the
MOSFET is turned on. controller.

1- Check if there is a short circuit or a low impedance

path between the negative terminal of the coils and –
AUX valve driver is B.
DRV. SHOR.
234 shorted.
EV 2- If the problem is not solved, replace the logic
board.

Check the parameter DUTY PWM CTRAP is

CTRAP It is a controller internal
correct. If the alarm is still, ask for assistance from
235 check fault
THRESHOLD an EP technician.

The maximum current

gain parameters are at
the default values, Ask for assistance from an EP technician to do the
CURRENT which means that adjustment procedure of the current gain
236 the maximum current parameters.
GAIN
adjustment procedure
has not been carried
out yet.

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 If the problem occurs permanently, it is
this diagnosis is to necessary to replace the logic board.
ANALOG detect a failure in the
237
INPUT A/D converter or a
problem in the code
flow that skips the
refresh of the analog
signal conversion.

96
Cod Error Text Explanation Troubleshooting
e

At start-up, the hardware circuit

dedicated to enable and disable This type of fault is not related to external
the EV drivers is found to be faulty. components. Replace the logic board.
238 HW FAULT EV. The hexadecimal value “XX”
facilitates EP technicians
debugging the problem.

The software is not compatible with

the hardware. Each controller
produced is “signed” at the end of line 1- Upload the correct firmware.
test with a specific code mark saved
CONTROLLE in EEPROM according 2- Ask for assistance from an EP technician to
239
R MISM. to the customized part number. verify that the firmware is correct.
According with this “sign”, only the
customized firmware can be
uploaded.

The EVP driver is not able to drive This fault is not related to external
EVP DRIVER the EVP coil. The device itself or its components. Replace the logic board.
240
OPEN driving circuit is damaged.

1- Check the connections between the

controller outputs and the loads.

2- Collect information about

This alarm occurs when an overload characteristics of the coils connected
of the EV drivers occurs. to the drivers and ask for assistance
COIL SHOR.
241 from an EP technician to verify that
EVAUX 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
must be replaced.

This fault appears when no load is

connected between one or more EV
outputs and the positive terminal 1- Check the coils.
PEV (pin A3). For the meaning of
2- Check the wiring.
code “XX”, refer to paragraph 10.5
242 OPEN COIL EVP1=BIT 0 EV1=BIT 1 3- If the problem is not solved, replace
EV. EV2=BIT 2 EV3=BIT 3 the
EVP2=BIT 4 EV4=BIT 5 logic board.
EV5=BIT 7 HORN=BIT 6

97
Code Error Text Explanation Troubleshooting

THROTTLE A wrong profile has been

243 set in the throttle profile. Set properly the throttle-related parameters
PROG.

WARNING Warning on supervisor Connect the Console to the supervisor uC and

244 uC. check which alarm is present.
SLAVE

The error between the Ask for assistance from an EP technician to do

Iq (q-axis current) the correct adjustment
IQ setpoint and the
245 of the motor parameters.
MISMATCHED estimated Iq is out of
range.

The EB coil driver is not

This type of fault is not related to external
able to drive the load.
components. Replace the logic
246 EB. DRIV.OPEN The device itself or its
board.
driving circuit is
damaged.

DATA Controller in calibration The alarm ends when the acquisition is

247 state. done.
ACQUISITION

CANbus communication
does not work properly. 1- Verify the CANbus network (external issue).
The hexadecimal value
248 NO CAN MSG. “XX” identifies the faulty 2- Replace the logic board (internal issue).
node.

This is a warning to
Turn on the CHECK UP DONE option after that
CHECK UP point out that it is time
249 the maintenance service.
NEEDED for the programmed
maintenance.

The output of the

THERMIC controller thermal This kind of fault is not related to external
250 components. Replace the controller.
SENS. KO sensor is out of range.

98
Code Error Text Explanation Troubleshooting

1- Check that the SET BATTERY parameter inside

the ADJUSTMENTS list matches with the battery
nominal voltage.
2- If the battery nominal voltage is not
At start-up, the available for the SET BATTERY parameter
controller checks the inside the ADJUSTMENTS list, record the
battery voltage value stored as HARDWARE BATTERY
(measured at the RANGE parameter in the SPECIAL ADJUST.
KEY input A10) and it list and contact an EP technician.
WRONG SET verifies that it is 3- Through the TESTER function, check that
251 within a range of ±20%
BAT. the KEY VOLTAGE reading shows the same
around the nominal value. value as the key voltage measured with a
voltmeter on pin A10. If it does not match,
then modify the ADJUST BATTERY
parameter according to the value read by the
voltmeter.
4- Replace the battery.

The error between the

Id (d-axis current)
FIELD setpoint and the Ask for assistance from an EP technician in order to
253 estimated Id is out of do the correct adjustment of the motor parameters.
ORIENT. KO
range.

1- The EB driver is 1- Check if there is a short or a low impedance path

shorted. between the negative coil terminal and -B.
2- The microcontroller 2- Check if the voltage applied is in accordance with
detects a mismatch the parameter settings.
EB. DRIV.
254 between the valve
SHRT. 3- If the problem is not solved, replace the
setpoint and the feedback
at the EB output. controller.

99
Electrical Schematic Diagrams

100
101
Cable Wiring Diagrams

No. Name No. Name

1 Battery Assembly 7 Pump Motor cable V
2 Battery Cable 8 Pump Motor cable W
3 Power Cable 9 Motor Cable W
4 Controller Cable + 10 Motor Cable V
5 Controller Cable - 11 Motor Cable U
6 Pump Power Cable U

102
Wiring Harness and Connectors

103
TROUBLESHOOTING

104
Preparation Before Troubleshooting
CAUTION
• Park the truck on level ground and block the
wheels with wedges or chocks. If the battery voltage is still abnormal after being
charged: open the battery compartment, check
• Fully lower the forks and press the emergency
the voltage of each battery and its connection
stop switch.
circuit respectively.
• Turn off the key switch.
• Open the cover and check the controller. 1) Check if the voltage of the battery is
normal.

CAUTION
2) Check if the cables for connections between
Even if the key switch is turned off, the each battery are normal, check for an open
controllers are still energized. circuit and if the connection between the
Before checking or repairing the controllers, connectors is secure.
make sure the battery plug has been
unplugged and the electrical circuit is • Battery leakage check: disconnect the battery
disconnected. connection, black probe (-) connected to
(-) terminal of battery plug; red probe (+)
connected to the chassis. Read the voltage
Check the Voltage of Battery reading on the meter.
- Press the button next to the BDI on the battery No voltage (0V): normal;
cover. It will turn on and display battery information. With voltage: battery leakage (remove battery
This means the battery BMS is not damaged. compartment, check each battery and cables)

- If the display does not turn on, BMS or BDI may

have issues. Check the wiring harness and
connections.
- Measure the DC voltage between KEY and
BATT+. The voltage should be higher than
72V, otherwise battery may have been over-
discharged.

i NOTE

Enter TESTER voltage. Menu to check the battery

105
Troubleshooting Solutions of Common Faults
Table 3.1 lists the common faults that may occur and handling methods.
Mainly consists of the following items:

Table 3.1 Troubleshooting of Common Faults

Fault Fault Symptom Probable Causes Troubleshooting

• Check the voltage of battery.

• Power supply failure.
• Check the fuses
• Fuse failure.
Power supply 1. Whole vehicle power • Check key switch and its
• Emergency stop switch circuit.
failure outage. or circuit failure.
• Check the emergency stop
• Key switch or circuit switch and its circuit.
failure.
Controller failure error, carry out
troubleshooting according to the
• Parking brake switch and seat fault code information on the
switch or its circuit instrument.
connection failure. • Check if parking brake
1. Vehicle will not • Gearbox failure. switch and seat switch or
travel in forward or • Travel switch or its circuit its circuit is normal.
reverse, but other connection failure. • Check the gearbox;
functions are • Drive motor or its circuit • Check the travel switch and
normal. connection failure. its circuit.
• Controller failure. • Check the drive motor and its
circuit.
• Replace the controller.

Travel Fault Controller failure error, carry out

troubleshooting according to the
Failures due to external factors:
fault code information on the
• Motor bearing blocked. instrument.
2. The vehicle can • Gearbox bearing blocked. 1. Remove the motor, check if
travel at low speed the motor rotation is
but cannot travel at Failures due to internal factors: normal.
high speed. • Drive motor speed 2. Check the speed encoder
encoder failure. and its connection
• Controller failure. circuit.
3. Remove the gearbox, check
if the gear rotation is
smooth and if there is
blocking.
4. Replace the controller.

3. Drive axle Bearings • Bearing fatigue damage or

1. Replace the bearings.
noise or jammed. foreign.

* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve them accordingly.

106
 Table 3.1 Troubleshooting of Common Faults

Fault Fault Symptom Probable Causes Troubleshooting

4. Abnormal tire 1. Replace the drive wheel.

wear, cracking or • Improper use. 2. Replace the rear steering
separation. wheel.

5. Drive wheel slipping

• Wear & tear. 1. Replace the drive wheel.
or jumping.
Travel Fault
6. Vehicle sways while
• Wheel lock nut loosening. 1. Tighten the nuts.
running.

• Insufficient brake fluid. 1. Add brake fluid.

7. Brake performance
• Brake master pump blocked. 2. Replace the master pump.
weakened or
• Brake pipeline leaks. 3. Replace the brake pipeline.
failure.
• Cable U, V, or W are broken.
1. Replace the Cable U, V, or W.
• Loosening connections to cable
2. Tighten the nut.
U, V or W.
1. Motor does not 3. Check the stator coil.
• Stator coil open circuit.
rotate. 4. Replace the motor bearing.
• Motor bearing damage.
5. Check the speed encoder, if
• Speed encoder or its circuit
necessary, replace it.
failure.
2. Motor is rotating
1. Remove the cables and re-in-
in slow speed and • Cable connection error.
stall.
reverse.

• Uneven clearance between the

1. Replace the drive motor
stator and rotor.
3. Motor with abnormal or pump motor.
• Bearing failures.
noise or vibration. 2. Replace bearings.
Motor Fault • Loosening fixing screws on motor
3. Tighten/Replace screws.
housing.

4. Motor smoking or • Stator winding short circuit, motor 1. Replace the drive motor or
burning smell. burnt. pump motor.

• Stator winding short circuit.

• Motor U, V and W terminals with
surface corrosion.
5. Motor temperature
• Bearing failure, resulting in 1. Refer to the rated capacity
too high, controller
severe heating. marked on the nameplate.
failure.
• Motor cooling duct blockage with
foreign body.
• Overload.

* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.

107
 Table 3.1 Troubleshooting of Common Faults

Fault Fault Symptom Probable Causes Troubleshooting

• Insufficient voltage of battery. 1. Check the voltage of battery.

• Overload. 2. Refer to the rated capacity
6. On load, motor
• U, V, W terminals with abnormal marked on the nameplate.
Motor Fault speed is turning
voltage input. 3. Check the battery output.
slow.
• Speed encoder or its circuit 4. Replace the speed encoder
failure. or wiring harness.

• Supporting bearing wear. 1. Replace the bearing.

1. Gearbox Abnormal
• Gear wear, the gap is too big. 2. Replace the gear.
Noise.
• Foreign objects in gear oil. 3. Replace the gear oil.

2. Gearbox Oil Leaks. • Oil seal wear or aged. 1. Replace the oil seal.
Gearbox Fault

• Gear fastening screws or nuts

1. Tighten the screws or nuts.
loosening.
3. Gearbox Stuck. 2. Replace the support bearing.
• Support bearing damage.
3. Replace the gear oil.
• Foreign objects in gear oil.

• Supporting bearing wear. 1. Replace the bearing.

1. Drive Axle Abnormal
• Gear wear, the gap is too big. 2. Replace the gear.
Noise.
• Foreign objects in gear oil. 3. Replace the gear oil.

Drive Axle
2. Drive Axle Oil Leaks. • Oil seal wear or aged. 1. Replace the oil seal.
Fault

• Drive Axle fastening screws or

1. Tighten the screws or nuts.
nuts loosening.
3. Drive Axle Stuck. 2. Replace the support bearing.
• Support bearing damage.
3. Replace the gear oil.
• Foreign objects in gear oil.

* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.

108
 Table 3.1 Troubleshooting of Common Faults

Fault Fault Symptom Probable Causes Troubleshooting

1. Pump motor does not work: 1. Pump motor does not work:
• Parking brake switch and seat i. Check if parking brake switch
switch or its circuit connection and seat switch or the
failure. connection of its circuit is
• Pump motor or its normal.
circuit connection ii. Check the pump motor and
failure. its connection circuit.
• Control switch or its iii. Check the control button
circuit connection failure. and its connection circuit.
• Controller failure. iv. Replace the controller.

2. Pump motor works:

2. Pump motor works: i. Refer to the rated
1. The vehicle cannot • Overload.
capacity marked on the
lift. • Insufficient hydraulic oil. nameplate.
• Hydraulic pipeline leakage. ii. Lower the mast to the bot-
• Pump motor reverse rotation. tom, check if the amount of
• Cylinder failure (blocked). oil in the oil tank can meet
• Solenoid valve blocked and the requirements.
cannot reset. iii. Check the pipe and hydraulic
Hydraulic • Valve body failure. components for oil leaks.
Failure • Excessive wear of gear pump, iv. Check the pump motor wiring.
serious internal leaks, insufficient v. Check the cylinder for
pressure of relief valve or damage or deformation,
blocked, check valve blocked. remove the cylinder to check
for wear or aged seals inside.
vi. Wash or replace the solenoid
spool.
vii. Wash or replace the valve
body.

1. Check the lowering button and

its connection circuit.
• Solenoid valve (or manual valve)
2. Check the solenoid valve
or its circuit connection failure.
and its connection circuit.
• Lowering switch or its
3. Check the cylinder for
2. The vehicle cannot circuit connection failure.
deformation, remove the
be lowered. • Valve failure.
cylinder to check if the internal
• Cylinder deformation or blocked.
assembly is normal.
• Explosion-proof valve blocked.
4. Clean or replace the valve.
5. Replace the explosion-proof
valve.

* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.

109
 Table 3.1 Troubleshooting of Common Faults

Fault Fault Symptom Probable Causes Troubleshooting

• Check the hydraulic oil level.

4. Insufficient oil.
• Replace the hydraulic oil.
5. High viscosity of oil.
• Check the oil suction pipe.
3. Noisy pump. 6. Oil suction pipe air leak.
• Clean the oil inlet piping,
7. Filters clogged by impurities.
replace the filter, if
8. Hydraulic oil with foam. necessary.
• See Fault 2.
• Check the amount of oil.
• Check if the viscosity of
hydraulic oil is normal.
4. Hydraulic oil with 4. Pump cavitation. • Check the oil inlet piping for
foam. 5. There is water in the oil. air leaks.
• Discharge, clean, and
replace with new hydraulic
oil.

4. Discharge, clean, and

5. Pump or oil • Oil is too thin. add new hydraulic oil.
temperature is too • Pump cavitation. 5. Check the oil inlet piping for
high. • Valve body internal relief. air leaks.
Hydraulic 6. Replace the valve body.
Failure

• Insufficient oil. • Check the hydraulic oil level.

6. Low System
• Relief valve failure. • See Fault 6.
Pressure.
• Pump wear, internal leakage. • Replace the gear pump.

i. Check and clean the solenoid

valve spool.
7. On load, declined. i. Solenoid valve failure.
ii. Check the multi-way manual
valve and its installation.

• Pressure adjustment screw too 1. Adjust to proper pressure

loose. through hydraulic
8. Relief valve pressure • Relief valve spring breakage or pressure gauge.
unstable or too low. deformation. 2. Replace the relief valve.
• Relief valve spool wear or 3. Clean or replace the relief
blocked. valve.

* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.

110
Table 3.1 Troubleshooting of Common Faults (continued)

Fault Fault Symptom Probable Causes Troubleshooting

• Overload. 1. Refer to the rated capacity

• Hydraulic pipeline leakage marked on the nameplate.
• Valve failure. 2. Check the pipe and hydraulic
1. Slow Lifting of
• Gear pump wear, internal components for oil leaks.
Vehicle.
leakage occurs. 3. Wash or replace the valve
• Insufficient relief valve pressure body.
or blocked.

1. Wash or replace the solenoid

• Solenoid valve blocking.
2. Slow Lowering of pool.
• Valve body failure: throttle valve
Lift Failure Vehicle. 2. Wash or replace the valve
failure or blocked.
body.

1. Adjust the chain tension.

• Chain loosening. 2. Check if the steel channel
• Poor lubrication between steel grease is normal, clean and
3. Unstable channel and rollers. relubricate steel channel and
Lifting/Lowering of • Improper adjustment of rollers or rollers.
Vehicle. blocked. 3. Adjust the side roller spacing
through roller screw; or
replace the roller.

• Valve failure.
1. Replace the manual valve;
• Valve seat blocked by large
2. Remove and clean the valve
impurities.
seat.
1. The vehicle cannot • External leakage.
3. Replace the sealing.
perform the i. sealing damaged.
4. Replace the screwed joint.
hydraulic control ii. poor threaded connection.
5. Replace the manual valve.
instructions. iii. valve body defects.
6. Replace the hydraulic oil with
• High viscosity of hydraulic oil.
lower viscosity.
• High frequency of use, service
Manual Valve 7. Replace the manual valve.
life has expired already.
Fault
• Overflow valve in the connection
1. Restart the truck.
block started.
2. Replace the valve seat.
• Valve seat leakage.
3. Clean the valve rod and, if
• Valve rod cannot push/pull to
8. Slow pace of necessary, replace the
bottom; the channel cannot be
actuator. valve.
fully opened.
4. Replace the hydraulic oil with
• High viscosity of hydraulic oil.
lower viscosity.
• High frequency of use, service
5. Replace the manual valve.
life has expired already.
* Under the circumstances of normal lifting and lowering, if failure occurs to any of other
hydraulic functions (forward/backward shifting, forward/backward tilting and left/right
shifting), perform troubleshooting to the corresponding control switch and its control circuit.

* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.

111
 Table 3.1 Troubleshooting of Common Faults (continued)

Fault Fault Symptom Probable Causes Troubleshooting

• Insufficient hydraulic oil. 1. Replace the hydraulic oil.

1.Gear pump does not • Pump body defects. 2. Replace the gear pump.
absorb oil or has low • Poor sealing with leakage. 3. Replace the sealing.
flow. • Oil filter clogging. 4. Clean or replace the oil filter.
• Oil temperature is too high. 5. Cool down the hydraulic oil.

1. Replace the gear pump.

• Pump body defects. 2. Replace the gear pump.
• Pump body with cracks or leaks. 3. Replace the hydraulic oil and
2. Insufficient gear
• Impurities in the pump, oil filter clean the gear pump.
pump output
Clogging. 4. Replace the hydraulic oil with
pressure.
• Low viscosity of hydraulic oil. higher viscosity.
• Oil temperature is too high. 5. Cool down the hydraulic oil.

• Pump body defects.

1. Replace the gear pump.
Gear Pump • Gear pump inlet tubing diameter
2. Replace the inlet tubing.
Fault is too small.
3. Too much vibration 3. Clean the oil filter, adjust the
• Oil filter clogging, or motorspeed
and noise. motor speed to a lower value.
is too high.
4. Remove and reinstall the
• Motor and oil pump shaft
motor.
misalignment.

1. Replace the gear pump.

• Pump body defects.
2. Remove and reinstall the seal
4. Oil leaks. • Seal skeleton spring off.
skeleton.
• Shaft sealing surface scratche
3. Replace the shaft seal.

1. Replace the gear pump.

• Pump body defects.
5. Pump is not 2. Remove and reinstall the gear
• Poor alignment of pump
functioning properly pump.
and motor coupling.
or blocked. 3. Remove and clean the gear
• Impurities in the pump.
pump.

1. Replace the redirector.

• Redirector defects; 2. Remove and reinstall the
1. Oil leaks.
• Poor sealing with leakage; redirector, if necessary,
replace the redirector.

Redirector
Fault 1. Replace the redirector.
• Redirector defects.
2. Redirector is not 2. Add the hydraulic oil.
• Insufficient oil.
functioning properly 3. Discharge the air in the oil.
• There is air in the oil.
or noise. 4. Replace the hydraulic oil with
• High viscosity of oil.
lower viscosity.

* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.

112
Table 3.1 Troubleshooting of Common Faults (continued)

Fault Fault Symptom Probable Causes Troubleshooting

Controller failure error, carry out

troubleshooting according to the
fault code information on the
instrument.
• The steering potentiometer
1. Check the steering
or its circuit has a
potentiometer or its
connection failure.
connection circuit.
1. The vehicle cannot • Redirector or hose
2. Check if the mechanical
connection failure.
be steered but can connection between steering
• Steer axle or hose
travel. wheel and redirector is solid.
connection failure.
3. Check the redirector or
• Pump motor failure
hose connections.
• Gear pump failure
4. Check the steer axle or
• Pump controller failure
hose connections.
5. Check the pump motor or its
Steering Fault connection circuit.
6. Check the pump.
7. Replace the controller.

2. Steer axle
• Supporting bearing wear. 1. Replace the bearing.
abnormal noise.

3. Steer axle oil

• Oil seal wear or aged. 1. Replace the Oil seal.
leaks.

4. Steer axle
• Support bearing damage. 1. Replace the bearing.
stuck.

* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.

113
Table 3.1 Troubleshooting of Common Faults (continued)

Fault Fault Symptom Probable Causes Troubleshooting

1. Check the light and its

a. Light failure or circuit not
circuit connection.
conducted
2. Check Lighting combination
b. Lighting combination switch or switch and its connection
1. Lights do not light its circuit connection failure circuit.
c. Fuse failure 3. Check fuse and its
connection circuit.
d. DC-DC converter failure
4. Check DC-DC converter
and its connection circuit.

Other Failures
1. Check the horn button and
its connection circuit.
a. Horn switch or its circuit 2. Check the horn and its
connection failure connection circuit.
2. Horn does not b. Horn failure 3. Check fuse and its
sound connection circuit.
c. Fuse failure 4. Check DC-DC converter
d. DC-DC converter failure and its connection circuit.

* Carry out trouble shooting in accordance with the order listed in the
table, it can help you quickly identify problems and resolve
accordingly.

114
Operation Manual
Lithium-ion Battery
Version 2.0
6/21/2023
Table of Contents
1. Introduction......................................................................................................... 1
1.1 Overview ...................................................................................................... 1
2. Getting Started .................................................................................................... 2
2.1 Safety & Warnings ........................................................................................ 2
2.2 Intended Use ................................................................................................ 3
2.3 Battery Management System ......................................................................... 3
3. Potential Hazards ................................................................................................ 4
3.1 Fire Hazard .................................................................................................. 5
3.2 Touch Voltage Hazard ................................................................................... 5
3.3 Battery Storage ............................................................................................. 5
3.4 Battery Handling ........................................................................................... 6
4. Performance Data ............................................................................................... 7
5. Battery Indicator .................................................................................................. 8
6. Transportation................................................................................................... 10
7. Service ............................................................................................................. 11
8. Troubleshooting & Recycling .............................................................................. 13
8.1 Damaged / Leaking Battery Handling ............................................................ 13
8.2 Charging .................................................................................................... 14
8.3 Recycling ................................................................................................... 15
9. Appendix A: Daily Spot Check Record................................................................. 16
10. Appendix B: Box Structure ................................................................................. 17

cxvi
Introduction
This manual is intended to provide information on correctly using the Li-ion battery and
maximizing its productivity and longevity through preventive maintenance and safe operation.
Operators should read through the manual before using the battery.
All the information, specifications, and illustrations in the manual are effective at time of print.
The company maintains the right to modify the specification(s) or design(s) of the products at
any time without prior notification.

Overview
Lithium-ion (Li-ion) batteries have many advantages over traditional lead acid and other types
of batteries. Big Lift’s Li-ion batteries are classified as LFP ‘Lithium Iron Phosphate’ or LiFePO4.
When stored, handled, and used properly, they also have a longer service life, a higher power
density, don’t need a cooling down period, and can be opportunity charged.
Big Lift’s priority is safety, and establishing the following safety procedures for storing, handling
and use of these batteries will help prevent fires and explosions.
Companies training employees to recognize the hazards of Li-ion and other types of batteries as
well as how to handle, store and manage them properly will help to avoid damage to the
batteries resulting in possible fires and explosions.
This battery should not be used at a very low SOC (state of charge) status. To ensure the
battery life, the operator should avoid the discharge depth of more than 80% of the rated
capacity of the battery. Whether it is partially discharged or fully discharged, the battery should
be immediately charged.
Lithium batteries have a special charger and may not be charged with other types of battery
chargers.
NOTE: A new battery from the factory should be fully charged before its initial use.

1
Getting Started
The lithium-ion battery unit is composed of battery cells in series or in parallel. It is equipped
with battery management system (BMS) for monitoring and protecting the lithium-ion battery.
The truck's key switch can control power supply of the battery. The circular meter shows various
data including SOC (State of Charge), error code, total voltage, and temperature.

Safety & Warnings

• Always wear personal protective equipment (PPE) (e.g., safety goggles and safety
gloves) when working on cells and batteries.
• Abide by the operation manual.
• Check the battery for leakage and mechanical damage before use and charging.
NOTE: STOP using the battery if leaking or damaged and follow the recycling
instructions found in section 8.3 in this manual. We recommend the battery be recycled
within 3 days.
• Inspect easy exchange batteries daily. See Appendix A for detailed daily inspection
instructions for the pallet truck easy exchange batteries. If new or replacement visual
inspection reminder decals are needed, they can be ordered via PN 056747.

• Check charger connectors and bracket for contamination daily, clean the bracket with a
dry cloth if needed.
• All operations related to the battery must be implemented under the instruction of
professionals.
• Do NOT smoke near the battery because it may cause fire.
• Do NOT place the battery near open flame, sparks, or energized wires as fire or
explosion may occur.
• Avoid short-circuiting the battery, as fire or explosion is likely to occur.
• Keep the battery away from all fire sources, heat sources, and flammable or
explosive materials.
• Don’t knock over the battery, drop the battery, or expose it to abusive vibration
applications.
• Use lifting and delivery devices as specified. Prevent the battery cell, interface, and
connection cable from being damaged by the lifting hook.
• If the internal battery components start to leak out, do not inhale the fumes. Always wear
PPE when in close contact with the battery.
• Wash hands after working on a battery.
• Use only insulated tools.
• Make sure the truck is turned off before connecting the battery.

2
 • The metal part of the battery cell is electrified, don’t place any external object or tool on
the battery cell.
• Do NOT place the battery on top of conductive objects.
• Do NOT trample on the battery to prevent it from fierce shaking.
• Protect the battery from solar or other forms of heat radiation.
• Do NOT physically alter the battery, strike, crush, compress, notch, dent or modify it in
any way.
• Do NOT open the battery without Big Lift Forklift’s official authorization.
• Do NOT spray wash the battery with water.

Intended Use
• Discharge/Operational application temperatures: 32° F - 104° F
• Charging application temperatures: 41° F - 104° F.
• Humidity＜ 80%.

• The battery's maximum operation altitude is up to 6500ft (2000m).

NOTE:
• A high-rate recharging operation below 0°C may lead to battery damage, so the
recommended charging temperature range is 41° F - 104° F.
• The discharging temperature range can be used in more extreme temperature
conditions as follows -4° F - 131° F however, this isn’t the recommended range for
optimal life which is identified above. Also, the truck may not be rated for those extreme
conditions or extended durations in a cold operating environment as that is truck and
option dependent.
o If used at low temperatures -4° F - 32° F, battery discharge capacity will be
smaller compared with one in normal temperature conditions.
o A battery used between 104° F - 131° F will accelerate the aging of the internal
material which may shorten the service life of the battery, so is not
recommended.

Battery Management System

The battery is permanently monitored by the Battery Management System (BMS). This provides
communication with the truck.
The BMS continually monitors items such as the cell temperature, voltage, and charge status of
the cells. It also functions as a safety cut-off device in case of overcharging, overcurrent, or
overheating.

3
Potential Hazards
Hazards are not anticipated if the equipment is used correctly. Do not use the equipment for
anything other than its intended purpose.

The following hazards can arise in the event of improper use:

Physical Damage:

This can occur if a battery falls or is deformed through pressure or high impact (e.g., truck forks
penetrate the battery housing).
Physical damage includes cracks, breakage, splinters, or holes in the battery housing. This type
of damage may be caused by a short circuit inside the battery, which may result in harmful
materials leaking, fire or battery explosion.
Some physical damage may not show on the battery enclosure, but there may be damage to
the internal cell pack, which could cause electrolyte leaking and short circuit. Always check for
leakage before use and charging.

Short Circuits:

These may be caused by inadvertently creating a connection between the two battery terminals
(e.g., battery immersed in water, battery leakage, contamination on the charger connector or
battery connector).

Temperature Effects:

High temperatures caused by sunlight or being stored in warm locations (e.g., near ovens) can
result in harmful material leakage and fire.
To avoid fire and leakage of harmful materials, a safe place for storing batteries must satisfy the
following criteria:
• Do not store in places often frequented by personnel.
• Do not store in places where valuable objects (e.g., cars) are stored.
• Fire extinguishers must be available to put out any fires.
• Caution should be taken with fire or smoke detectors in the vicinity to ensure that an
automatic fire detection system is only activated in the event of actual danger (e.g.,
naked flames).
• Small amounts of discharge from a single battery are not critical to the environment.
Above-average natural ventilation is required in this case.
• No ventilation intake pipes should be in the vicinity, as discharged content could spread
within a building.

Examples of where to store a non-functional battery:

• Covered area outdoors.
• Ventilated metal container.

4
 • Covered box with pressure and smoke discharge option.

Fire Hazard
Physical damage, thermal effects, or incorrect storage in the event of a defect can result in fire.
Please note that the battery materials can be flammable.
WARNING: Contact with combustion products can be hazardous. Fires produce combustion
products. Combustion is a chemical process by which a flammable material combines with
oxygen under heat and light (fire). The resulting combustion products can occur in the form of
smoke, leaking fluids, escaping gases, debris, as well as decomposition products of certain
chemicals. These combustion products are substances that enter the body through the
respiratory tract and/or the skin and can cause serious health issues.
Avoid contact with combustion products and use personal protective equipment (PPE).
• Hydrogen fluoride (HF) Hydrofluoric acid = extremely corrosive
• Risk of toxic substances produced by pyrolysis
• Risk of highly flammable gas mixtures
• Other combustion products: Carbon monoxide & -dioxide, manganese, nickel, and cobalt
oxides.
WARNING: If a lithium battery fire occurs, use a CO2 (Class BC) or dry chemical (Class ABC)
fire extinguisher. Lithium batteries do not have actual lithium metal so DO NOT use a Class D
fire extinguisher.

Touch Voltage Hazard

Hazardous contact voltages only arise in the event of a technical or physical defect. The
batteries are normally charged. There is still some residual voltage in a discharged battery. This
must be considered a hazardous contact voltage.

Battery Storage
Proper storage prevents damage to batteries and prolongs their life expectancy. Follow these
battery storage tips:
• Store in dry, well-ventilated areas
• Store in temperatures between 32º F and 104ºF
• Store away from direct sunlight and heat sources
• Keep terminals covered when the battery is not in use
• Prevent terminals from touching each other
• Store separately from other types of batteries
• Keep the battery charged and do not store it for an extended period with a low state of
charge (SOC) < 20%. It is recommended to maintain a charge level of 50% or greater.
• For long-term storage, the Li battery must be recharged every 2-3 months regardless of
the SOC level. If a battery is stored longer than six months without charging, the cell
may be damaged due to over-discharge. This can cause the cell to bulge and break the
battery enclosure.
5
IMPORTANT: Monitor battery condition daily when in use and storage.

Battery Handling
Improper handling can cause damage to batteries, which may lead to overheating, fires, or
explosions. Here are some tips for proper Li-ion battery handling:
• Remove batteries from devices that will not be used for an extended time.
• Keep batteries away from electromagnetic sources.
• Keep batteries intact.
• Keep batteries and charger in a clean location, do not expose battery or charger to water
or other type of contaminations.
• Clean charger bracket and connector/pin with dry cloth if needed, since foreign material
and contamination may accumulate in the bracket.
• DO NOT use batteries that show any signs of damage, they must be isolated.
• DO NOT modify the battery in any way.
WARNING: Damaged Li-ion batteries have the potential to leak electrolytes, so it’s important to
wear proper personal protective equipment (PPE) (goggles, gloves, apron, etc.) during handling.

6
Performance Data

Battery Nominal Data

Battery Cell
1 Cell material LFP
Battery System
2 Burst mode Parallel Circuit or Series Circuit
3 Ambient relative humidity ≤80%RH
4 Operational application temperature 32-104°F

BMS Nominal Data

Battery Management System Function
No Item Function Description
Monomer voltage Accurate acquisition of all cell voltage
1
detection data
Total voltage Accurate acquisition of total voltage
2
detection data
Temperature Accurate detection of battery
3
collecting temperature
Inspection /
Accurate detection of charge-discharge
4 Estimates Current inspection
currents
Hall sensor is used to obtain the input
and output current of the battery, and
5 SOC Estimate the SOC estimation of the battery is
carried out by the method of ampere time
integration
Communication CAN
6 Communication and debugging
Function communication
Short-circuit Power circuit short circuit, contactor
7
protection disconnect
Over current Over-current occurs, contactor
8
protection disconnect
Protection Overcharging Overcharge occurs, contactor
9
Function protection disconnect
Over discharging Over discharge occurs, contactor
10
protection disconnect
Over temperature Over temperature occurs, contactor
11
protection disconnect
Sleep awakening Charge communication wake-up,
12 Sleep Wake
function Battery switch button wake-up

7
Battery Indicator

No Name Description
When the first cell and the second flash alternately, battery is
low and must be charged.
1 Energy Display
The battery remaining charge is displayed; “100%” indicates
that the battery is fully charged.

2 Total Voltage The sum of the total voltages of the lithium battery series

3 Temperature Battery temperature

4 Charging Current Current value when charging the lithium battery

8
No Name Description

5 Maximum Cell Voltage Maximum value of cell voltage

Identification number of the cell with maximum

6 Number of Cell
voltage

7 Minimum Cell Voltage Minimum value of cell voltage

Cell Number of Minimum Cell Identification number of the cell with minimum
8
Voltage voltage

9
Transportation
Before transporting any lithium-ion battery, check the current regulations on the transport of
dangerous goods. Comply with these when preparing the packaging and transport. Train
authorized staff to dispatch lithium-ion batteries.
NOTE:
It is recommended that the original packaging is kept for any subsequent dispatch.
A lithium-ion battery is a special product.
Special precautions should be taken when:
• Transporting a truck equipped with a lithium-ion battery
• Transporting only the lithium battery
A class 9 danger label must be affixed to the packaging for transport.
Handling differs if the battery is transported on its own or in a truck. An example of a label
appears in this supplement (see figure below). Refer to the latest current regulations before
dispatch as the information might have changed since this manual was written.
Special documents must be sent with the battery. Refer to the applicable standards or
regulations.

For UN3480 Lithium-ion Batteries

Lithium-ion Batteries packed with Equipment

For UN3481
or Lithium batteries built into Equipment

10
Service
Lithium-ion batteries typically require no maintenance. If needed, only a certified technician
should perform any service or maintenance.
Big Lift Forklifts recommends following the maintenance schedule below. Record all battery
service, maintenance, and inspections to maximize the service life of your battery and lift truck.

No. Maintenance Content Method of Operation Notes Frequency

1 Check if battery Check instrumentation Make sure the battery is Everyday

capacity is too low SOC display not stored without charge
for a long period. If the
battery system needs to
be put on hold for a long
period, keep the battery at
a half power state and
charge the battery every 3
months to ensure that the
battery system remains in
a half power state.

2 The battery pack charge Check instrumentation Make sure battery pack Everyday
and discharge current display charge and discharge
current meet the operation
manual requirements.

3 Check connector pins at Perform a visual If any ablation or Everyday

the bottom of the battery inspection deformation is found,
(if present) replace the battery
connector pins.

4 Check if appearance is Perform a visual If deformed/damaged Everyday

deformed, whether inspection follow battery recycling
surface is oxidized, procedure.
paint is peeling, the
mounting position is
offset or if cabinet is
damaged

5 Check the entire battery Perform a visual If leaking, follow battery Everyday
as well as the surface inspection recycling procedure.
beneath it for signs of
fluid leakage

No. Maintenance Content Method of Operation Notes Frequency

6 Check if battery and Perform a visual Clean the lithium battery Weekly
charger are clean inspection and charger with a dry
cloth or compressed air
Wear insulated gloves
before performing
cleaning

11
 7 Check if external wiring Perform a visual Replace the wiring Weekly
harness has worn spots, inspection harness if damaged
imprints, creases, or
exposed wire

8 Check the surface of No dust, water, Clean the surface if dust, Weekly
lithium-ion battery for corrosion, oxidation, corrosion, oxidation, or
cleanliness rust, etc. rust is found.
Use a dustless cloth or air
compressor.
Using water is strictly
prohibited.

9 Ensure outside battery Tighten screws if Weekly

screws are tight necessary

10 Check for water or Perform a visual Monthly

foreign material in the inspection
plug and socket. Check
for rust or charring (if
necessary)

11 Check the cable for Perform a visual Monthly

damages or loose joints inspection
(if necessary)

12 Check the battery case Perform a visual Stop using the battery if Monthly
for abnormalities such inspection abnormalities are found
as cracks, deformation,
and bulging

NOTE: The manufacturer recommends using compressed air at less than 30psi (207kPa).

12
Troubleshooting & Recycling
During the use and maintenance of the lithium-ion battery, the battery or battery system may
have one or more of the following abnormal conditions.
Only trained technicians are allowed to perform the necessary processing according to the
instructions in this manual.
If there are any questions about the status or solutions, please contact Big Lift Forklifts dealers
or after-sales service department of the company to obtain professional technical support.
• If the battery is found to have abnormal mechanical characteristics such as swelling,
cracked casing, melted casing or distortion of the casing before and during installation,
stop using the battery immediately, place it in open and well-ventilated space, and
contact the after-sales service.
• If abnormalities such as looseness, cracks, cracks in the insulation layer, burn marks,
etc. of the battery's pole pressing bolts, conductive strips, main circuit wires, and
connectors are found before and during the installation, STOP using the battery
immediately.
• If the polarity of the positive and negative terminals of the battery is found incorrect,
STOP using the battery immediately and contact the after-sales service department to
replace the battery or obtain other solutions.
• If the battery emits smoke; immediately STOP using the battery, use fire sand and an
explosion-proof box for burial and isolation, wearing a respirator and fireproof gloves
move the battery to a safe area, and notify the after-sales service department of the
company for record and obtain technical support.

Damaged / Leaking Battery Handling

• Put on personal protective equipment (PPE), such as gloves, goggles/safety glasses,
and a lab coat.
• Isolate and ventilate the area.
• Keep an appropriate fire extinguisher within reach.
• If batteries are showing evidence of overheating, use extreme care. Gases can be toxic
and flammable.
• Disconnect the battery (if possible).
• Remove the battery from the equipment/device (if possible).
• Use inert, non-cellulose absorbents to clean up the spilled electrolyte.
• Place used absorbents and PPE in a sealed bag and contact your environmental or
shipping container for proper disposal of the battery and absorbents.
• DO NOT place damaged batteries in regular trash or recycling containers.
• For safe storage while awaiting proper disposal, place the battery in a container of sand
or another chemically inert cushioning material like vermiculite. There are damaged Li-
ion battery kits commercially available for isolating a battery in a metal pail along with
fire-proof media (such as sand, and vermiculite) to cover the battery with.

13
 • If the electrolyte is leaking out, place the battery in a bucket of water for 7 days to
effectively discharge the internal cells. This is the only time the battery should be
exposed to water.
• Place the battery container away from combustibles.
• Contact the local fire department and ask for advice on how to proceed.

Charging
Designate a specific area for the purpose of charging lithium-ion batteries. When charging,
make sure the battery charger is turned OFF before connecting the battery charging cables.
Lithium-ion batteries allow for fast charging, if the battery does not charge completely in a
normal period or if the battery management system (BMS) indicates a fault, then remove the
battery from service. Big Lift Forklifts recommends the opportunity charge lithium-ion batteries.
This is when the battery is recharged for short intervals during a shift period. It reduces or
eliminates the need for long charging periods, changing batteries during a shift, and extending
shift periods.
Please follow the guidelines below:
• Battery must be charged when the remaining charge is lower than 20%, avoid over-
charging or over-discharging.
• Remaining charge should be higher than 60% during a short period of storage.
• Running the truck is prohibited in the case of a short circuit, low voltage, or high
temperature.
• Perform charging, discharging test, and battery status inspection at least once per
month, including total voltage, unit voltage, voltage difference, temperature, temperature
difference, the value of insulation resistance, remaining charge, etc.
• Handle battery gently. DO NOT throw, roll, or allow to collide with other objects.

14
 Recycling

Lithium-ion batteries must be disposed of according to the relevant environmental protection

regulations. Big Lift Forklifts recommends researching battery recycling companies and
choosing what is best for your situation. We have included two companies here with some
information about each. This information is not guaranteed to be current, please contact the
company for the most up-to-date information.
Note: The companies are not affiliated with Big Lift Forklifts and are considered third party.

Company: Battery Recyclers of America Li-Cycle

HQ: Dallas TX Toronto Canada

Years in Business: (as of 2023) 13 years 7 years

Recycling Process: Smelting Submerged

EPA Certified: Yes Yes

Refurb/Recycle: Both Recycle

Packaging Requirements: Per DoT Per DoT

Palletize Service: Yes No

Pickup: Yes Ship only

Logistics Support: Yes No

Min. Pickup Weight: 50 lbs. N/A

Accept Mix of Lead and Li: Yes No

15
 Appendix A: Daily Spot Check Record
Daily Spot Check Record of Lithium Batteries (Easy Exchange)

Routine Check Items Leakage Leakage Box Damaged Battery Bulge Terminal Damage

Diagram of Routine
Inspection Items

There is liquid leakage There are traces of The box body is cracked The battery expands The terminal is
causing corrosion at the liquid leakage at the and has pieces missing causing it to bulge deformed, discolored,
charging and discharging bottom of the battery, blackened or there are
Explanation
terminals on the bottom which caused stains traces of high
of the battery around the positive and temperature burning
negative terminal ports
Stop using, soak in Stop using, soak in
water for 7 days to water for 7 days to Stop using and recycle Stop using and recycle
Processing Method discharge and recycle discharge and recycle according to local according to local Replace the terminal
according to local according to local regulations regulations
regulations regulations
Inspection Frequency Daily Daily Daily Daily Daily
Inspection Method Visual inspection Visual inspection Visual inspection Visual inspection Visual inspection
Date
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Note: All spot inspectors shall conduct a visual inspection prior to work every day. Mark "√" if they meet the requirements. If they do not meet
the requirements, Mark “×” and report it to the proper personnel.
Place of use:
Person in charge of spot inspection:

16
Appendix B: Box Structure

Big Battery Box Structure – If equipped, only the inner box needs to be shipped with battery
cells and BMS plate for repair/return.

17
Big Lift LLC