Hyundai 50B-9 Manual

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SECTION 1 GENERAL

Group 1 Safety hints ----------------------------------------------------------------------------------------------------- 1-1

Group 2 Specifications ------------------------------------------------------------------------------------------------- 1-4

Group 3 Periodic replacement ------------------------------------------------------------------------------------- 1-12

SECTION 2 REMOVAL & INSTALLATION

Group 1 Major components ----------------------------------------------------------------------------------------- 2-1

Group 2 Removal and installation of unit -------------------------------------------------------------------- 2-2

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and operation --------------------------------------------------------------------------------- 3-1

Group 2 Troubleshooting ---------------------------------------------------------------------------------------------- 3-4

Group 3 Disassembly and assembly --------------------------------------------------------------------------- 3-5

SECTION 4 BRAKE SYSTEM

Group 1 Structure and function ------------------------------------------------------------------------------------ 4-1

Group 2 Operational checks and troubleshooting ------------------------------------------------------ 4-5

Group 3 Tests and adjustments ----------------------------------------------------------------------------------- 4-7

SECTION 5 STEERING SYSTEM

Group 1 Structure and function ------------------------------------------------------------------------------------ 5-1

Group 2 Operational checks and troubleshooting ------------------------------------------------------ 5-10

Group 3 Disassembly and assembly --------------------------------------------------------------------------- 5-13

SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and function ------------------------------------------------------------------------------------- 6-1

Group 2 Operational checks and troubleshooting ------------------------------------------------------- 6-17

Group 3 Disassembly and assembly ---------------------------------------------------------------------------- 6-21

SECTION 7 ELECTRICAL SYSTEM

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

Group 2 Electrical circuit ----------------------------------------------------------------------------------------------- 7-2

Group 3 Electric components --------------------------------------------------------------------------------------- 7-3

CONTENTS

Table of Contents

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Summarization of Contents

SECTION 1 GENERAL

Group 1 Safety hints

Essential safety guidelines and precautions for handling the forklift and its components.

Group 2 Specifications

Technical specifications for the forklift, including dimensions, capacities, and performance metrics.

Group 3 Periodic replacement

Schedule and guidelines for replacing consumable parts to ensure optimal performance.

SECTION 2 REMOVAL & INSTALLATION

Group 1 Major components

Identification and overview of the forklift's major components for removal and installation.

Group 2 Removal and installation of unit

Detailed procedures for removing and installing major units and components.

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and operation

Explanation of the power train system's structure, components, and operational principles.

Group 2 Troubleshooting

Guidance on diagnosing and resolving common issues within the power train system.

Group 3 Disassembly and assembly

Step-by-step instructions for disassembling and assembling power train components.

SECTION 4 BRAKE SYSTEM

Group 1 Structure and function

Detailed breakdown of the brake system's structure and how each component functions.

Group 2 Operational checks and troubleshooting

Procedures for checking brake system operation and troubleshooting common faults.

Group 3 Tests and adjustments

Procedures for testing brake system performance and making necessary adjustments.

SECTION 5 STEERING SYSTEM

Group 1 Structure and function

Explanation of the steering system's structure, components, and operational principles.

Group 2 Operational checks and troubleshooting

Guidance for checking steering system operation and troubleshooting common issues.

Group 3 Disassembly and assembly

Step-by-step instructions for disassembling and assembling steering system components.

SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and function

Detailed explanation of the hydraulic system's structure and functional principles.

Group 2 Operational checks and troubleshooting

Procedures for checking hydraulic system operation and troubleshooting common problems.

Group 3 Disassembly and assembly

Step-by-step instructions for disassembling and assembling hydraulic system components.

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component location

Identification and location of electrical system components on the forklift.

Group 2 Electrical circuit

Diagrams and explanations of the forklift's electrical circuits for understanding and troubleshooting.

Group 3 Electric components

Detailed information on individual electrical components used in the system.

SECTION 8 MAST

Group 1 Structure

Detailed breakdown of the mast assembly and its components.

Group 2 Operational Checks and Troubleshooting

Procedures for checking mast operation and troubleshooting common issues.

Group 3 Adjustment

Guidelines for adjusting mast components to ensure proper alignment and function.

Group 4 Removal and Installation

Step-by-step instructions for removing and installing mast components.

FOREWORD

1. STRUCTURE

General overview of the service manual's structure and purpose.

SECTION 1 GENERAL

Provides general information about the machine and safety hints for maintenance.

SECTION 2 REMOVAL & INSTALLATION OF UNIT

Explains procedures and techniques for removing and installing each component.

SECTION 3 POWER TRAIN SYSTEM

Details the structure of the transmission, control valve, and drive axle.

SECTION 4 BRAKE SYSTEM

Explains the brake piping, components, and overall operation.

SECTION 5 STEERING SYSTEM

Describes the steering unit, priority valve, trail axle, and steering circuit.

SECTION 6 HYDRAULIC SYSTEM

Explains the structure of the gear pump, main control valve, and work equipment circuit.

SECTION 7 ELECTRICAL SYSTEM

Details the electrical circuit and its individual components for understanding and troubleshooting.

SECTION 8 MAST

Explains the structure of the mast, carriage, backrest, and forks.

2. HOW TO READ THE SERVICE MANUAL

Distribution and updating

Information on how service manual updates are distributed and obtained.

Filing method

Instructions on how to properly file and organize the service manual pages.

Additional pages

Guidance on how to file additional or revised pages within the manual.

Symbols

Explanation of symbols used in the manual for safety and technical information.

3. CONVERSION TABLE

Method of using the Conversion Table

Instructions on how to use the conversion table for various measurements.

Example

Practical examples demonstrating the use of the conversion table for millimeters to inches.

4. TIGHTENING TORQUE FOR MAJOR COMPONENTS

5. TORQUE CHART

(1) BOLT AND NUT

Torque specifications for standard bolts and nuts, covering coarse and fine threads.

(2) Fine thread

Torque specifications for fine thread bolts and nuts.

6. RECOMMENDED LUBRICANTS

GROUP 3 PERIODIC REPLACEMENT

SECTION 2 REMOVAL & INSTALLATION OF UNIT

Group 1 MAJOR COMPONENTS

Identification and overview of the forklift's major components for removal and installation.

Group 2 REMOVAL AND INSTALLATION OF UNIT

Detailed procedures for removing and installing major units and components.

GROUP 1 MAJOR COMPONENTS

GROUP 2 REMOVAL AND INSTALLATION OF UNIT

1. MAST

Detailed information regarding the mast system.

1) REMOVAL

Step-by-step instructions for removing mast components.

(1) Forks

Procedure for removing the forks from the mast carriage.

(2) Backrest

Procedure for removing the backrest from the fork carriage.

(3) Carriage

Procedure for removing the carriage assembly.

(4) Piping

(5) Lift cylinder

(6) Inner mast

(8) Mast mounting block

2) INSTALLATION

(1) Mast mounting pin

Procedure for installing the mast mounting pin, including checks and tightening.

(3) Lift cylinder installation and adjustment

Instructions for installing and adjusting the lift cylinder.

2. POWER TRAIN ASSEMBLY

1) REMOVAL

Step-by-step instructions for removing power train components.

(1) Mast and counterweight

Procedure for removing the mast and counterweight for safety.

(2) Brake piping

Procedure for disconnecting the brake piping from the drive unit.

(3) Parking brake cable

Procedure for disconnecting the parking brake cable from the drive unit.

(4) Drive unit & motor assy

2) INSTALLATION

3. ELECTRICAL COMPONENTS

1) REMOVAL

Step-by-step instructions for removing electrical components.

(1) Battery

Procedure for removing the battery, including safety precautions.

4. STEERING AXLE

1) REMOVAL

Step-by-step instructions for removing the steering axle assembly.

① Counterweight

Procedure for removing the counterweight, including lifting and bolt removal.

② Hose

Procedure for removing hydraulic hoses connected to the steering axle.

③ Mounting bolt

Procedure for removing mounting bolts of the steering axle.

(2) Installation

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and operation

Explanation of the power train system's structure, components, and operational principles.

Group 2 Troubleshooting

Guidance on diagnosing and resolving common issues within the power train system.

Group 3 Disassembly and assembly

Step-by-step instructions for disassembling and assembling power train components.

GROUP 1 STRUCTURE AND OPERATION

1. DRIVE UNIT

Detailed breakdown of the drive unit's structure and components.

1) STRUCTURE (1/2)

Exploded view and part list for the first half of the drive unit structure.

STRUCTURE (2/2)

2) SPECIFICATION

GROUP 2 TROUBLESHOOTING

1. Noise

Troubleshooting common noise issues in the drive unit.

2. Leakage

Troubleshooting common leakage problems in the drive unit.

5. Transmission warms up

Troubleshooting common issues related to transmission overheating.

GROUP 3 DISASSEMBLY AND ASSEMBLY

1. BRAKE DISASSEMBLY PROCEDURE

Detailed procedure for disassembling the brake system.

1) GENERAL DESCRIPTION

General overview of the brake disassembly procedure.

2) REPLACE OF THE BRAKE DISCS

Instructions for replacing the brake discs within the unit.

3) REPLACING DISCS PUSHER

2. GEARBOX DISASSEMBLY

1) GENERAL DESCRIPTION

General overview of the gearbox disassembly process.

2) HOUSING REMOVAL

Procedure for removing the gearbox housing.

3) DISASSEMBLY OF THE RING GEAR AND OF THE WHEEL HUB

Procedure for disassembling the ring gear and wheel hub.

4) DISASSEMBLY OF THE SUN PINION AND THE INPUT SHAFT

5) DISASSEMBLY OF THE HELIX PINION

3. ASSEMBLY OF THE REDUCTION GEAR

1) ASSEMBLY OF THE SUN PINION

Step-by-step instructions for assembling the sun pinion into the flange.

2) ASSEMBLING THE RING GEAR AND THE WHEEL HUB

Instructions for assembling the ring gear and wheel hub components.

4) ASSEMBLY OF THE COVER

SECTION 4 BRAKE SYSTEM

Group 1 Structure and function

Explanation of the brake system's structure, components, and functional principles.

Group 2 Operational checks and troubleshooting

Procedures for checking brake system operation and troubleshooting common faults.

Group 3 Tests and adjustments

Procedures for testing brake system performance and making necessary adjustments.

GROUP 1 STRUCTURE AND FUNCTION

1. OUTLINE

General overview of the service brake system and parking brake system.

2. SPECIFICATION

Technical specifications for the brake system, including pressures and fluid volumes.

1) BRAKE

Specific parameters for the service brake system.

2) PARKING BRAKE

Specific parameters for the parking brake system.

3. BRAKE PEDAL AND PIPING

4. BRAKE INSTALLATION

5. BRAKE MASTER CYLINDER

1) STRUCTURE

Exploded view and part list for the brake master cylinder.

2) DISASSEMBLY

Step-by-step instructions for disassembling the brake master cylinder.

3) INSPECTION

Procedures for inspecting and cleaning brake master cylinder components.

4) ASSEMBLY

Step-by-step instructions for assembling the brake master cylinder.

GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS

Procedures for performing operational checks on the brake system.

1) BRAKE PIPING

Checks for damage, leaks, or interference in brake pipes and hoses.

2) BRAKING FORCE

Procedures for checking the braking force and stopping distance.

3) PARKING BRAKE

Checks for the operating force and holding capability of the parking brake.

2. TROUBLESHOOTING

1) STEERING SYSTEM

Troubleshooting guide for common problems related to the steering system.

GROUP 3 TESTS AND ADJUSTMENTS

1. BLEED THE BRAKE SYSTEM

Procedure for bleeding air from the brake system to ensure proper function.

2. ADJUSTMENT OF PEDAL

Adjusting the brake pedal height and play for optimal operation.

1) BRAKE PEDAL

Adjusting the pedal height using the stopper bolt.

(2) Play

Adjusting the pedal play using the rod of the mast cylinder.

SECTION 5 STEERING SYSTEM

Group 1 Structure and function

Explanation of the steering system's structure, components, and functional principles.

Group 2 Operational checks and troubleshooting

Guidance for checking steering system operation and troubleshooting common issues.

Group 3 Disassembly and assembly

Step-by-step instructions for disassembling and assembling steering system components.

GROUP 1 STRUCTURE AND FUNCTION

1. OUTLINE

General overview of the steering system components and their interconnections.

2. HYDRAULIC CIRCUIT

1) NEUTRAL

2) LEFT TURN

3) RIGHT TURN

3. STEERING UNIT

1) STRUCTURE

Exploded view and part list for the steering unit.

2) OPERATION

4. STEERING AXLE

1) STRUCTURE

Exploded view and part list for the steering axle assembly.

2) TIGHTENING TORQUE AND SPECIFICATION

GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS

Procedures for checking steering system operation.

Steering wheel

Checking steering wheel movement and play.

Knuckle

Checking knuckle for visual defects or cracks.

Steering axle

Checking steering axle for minimum turning radius.

Hydraulic pressure of power steering

Checking hydraulic pressure of the power steering system.

2. TROUBLESHOOTING

Guidance on diagnosing and resolving common steering system problems.

1) STEERING SYSTEM

Troubleshooting common issues related to the steering system.

GROUP 3 DISASSEMBLY AND ASSEMBLY

1. STEERING UNIT

Detailed breakdown of the steering unit and its components.

1) STRUCTURE

Exploded view and part list for the steering unit.

2) TOOLS

(1) Holding tool.

Description of the holding tool used for steering unit assembly.

3) TIGHTENING TORQUE

4) DISASSEMBLY

(1) Disassemble steering column...

Procedure to disassemble the steering column from the steering unit.

3. STEERING UNIT

2) DISASSEMBLY

Step-by-step instructions for disassembling the steering unit.

SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and function

Explanation of the hydraulic system's structure and functional principles.

Group 2 Operational checks and troubleshooting

Procedures for checking hydraulic system operation and troubleshooting common problems.

Group 3 Disassembly and assembly

Step-by-step instructions for disassembling and assembling hydraulic system components.

GROUP 1 STRUCTURE AND FUNCTION

1. HYDRAULIC CIRCUIT (LEVEL TYPE)

Hydraulic circuit diagram and explanation for the level type mast.

HYDRAULIC CIRCUIT (FINGERTIP TYPE)

1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION

2) WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION

3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION

4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION

2. HYDRAULIC GEAR PUMP

1) STRUCTURE

Exploded view and part list for the hydraulic gear pump.

3. MAIN CONTROL VALVE

1) STRUCTURE

Exploded view and part list for the main control valve.

2) INLET SECTION OPERATION

(1) Structure and description

Description of the inlet section's structure and components.

(2) Operation

3) LIFT SECTION OPERATION

(1) Lift position

Description of hydraulic flow when the lift control lever is in the lift position.

(2) Lower position

4) TILT SECTION OPERATION

(1) Tilt forward position

Description of hydraulic flow when the tilt control lever is in the forward position.

(2) Tilt backward position

5) MAIN RELIEF VALVE

(1) Pressure setting

Procedure for setting the pressure for the main relief valve.

(2) Operation

Explanation of how the main relief valve operates to control pressure.

4. LIFT CYLINDER

5. TILT CYLINDER

GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS

Procedures for checking hydraulic system operation.

2) HYDRAULIC OIL

Checks and maintenance procedures for the hydraulic oil.

3) CONTROL VALVE

Checks and measurement of oil pressure for the control valve.

2. TROUBLESHOOTING

1) SYSTEM

Troubleshooting common issues across the entire hydraulic system.

Large fork lowering speed

Troubleshooting causes for slow fork lowering.

Large spontaneous tilt of mast

Troubleshooting causes for unexpected mast tilting.

Slow fork lifting or slow mast tilting

Troubleshooting causes for slow fork lifting or mast tilting.

Hydraulic system makes abnormal sounds

Troubleshooting causes for abnormal noises in the hydraulic system.

Control valve lever is locked

Troubleshooting causes for a locked control valve lever.

High oil temperature

Troubleshooting causes for high hydraulic oil temperature.

GROUP 3 DISASSEMBLY AND ASSEMBLY

1. HYDRAULIC GEAR PUMP

Step-by-step instructions for disassembling and assembling the hydraulic gear pump.

1) DISASSEMBLY

Procedure for disassembling the hydraulic gear pump.

(1) Put the unit back side down...

Initial step for disassembly: placing the unit correctly.

(2) Remove all fasteners, bolts and nuts.

Instruction to remove all fasteners, bolts, and nuts.

(3) Put all removed parts on a safe place.

Guidance on safely storing removed parts.

(4) Remove the mounting flange.

Procedure for removing the mounting flange.

2. MAIN CONTROL VALVE

1) Remove bolt (1) to separate the valve section.

Step to separate the valve section by removing a specific bolt.

2) Divide the valve body.

Procedure to divide the main control valve body into sections.

3) Remove dust cap (3) and bolt (2)...

Procedure to remove dust cap and bolt from the valve body.

4) Remove attachment spool (4)...

Procedure to remove the attachment spool from the valve body.

5) MAIN RELIEF VALVE

(1) Pressure setting

Procedure for setting the pressure for the main relief valve.

(2) Operation

Explanation of how the main relief valve operates to control pressure.

4. LIFT CYLINDER

5. TILT CYLINDER

GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS

Procedures for checking hydraulic system operation.

2) HYDRAULIC OIL

Checks and maintenance procedures for the hydraulic oil.

3) CONTROL VALVE

Checks and measurement of oil pressure for the control valve.

2. TROUBLESHOOTING

1) SYSTEM

Troubleshooting common issues across the entire hydraulic system.

Large fork lowering speed

Troubleshooting causes for slow fork lowering.

Large spontaneous tilt of mast

Troubleshooting causes for unexpected mast tilting.

Slow fork lifting or slow mast tilting

Troubleshooting causes for slow fork lifting or mast tilting.

Hydraulic system makes abnormal sounds

Troubleshooting causes for abnormal noises in the hydraulic system.

Control valve lever is locked

Troubleshooting causes for a locked control valve lever.

High oil temperature

Troubleshooting causes for high hydraulic oil temperature.

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component location

Identification and location of electrical system components on the forklift.

Group 2 Electrical circuit

Diagrams and explanations of the forklift's electrical circuits for understanding and troubleshooting.

Group 3 Electric components

Detailed information on individual electrical components used in the system.

GROUP 1 COMPONENT LOCATION

GROUP 2 ELECTRICAL CIRCUIT

ELECTRICAL CIRCUIT

GROUP 2 ELECTRICAL CIRCUIT

ELECTRICAL CIRCUIT

GROUP 3 ELECTRIC COMPONENTS

1. FUNCTIONS OF BATTERY FORKLIFT TRUCK AND ELECTRIC COMPONENTS

Overview of the driving, loading, and unloading functions powered by AC motors and battery.

2. BATTERY

1) STRUCTURE

Exploded view and part list of the battery assembly.

3) SPECIFICATION AND SERVICE DATA

4) SAFETY PRECAUTIONS

When sulfuric acid contact with skin

Safety measures for handling sulfuric acid exposure.

Strict prohibition of fire and ventilation

Safety guidelines regarding fire prevention and ventilation during battery charging.

Never place metallic articles on the batteries

Warning against placing metallic items on batteries to prevent short circuits.

Handling of charger

Safety precautions for connecting/disconnecting and maintaining the battery charger.

5) OPERATION PRECAUTIONS

Avoid over-discharge

Guidelines to prevent over-discharging the battery for longevity.

Avoid over-charge

Guidelines to prevent over-charging the battery and its negative effects.

Avoid excessive elevation of temperature

Precautions regarding battery temperature during charging operations.

6) CHECKING

Unpacking

Procedure for unpacking and checking batteries for damage.

Performance and maintenance of batteries

Initial charge

Procedures for initial charging of wet-charged batteries.

Discharge and capacity

Explanation of battery capacity indication and discharge conditions.

Specific gravity of electrolyte

Information on measuring and correcting electrolyte specific gravity.

Normal charge

Charging by modified constant voltage automatic charger

Charging by constant current constant voltage automatic charger

Charging by constant current charger

Equalizing charge

Replenishment of distilled water

Determination of replenishment time and methods (cell with ONE TOUCH CAP)

Instructions for checking and replenishing electrolyte levels using the ONE TOUCH CAP.

Cleaning

Notice on charging

Repair of failure cell

Summary of daily maintenance

Others

Storage of batteries

Guidelines for storing batteries safely and maintaining their condition.

Maintenance record

Electrolyte temperature

7) TROUBLESHOOTING

Nature of trouble

Classification of common battery troubles and their symptoms.

Deformation

Troubleshooting causes and corrective actions for container deformation.

Breakage

Troubleshooting causes and corrective actions for battery breakage.

Sulfate

Troubleshooting causes and corrective actions for sulfate issues.

Decrease and falling of specific gravity

Troubleshooting causes and corrective actions for specific gravity issues.

Rise of specific gravity

Troubleshooting causes and corrective actions for specific gravity rise.

Mixing of impurities

Troubleshooting causes and corrective actions for impurities in electrolyte.

3. DRIVE MOTOR

1) STRUCTURE

Exploded view and part list for the drive motor.

2) SPECIFICATION

3) MAINTENANCE INSTRUCTION

(1) Ball bearing

Maintenance guidelines for ball bearings in the drive motor.

(2) Disassembly and assembly

Instructions for disassembling and assembling the drive motor.

4. PUMP MOTOR

1) STRUCTURE

Exploded view and part list for the pump motor.

2) SPECIFICATION

3) INTERNAL INVOLUTE SPLINE DATA

4) MAINTENANCE INSTRUCTION

(1) Ball bearing

Maintenance guidelines for ball bearings in the pump motor.

(2) Disassembly and assembly

Instructions for disassembling and assembling the pump motor.

5. CONTROLLER SYSTEM

1) STRUCTURE

Overview of the controller system structure.

(1) Specifications

Technical specifications for the controller modules (ACE4 Premium, ACE4 Standard, VCM Premium).

2) OPERATIONAL FEATURES

① Speed control.

Description of speed control features, including slope behavior and ramp stops.

② Optimum behavior an a slope due to the speed feedback:

Details on how speed feedback affects performance on slopes.

③ Electronic differential feature with torque balance between external and internal wheel.

Explanation of the electronic differential feature for torque balancing.

④ Regenerative release braking based upon deceleration ramps.

Description of regenerative braking during deceleration ramps.

⑤ Regenerative braking when the accelerator pedal is partially released (deceleration).

Explanation of regenerative braking activated by partial accelerator release.

⑥ Direction inversion with regenerative braking based upon deceleration ramp.

Description of direction changes combined with regenerative braking.

⑦ Regenerative braking and direction inversion without contactors: only the main contactor is present.

Explanation of regenerative braking and direction inversion without separate contactors.

⑧ Optimum sensitivity at low speeds.

Description of the controller's optimum sensitivity at low operating speeds.

⑨ Voltage boost at the start and with overload to obtain more torque (with current control).

Explanation of voltage boost function for starting and overload torque.

⑩ Hydraulic steering function:

Details on the hydraulic steering function managed by the traction inverter.

⑪ Backing forward and reverse options are available, with the tune and the speed of the function programmable with Zapi console or buttons on a display.

Information on programmable forward/reverse options via Zapi console or display.

⑫ High efficiency of motor and battery due to high frequency commutations.

Explanation of the high efficiency of motor and battery due to frequency commutations.

⑬ Modification of parameters through the programming console or buttons on a display.

Instructions on how to modify parameters via console or display.

⑭ Internal hour-meter with values that can be displayed on the console.

Description of the internal hour-meter and its display capabilities on the console.

⑮ Memory of the last five alarms with relative hour-meter and temperature displayed on the console.

Information on the console's memory for alarms, hour meter, and temperature.

⒃ Diagnostic function with Zapi console for checking main parameters.

Using Zapi console for diagnosing and checking main parameters.

⒄ Built in BDI feature.

Description of the built-in Battery Discharge Indicator (BDI) feature.

⒅ Flash memory, software downloadable via serial link and via CANBUS.

Information on flash memory and software download capabilities.

(2) Diagnosis

Diagnosis on key switch closing...

Diagnostic checks performed when the key switch is closed.

Standby diagnosis in standby...

Diagnostic checks performed when the system is in standby mode.

Diagnosis during operation...

Diagnostic checks performed while the equipment is operating.

Continuous diagnosis that checks...

Continuous diagnostic checks for inverter and motor temperature.

3) DESCRIPTION OF THE CONNECTORS

(1) Traction controller (Master)

Description of the connectors for the traction controller (Master unit).

Encoder installation

① Traction controller card is fit for different types of encoder.

Information on traction controller card compatibility with various encoder types.

② Connection of encoder with open collector output; +12V power supply.

Diagram showing encoder connection with open collector output and power supply.

③ The encoder power supply voltage and output electronic has to be communicated to ZAPI in order to correctly set the selection jumpers in the logic card.

Communication requirements for encoder power and output electronics with Zapi.

(2) Traction controller (Slave)

Encoder installation

① Traction controller card is fit for different types of encoder.

Information on traction controller card compatibility with various encoder types.

② Connection of encoder with open collector output; +12V power supply.

Diagram showing encoder connection with open collector output and power supply.

4) FUNCTION CONFIGURATION

TRACTION CONTROLLER-MASTER

Configuration options for the traction controller (Master unit).

(1) Submenu "SET OPTIONS"

Menu for setting various operational options for the controller.

Hour counter

Setting the mode for the hour counter (running time or key-on time).

Battery check

Configuration for battery discharge level monitoring and alarms.

Traction cutout

Setting for traction speed reduction when battery is low.

Lift cutout

Setting for disabling lift function when battery is low.

Hydro key on

Setting for enabling hydraulic steering function when the key is ON.

Stop on ramp

Enabling the stop-on-ramp feature for electrical holding on slopes.

Aux input #1

Configuration options for auxiliary input 1 (hydraulic steering or handbrake).

Pedal braking

Defining the brake pedal type (analog or digital) for electrical braking.

Set temperature

Setting the type of motor thermal sensor (digital, analog, or none).

Steer table

Selecting the appropriate steering table based on truck geometry.

⑪ Display

⑫ S.R.O.

⑬ Pedal brake stop

(2) Submenu "ADJUSTMENTS"

① Set battery type

Selecting the nominal battery voltage for the controller.

② Adjust battery

Fine adjustment of the battery voltage measured by the controller.

③ Max steer right

Recording the steering potentiometer output for full right turn.

④ Max steer left

Recording the steering potentiometer output for full left turn.

⑤ Set steer 0-pos.

Recording the steering potentiometer output for straight wheel position.

⑥ Set steer right

Setting the maximum steering angle in the right direction.

⑦ Set steer left

Setting the maximum steering angle in the left direction.

(3) Parameter change

① Acceler delay

Determines the acceleration ramp; less value means better performance.

② Deceler delay

Determines the deceleration ramp; less value means better performance.

③ Max speed up

Determines the maximum lifting speed with potentiometer control.

④ Min speed up

Determines the minimum lifting speed with potentiometer control.

⑤ Cutback speed

Determines lift speed reduction when speed reduction switch is activated.

⑥ Tilt speed

Parameter for tilt speed and fine regulation.

⑦ Shift speed

Parameter for shift speed and fine regulation.

⑧ Aux speed

Parameter for auxiliary function speed and fine regulation.

⑨ Hyd speed fine

Parameter for hydraulic speed and fine regulation.

⑩ Maximum current

Sets the maximum current limit for the inverter.

⑪ Idle time

Time delay for hydraulic steering function request when switched off.

■ DISPLAY

(1) Password

Setting the user password for activation.

(2) Maintenance

Activating and setting the maintenance alarm function.

(3) Hour counter

Determining the default hourmeter display for truck key, traction, and pump.

5) PROGRAMMING & ADJUSTMENTS

ADJUSTMENTS VIA SMART CONSOLE (Option)

Adjusting parameters and configuring the inverter using the smart console.

(1) Descriptions of console

Overview of the smart console's display and buttons.

(2) Description of standard console menu

① Traction controller-Master

Menu structure and navigation for the Traction Controller-Master.

② Traction controller-Slave

③ Pump controller

(3) Description of the console SAVE function

(4) Description of the console RESTORE function

(5) Description of alarms menu

(6) Description of console program vacc function

7) ALARM & ALARM HISTORY

(1) How to check alarms

Instructions on how to navigate the alarm screen and check alarms.

(2) Detail description of ALARM SCREEN

First yellow capital letter shows in which controller the alarm happens as below;

Explanation of alarm codes indicated by the first yellow capital letter.

Following two letters or digits show alarm code.

Explanation of how to interpret the alarm code digits.

This shows a name of ALARM.

Explanation of how to identify the name of an alarm.

(3) Alatm history

Alarm History can be looked up as follows ;

Step-by-step guide to accessing and reviewing the alarm history.

8) VASS SETUP USING DISPLAY MENU

(1) ACCEL VASS setting method

Procedure for setting the accelerator pedal VASS values.

(2) LIFT VASS setting method

(3) STEER ANGLE VASS setting method

9) STRUCTURE OF TRUCK MENU

(1) Setting

Navigating the truck menu to configure settings for Master, Slave, or Pump controllers.

(2) Monitoring

Checking the status of the truck by monitoring Master, Slave, or Pump controllers.

(3) Alarm history

Accessing and checking the alarm history for different controllers.

7. ALARM CODE

1) TRACTION-MASTER CONTROLLER

List of alarm codes and their causes/troubleshooting for the traction master controller.

2) TRACTION-SLAVE CONTROLLER

Code Alarm Description