h:jx3 operation manual - ep equipment new zealand€¦ · – place directional control in neutral...

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ForewordThanks for purchasing our order pickers.The present original operating instructions are designed to provide sufficient

instruction for the safe operation and maintenance of the truck. Please be sure to readthis operator manual carefully if you are operator or are in charge of the truck,beforeyou operate and service the truck. Only in this way can you protect yourself and makethe truck play a role as much as possible.

Our trucks are subject to ongoing development, so maybe there are somedifferences between your product and the description in this manual. And the operatormanual details will be different because of customer's special requirements.

If you have any questions ,please keep in touch with the sales department ofEquipment or let the dealer know.

Notes:1. This manual is used for operation and maintenance , the detail parameters, sizeand specifications in context is only for reference , the real parameters will depend onsale files.2. Manual pictures for reference only, the real car shall prevail, and shall not affect themanual use.

Warning!The truck can only be used indoors !

EP EQUIPMENT CO.,LTD.Address: XIAQUAN,DIPU,ANJI,ZHEJIANG,CHINATel:86-571-28031990Fax:86-571-28035616Net:www.ep-ep.comEmail:[email protected]

2016.12 1st EDITION

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WARNING!TO PREVENT SETIOUS RISK OF INJURY TOYOUORSELF AND OTHERS OBSERVE THE

FOLLOWING SAFETY INSTRUCTIONS.These trucks may become hazardous if adequate maintenance is neglected.Therefore, adequate maintenance facilities, trained personnel and procedures shouldbe provided.

Maintenance and inspection shall be performed in conformance with the followingpractices:

1. A scheduled planned maintenance,lubrication and inspection system should befollowed.

2. Only qualified and authorized personnel shall be permitted to maintain, repair,adjust, and inspect truck.

3. Before leaving the truck:– Do not park the truck on an incline.– Fully lower the operator position.– Press the emergency brake switch .– Set the key switch to the "OFF" position and remove the key.

4. Before starting to operate truck:– Be in operating position– Place directional control in neutral– Before operating truck, check functions of lift systems, directional control,speedcontrol,steering, warning devices and brakes.

5. Do not use open flame to check lever, or for leakage of electrolyte and fluids or oil.Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.

6. Brakes,steering mechanisms, control mechanisms,guards and safety devices shallbe inspected regularly and maintained in legible condition.

7. Capacity, operation and maintenance instruction plates or decals shall bemaintained in legible condition.

8. All parts of lift mechanisms shall be inspected to maintain them in safe operatingcondition.

9. All hydraulic systems shall be regularly inspected and maintained in conformancewith good practice. Cylinders, valves and other similar parts shall be checked to

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assure that "drift" has not developed to the extent that it would create a hazard.

10. Truck shall be kept in a clean condition to minimize fire hazards facilitatedetection of loose or detective parts.

11. Modifications and additions which affect capacity and safe truck operation shallnot be performed by the customer or user without manufacturers prior writtenapproval. Capacity, operation and maintenance plates or decals shall be changedaccordingly.

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CatalogCorrect use and Application...............................................................................................V

1. Truck Description..............................................................................................................21.1Application....................................................................................................................21.2 Truck Assemblies.......................................................................................................31.3 Standard Version Specifications..............................................................................5

1.3.1 Performance data for standard trucks.........................................................51.3.2 Dimensions......................................................................................................5

1.4 Identification points....................................................................................................81.4.1 Truck data plate....................................................................................................9

2. Commissioning................................................................................................................102.1 Using the truck for the First Time..........................................................................102.2 During brake-in........................................................................................................ 10

3.Operation............................................................................................................................ 113.1 Safety Regulations for the Operation of trucks...................................................113.2 Controls and Displays.............................................................................................12

3.2.1 Control panel controls and displays...........................................................123.2.2 Display unit controls and displays..............................................................14

3.3 Run the truck............................................................................................................16To prepare the truck for operation........................................................................16

3.4 Industrial Truck Operation......................................................................................173.4.1 Safety regulations for truck operation....................................................... 173.4.2 Travel, Steering, Braking.............................................................................173.4.3 Lifting - Lowering.......................................................................................... 193.4.4 fixture............................................................................................................. 20

3.5 Parking the order picker securely.........................................................................21

4.Battery Maintenance & Charging.................................................................................224.1 Safety regulations for handling acid batteries.....................................................224.2 Charging the battery................................................................. 错误！未定义书签。4.3Battery removal and installation.............................................................................224.4 Battery maintenance...............................................................................................234.5 Battery disposal....................................................................................................... 23

5. Maintenance..................................................................................................................... 265.1 Operational safety and environmental protection...............................................265.2Maintenance Safety Regulations........................................................................... 265.3 Servicing and inspection........................................................................................ 27

5.3.1 Maintenance Checklist.................................................................................285.3.2 Lubrication Schedule................................................................................... 30

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5.3.3 Maintenance Instructions............................................................................ 315.3.4 Recommissioning......................................................................................... 32

5.4 Decommissioning the order picker....................................................................... 335.4.1Prior to decommissioning.............................................................................335.4.2 Restoring the order picker to operation after decommissioning........... 33

5.5 Safety checks to be performed at regular intervals and following any unusualincidents...........................................................................................................................345.6 Final de-commissioning, disposal.........................................................................34

6.Troubleshooting............................................................................................................... 346.1 Error Message..........................................................................................................36

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Correct use and Application

The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) aresupplied with the truck. The guidelines is an important component of these operatinginstructions and must be observed. Your country's relevant laws and regulations is notaffected.The truck described in the present operator manual is an industrial truck designed forlifting and transporting load units.It must be used, operated and serviced in accordance with the present instructions.Any other type of use is beyond the scope of application and can result in damage topersonnel, the truck or property. In particular, avoid overloading the truck with loadswhich are too heavy or placed on one side. The data plate attached to the truck or theload diagram are binding for the maximum load capacity. The truck must not be usedin fire or explosion endangered areas, or areas threatened by corrosion or excessivedust.

Proprietor responsibilitiesFor the purposes of the present operator manual the “proprietor” is defined as anynatural or legal person who either uses the truck himself, or on whose behalf it is used.In special cases (e.g. leasing or renting) the proprietor is considered the person who,in accordance with existing contractual agreements between the owner and user ofthe truck, is charged with operational duties.The proprietor must ensure that the truck is used only for the purpose it is intended forand that danger to life and limb of the user and third parties are excluded.Furthermore, accident prevention regulations, safety regulations and operating,servicing and repair guidelines must be followed. The proprietor must ensure that alltruck users have read and understood this operator manual.Failure to comply with the operator manual shall invalidate the warranty. The sameapplies if improper work is carried out on the truck by the customer or third partieswithout the permission of the manufacturer’s customer service department.

Adding accessoriesThe mounting or installation of additional equipment which affects or enhances theperformance of the truck requires the written permission of the manufacturer. Localauthority approval may also need to be obtained.Local authority approval does not however constitute the manufacturer’s approval.

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1. Truck Description

1.1ApplicationThe truck is an electric order picker.The JX2-126/JX2-144 is designed to transportand pick goods on level surfaces.Loads can be stacked, unstacked and transportedover long distances.The capacity can be obtained from the data plate.

Warning!The truck can only be used indoors !

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1.2 Truck Assemblies

Item Component Item Component1 Control panel 9 Hydraulic pump2 Fork 10 Mast3 Warning lamp 11 Battery4 Cover 12 Drive pedal5 Controller 13 Height-adjustable operator position6 Fixture 14 Load wheel7 Frame 15 Gates8 Drive wheel

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Safety mechanisms: An enclosed truck geometry with rounded edges ensures safehandling of the truck. Pressing the Emergency brake switch disconnects allelectrical functions in hazardous situations.Gates on either side of the cab interrupt alltruck operations as soon as they are opened.When you start up the truck the drivepedal must be applied.

Drive: The entire drive unit is enclosed in the truck chassis.The electronic traction controller ensures the smooth rotation of the drive motor andas a result smooth driving, powerful acceleration.

Brake system: The operator can brake gently and wear-free by pulling back thetravel control button.The electromagnetic spring pressure brake acting on the drivemotor serves as both parking and handbrake.

Steering system:Extremely smooth steering with three phase drive system.Thesteering wheel is integrated in the control panel. The position of the steered drivewheel is shown in the control panel display unit. The maximum steer angle is ± 90°.

Controls and Displays：The functions are activated via ergonomic thumb movementto ensure fatigue-free operation without stressing the wrists; sensitive application oftravel and hydraulic movements to spare and position the goods precisely.Driver'sdisplay unit for all important driver information such as steering wheel position,overalllift, truck status reports (e.g. faults), battery capacity and time etc..

Hydraulic system ： All hydraulic operations are controlled by a sturdy,maintenance-free AC motor with no wear parts and with a flanged low emission gearpump.Oil is distributed via electromagnetic switch valves.

Electrical system:Standard electronic drive, lift and steering control system.Theelectronic drive control enables plugging when changing direction.

For controls options see chapter three.

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1.3 Standard Version SpecificationsTechnical specification details in accordance with VDI2198. Technicalmodifications and additions reserved.

1.3.1 Performance data for standard trucks

Item Description JX2-126 JX2-144 Unit

Q Load capacity 1000 KgService brake type electromagnetism

Travelspeed

Height :0-380mm 8.0 Km/hHeight :380-1930mm 3.2 Km/hHeight :1930-2600 mm 2.1 Km/hHeight :2600-Max mm 0.6 Km/h

Lifting speed, laden/ unladen 0.13 / 0.16 m/ sLowering speed, laden/ unladen 0.16 / 0.18 m/ sService weight (with battery) 1900 1965 KgThe maximum allowed size 740*275*630 mmAxle loading, laden drivingside/loading side

730/2170 760/2205 Kg

Axle loading, unladen drivingside/loading side

1170/730 1200/765 Kg

Drive motor rating S2 60 min. 4.0 kwLift motor rating at S3 15% 3.0 kwBattery voltage/ rated capacity 24/360 V/Ah

1.3.2 Dimensions

Item Description JX2-126 JX2-144 Unit

XLoad distance，centre of driveaxle to fork

115 mm

y Wheelbase 1365 mmb10 Track width, front,driving side 570 mmb11 Track width,rear,loading side 770 mmh1 Height, mast lowered 2270 2360 mmh3 Lift height 3160 3620 mmh4 Height, mast extended 3680 4170 mm

h6Height of overhead guard(cabin)

5365 5825 mm

h7 Seat height/standing height) 220 mmh12 Stand height, elevated 3365 3765 mm

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h13 Lowered height 56 mml1 Overall length 2750 mml2 Length to face of forks 1680 mm

b1/ b2 Overall width 860 mms/ e/ l Fork dimensions 1070*100*40 mmb5 Distance between fork-arms 540 mmh2 Fork lift height 3200 3600 mmN width of pallet clamp 25-150 mm

m2Ground clearance, center ofwheelbase

50 mm

AstAisle width for pallets 1000 ×1200 crossways1）

3100 mm

AstAisle width for pallets 800 ×1200 lengthways1）

3150 mm

Wa Turning radius 1600 mmTyre type, Drivingwheels/Loading wheels

polyurethane

Tyre size, driving wheels（Diameter×Width）

Ф230×75 mm

Tyre size, load wheels（Diameter×Width）

Ф165×120 mm

Wheels, number driving/loading(x=drive wheels)

1/2

1） Including safety distance a = 200 mm

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1.4 Identification points

Item Description

1 “Never put your hands in inner .“ warning

2 Key switch decal

3 Caution

4 AC Power

5 Data Plates

6 Lifting hole mark

7 "Safety" warning

8 Drive pedal

9 Horn/Lower/Lift

10 Travel FWD.&REV.

11 Power shut off

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1.4.1Truck data plate

For queries regarding the truck or ordering spare parts always quote the truckserial number (4).

Item Description Item Description1 Manufacturer 11 Max capacity2 Vehicle name 12 Alt capacity3 Model 13 Year of build4 Series No. 14 Occupant No.5 Made in 15 Max horizontal force6 Load capacity 16 Attachment capacity7 Load center 17 Weight with battery8 Max gradient 18 Weight without battery9 Voltage 19 Max battery weight10 Drive output 20 Min battery weight

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2. Commissioning

2.1 Using the truck for the First TimeOnly operate the truck with battery current.Preparing the truck for operation after delivery or transport.Procedure• Check the equipment is complete.• Check the hydraulic oil level.• Install the battery if necessary (where required), (see "4.3 Battery removal andinstallation" ) do not damage battery cable.• Charge the battery, (see "4.2 Charging the battery" ).When the truck is parked the surface of the tyres will flatten. The flattening willdisappear after a short period of operation.

2.2 During brake-inWe recommended operating the machine under light load conditions for the first stageof operation to get the most from it. Especially the requirements given below shouldbe observed while the machine is in a stage of 100 hours of operation.• Must prevent the new battery from over discharging when early used. Pleasecharging when remain power less than 20%.• Perform specified preventive maintenance services carefully and completely.• Avoid sudden stop, starts or turns.• Oil changes and lubrication are recommended to do earlier than specified.• Limited load is 70～80% of the rated load.

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3.Operation

3.1 Safety Regulations for the Operation of trucks

Driver authorization: The truck may only be used by suitably trained personnel, whohave demonstrated to the proprietor or his representative that they can drive andhandle loads and have been authorized to operate the truck by the proprietor or hisrepresentative.

Driver’s rights, obligations and responsibilities: The driver must be informed ofhis duties and responsibilities and be instructed in the operation of the truck andshall be familiar with the operator manual . The driver shall be afforded all due rights .Safety shoes must be worn with pedestrian operated trucks.

Unauthorized Use of truck: The driver is responsible for the truck during the time itis in use. He shall prevent unauthorized persons from driving or operating the truck. Itis forbidden to carry passengers or lift personnel.

Damage and Faults: The supervisor must be immediately informed of any damage orfaults to the truck. trucks not safe for operation (e.g. wheel or brake problems) mustnot be used until they have been rectified.

Repairs: The driver must not carry out any repairs or alterations to the truck withoutthe necessary training and authorization to do so. The driver must never disable oradjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is atrisk due to truck movement, lifting operations, the load handler (e.g. forks orattachments) or the load itself. This also includes areas which can be reached byfalling loads or lowering operating equipment.

· Unauthorized persons must be kept away from the hazardous area.· Where there is anger to personnel, a warning must be sounded with sufficientnotice.· If unauthorized personnel are still within the hazardous area the truck shall bebrought to a halt immediately.

Safety Devices and Warning Signs: Safety devices, warning signs and warninginstructions shall be strictly observed.

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3.2 Controls and Displays

3.2.1 Control panel controls and displays

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Item Control / Display Function

1 Steering wheel Steers the truck in the required direction.

2 Display unit Operating information and warning message display.

3 "Lifting" button Lift the operator position.

4 "Lowering" button Lower the operator position.

5 "Horn" button Activates the horn.

6Emergency brakeswitch

Disconnects the supply current, deactivates all electricalfunctions, causing the truck to brake automatically.

7 Travel switch Select the required driving direction.

8 Key switchSwitches control current on and off. Removing the key preventsthe truck from being switched on by unauthorized personnel.

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3.2.2 Display unit controls and displays

1 Low battery alarm lamp

When the electricity is too low, the lamp will illuminate.Must preventthe battery from over discharging , please charging.

2 Fault alarm lampWhen the order picker has fault, the lamp will illuminate.At this time, the

Information display area of LCD screen will display the warning and faultindication .

3 Temperature alarm lampWhen overuse makes the temperature of drive motor high, the lamp will

illuminate.At the moment,in order to preventing the motor from being burnedout,please don't use the order picker temporarily.And when the temperaturedrop,continue to use.

4 Drive pedal alarm lampWhen you don't step on the drive pedal, the lamp will illuminate.

5 Brake alarm lampStop driving.The lamp will illuminate.

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6 Function keysUse the "left" button to adjust the speed mode;Use the

"down" button to switch the driving mode. Use the "middle" tocode.

7 LCD screen

Power display areaIt will display the rate of charge here.Each cell

represents 10% charge,a total of 10 lattice.

For example, figure shows the order picker has80% charge.

Information display areaDisplays the warning and fault indication(see 6.1

Error Message,Page 35 )

Speed display areaDisplays possible travel speeds.Unit:Km/h .

Steering display area

Use the steering wheel to steer the truck outsidenarrow aisles.The position of the drive wheel is shownhere,area:+/- 90° .

Driving mode display area

" 0h " ：Hour meter;" " ：Crawl speed.

Speed mode display areaFour modes : Mode 1、Mode 2、Mode 3 and Mode 4 .Switch the mode:Press the left button of Function keys(6)

to switch the mode.

Low Voltage ProtectionThis vehicle has a low-voltage protection function.When the battery voltage is less than, the vehicle will appear that the driving speedis slow and the platform can not be lifted.And now the battery needs to be charged.

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3.3 Run the truck

Checks and operations to be performed before starting daily work• Visually inspect the entire truck (in particular wheels and load handler) for obviousdamage.• Visually inspect the battery attachment and cable connections.• Check the load handler for visible damage such as cracks, bent or severely wornload forks.• Check wheels for wear and damage.• Test the warning device.• Make sure the load chains are evenlytensioned.• Check whether the normal function ofall safety devices.

To prepare the truck for operation

• Close the safety gates.• Insert the key in the key switch and turn it to the “ON” position .• Pull up the emergency brake switch .• Test horn.• Check the operation of the brake.

Warning!Before the order picker can becommissioned, operated or a load unitlifted, the driver must ensure that thereis nobody within the hazardous area.

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3.4 Industrial Truck Operation

3.4.1 Safety regulations for truck operation

Travel routes and work areas: Only use lanes and routes specifically designated fortruck traffic. Unauthorized third parties must stay away from work areas. Loads mustonly be stored in places specially designated for this purpose.

Driving conduct: The driver must adapt the travel speed to local conditions. Thetruck must be driven at slow speed when negotiating bends or narrow passageways,when passing through swing doors and at blind spots. The driver must alwaysobserve an adequate braking distance between the forklift truck and the vehicle infront and must be in control of the truck at all times. Abrupt stopping (except inemergencies), rapid U turns and overtaking at dangerous or blind spots are notpermitted. It is forbidden to lean out of or reach beyond the working and operatingarea.

Negotiating lifts and docks: Lifts and docks must only be used if they have sufficientcapacity, are suitable for driving on and authorized for truck traffic by the owner. Thedriver must satisfy himself of the above before entering these areas. The truck mustenter lifts with the load in front and must take up a position which does not allow it tocome into contact with the walls of the lift shaft.Persons riding in the lift with the forklift truck must only enter the lift after the truck hascome to a rest and must leave the lift before the truck.

Nature of loads to be carried: The operator must make sure that the load is in asatisfactory condition. Only carry loads that are positioned safely and carefully. Usesuitable precautions, e.g. a load guard, to prevent parts of the load from tipping orfalling down.

3.4.2 Travel, Steering, Braking

The following definitions apply totravel direction specifications.

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Do not drive the truck unless the panels are closed and properly locked.When you start up the truck the drive pedal must be applied.

1.Driving• Close the safety gates.• Insert the key in the key switch(5)and turn it to the “ON” position .• Pull up the emergency brakeswitch(4) .• Apply the drive pedal(2).• Use the travel switch (3) to selectthe required driving direction.

Forward = V.Backward = R .

• The travel speed is governed by the speed mode .

Warning!When the circuit is switched on, thevehicle will have a self-test process.Makesure the lamps on the display unit stopflashing before operation.

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• Use steering wheel (1) to steer the truck in the required direction.2.SteeringUse steering wheel (1) to steer the truck in therequired direction.The drive wheel position isindicated in the driver’s display.3.BrakingThe brake pattern of the truck depends largely onthe ground conditions. The driver must take thisinto account when operating the truck.The drivermust be looking ahead when traveling. If there is no hazard, brake moderately toavoid moving the load .The truck can brake in three different ways:

• with the reversing brake• with the coasting brake• with the emergency brake

• With the reversing brakeWhile the truck is traveling press the travel switch (3). It switches to the opposite traveldirection and the truck deceleratesthrough the traction current controlleruntil it starts to move in the oppositedirection.• With the coasting brakeNot apply the drive pedal (2): Travelinhibited, truck decelerates.• With the emergency brakePress the emergency brake switch（4）The truck brakes until it comes to a halt.

3.4.3 Lifting - Lowering

Ensure there are no other people standing underneath the raised load anddriver's cab.Instruct other people to move out of the hazardous area.

Operator position

LiftingPull the "Lifting" button (1) until you reach the desired lift height.

LoweringPull the "Lowering" button (2) until you reach the desired height.

Warning!This method of braking only acts as aparking brake and not as a service brake.

Warning!The emergency brake switch (4) mustonly be used in dangerous situations.

Caution!Lowering,the vehicle sounds an intermittent alarmbeeper.

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Emergency Lowering ProceduresIf you lose power while elevated in the cage,instruct someone on ground level to pull theemergency lowering valve(1),which can lower theoperator position or fork.

3.4.4 Fixture

Pick palletWhen fork is going to pick pallet, press onpedal switch (1) ,and then fixture plate (2)is rotated. While the plate is in an openstate, the pallet can be picked; releasethe pedal switch(1) after picking pallet,andmake the plate stuck pallet.

Unload palletWhen fork is going to unloaded pallet,press on pedal switch (1) , and then theplate (2) is rotated. While the plate is in anopen state,the pallet can be unload;release the pedal switch (1) afterunloading pallet.

Warning!Do not climb out of the lift cage while theoperator position is elevated. The lift mastcannot be climbed safely. An elevatedoperator position has a high center of gravityand can be tipped easily. Standing on orleaning out from the outside of a cage rail maycause the lift vehicle to tip over. Tipping the liftvehicle over can cause severe injury or deathand equipment damage.

CAUTION!Fixture must clamp pallet beforetransporting.

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3.5 Parking the order picker securelyWhen you leave the order picker it must be securely parked even if you only intend toleave it for a short time.

• Lower the load completely andposition it horizontally.• Retract the mast and fork fully.• Set the emergency brake switch (2)“OFF”.• Turn off the key switch and remove the key(1).

Warning!Do not park the order picker on aslope. The load must always belowered to the ground.

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4.Battery Maintenance & Charging

4.1 Safety regulations for handling acid batteriesPark the order picker securely before carrying out any work on the batteries.

Maintenance personnel : Batteries may only be charged, serviced or replaced bytrained personnel .The present operator manual and the manufacturer ’s instructionsconcerning batteries and charging stations must be observed when carrying out thework.

Fire protection :• Smoking and naked flames must be avoidedwhen working with batteries.• Wherever a order picker is parked forcharging there shall be no inflammablematerial or operating fluids capable of creatingsparks within 2 meters around the orderpicker.• The area must be well ventilated.• Fire protection equipment must be provided.

Protection against electric shock:• Battery has high voltage and energy.• Do not bring short circuit.• Do not approach tools to the two poles of the battery，which can cause the sparkle.

4.2 Charging the battery

Safety regulations for Charging the battery

• To charge the battery, the tractor must be parked in a closed and properly ventilatedroom. When charging, the tops of the battery cells must be exposed to providesufficient ventilation.• Do not place any metal objects on the battery.• Before charging, check all cables and plug connections for visible signs of damage.• Forbid add water to battery directly.• Before start and finish charging tomake sure power is turn OFF.• It is essential to follow the safetyregulations of the battery and chargingstation manufacturers.

Warning!Before closing the battery cover makesure that the battery lead cannot bedamaged.

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Charging step• Check whether the condition is accordingwith "Safety regulations for Charging thebattery".• Park the order picker securely(See 3.5Parking the order picker securely ).• Remove the plug (1).• Connect the battery plug (1) with thecharging lead of the stationary charger(2)and turn on the charger.

4.3 Battery removal and installation

• Park the truck securely(See 3.5Parking the order picker securely ).• Place the battery plug or the batterycable in such a way that they will not getcaught on the order picker when thebattery(1) is removed.• .Remove battery baffle(2).Pull the batteryout from the side.• Installation is in the reverse order ofoperations.

CAUTION!The truck must be parked on level ground.When transporting batteries using a crane,ensure that the crane is of adequate Capacity.The lifting gear must exert a vertical pull sothat the battery container is not compressed.

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Warning!1. Do not use dry cloth or fabric cloth to clean the battery，avoiding static to bring theexplosion.2. Unfixing battery plug.3. Cleaning with wet cloth.4. Wearing glasses for protecting eyes rubber overshoes and rubber glove.

4.4 Battery maintenance

Do not overuse battery:• If you use up the energy of battery till the forklift immovability, you will shorten itsworking hours.• Shower for battery appears need for charge，please charge it quickly.

Inspection for electrolyte:• Do not using tow which is absent electrolyte.• Inspection for electrolyte level every week.• When electrolyte level is low，you must add distilled water to the level appointed.

Battery maintenance:The battery cell covers must be kept dry and clean. The terminals and cable shoesmust be clean, secure and have a light coating of dielectric grease.Batteries with noninsulated terminals must be covered with a non slip insulation mat.

Battery storage：If batteries are taken out of service for a lengthy period they should be stored in thefully charged condition in a dry, frost-free room. To ensure the battery is always readyfor use a choice of charging methods can be made:• a monthly equalizing charge as in point 4.2.

4.5 Battery Disposal

Batteries may only be disposed of in accordance with national environmentalprotection regulations or disposal laws.The manufacturer’s disposal instructions mustbe followed.

Batteries contain an acid solution which is poisonous and corrosive . Therefore ,always wear protective clothing and eye protection when carrying out work onbatteries . Above all avoid any contact with battery acid.

Nevertheless, should clothing, skin or eyes come in contact with acid the affectedparts should be rinsed with plenty of clean water-where the skin or eyes are affected

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call a doctor immediately. Immediately neutralize any spilled battery acid.

Only batteries with a sealed battery container may be used.

The weight and dimensions of the battery have considerable affect on the operationalsafety of the tractor. Battery equipment may only be replaced with the agreement ofthe manufacturer.

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5. Maintenance

5.1 Operational safety and environmental protection• The servicing and inspection operations contained in this chapter must be performedin accordance with the intervals indicated in the servicing checklists.• Any modification to the order picker assemblies, in particular the safety mechanisms,is prohibited. The operational speeds of the order picker must not be changed underany circumstances.• Only original spare parts have been certified by our quality assurance department.To ensure safe and reliable operation of the order picker, use only the manufacturer'sspare parts. Used parts, oils and fuels must be disposed of in accordance with therelevant environmental protection regulations. For oil changes, contact themanufacturer’s specialist department.• Upon completion of inspection and servicing, carry out the activities listed in the“Recommissioning” section.

5.2Maintenance Safety RegulationsMaintenance personnelOrder pickers must only be serviced and maintained by the manufacturer’s trainedpersonnel.The manufacturer’s service department has field technicians specially trained forthese tasks. We therefore recommend a maintenance contract with themanufacturer’s local service center.

Lifting and jacking upWhen a order picker is to be lifted, the lifting gear must only be secured to the pointsspecially provided for this purpose.When jacking up the order picker, take appropriate measures to prevent it fromslipping or tipping over (e.g. wedges, wooden blocks). You may only work underneatha raised load handler if it is supported by a sufficiently strong chain.

CleaningDo not use flammable liquids to clean the order picker.Prior to cleaning, all safety measures required to prevent sparking (e.g. through shortcircuits) must be taken. For battery-operated order pickers, the battery connectormust be removed. Only weak suction or compressed air and non-conductive antistaticbrushes may be used for cleaning electric or electronic assemblies.If the order picker is to be cleaned with a water jet or a high-pressure cleaner, allelectrical and electronic components must be carefully covered beforehand asmoisture can cause malfunctions.Do not clean with pressurised water.After cleaning the order picker, carry out the activities detailed in the“Recommissioning” section.

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Electrical SystemOnly suitably trained personnel may operate on the order picker’s electrical system.Before working on the electrical system, take all precautionary measures to avoid –electric shocks.For battery-operated order pickers, also de-energise the order picker by removing thebattery connector.

WeldingTo avoid damaging electric or electronic components, remove these from the orderpicker before performing welding operations.

SettingsWhen repairing or replacing electric or electronic components or assemblies, alwaysnote the truck-specific settings.

TyresThe quality of tyres affects the stability and performance of the order picker. Whenreplacing factory fitted tyres only used original manufacturer’s spare parts, asotherwise the data plate specifications will not be kept.When changing wheels and tyres, ensure that the order picker does not slew (e.g.when replacing wheels always left and right simultaneously).Hydraulic hosesThe hoses must be replaced every six years. When replacing hydraulic components,also replace the hoses in the hydraulic system.

5.3 Servicing and inspectionThorough and expert servicing is one of the most important requirements for the safeoperation of the order picker. Failure to perform regular servicing can lead to truckfailure and poses a potential hazard to personnel and equipment.The service intervals stated are based on single shift operation under normaloperating conditions. They must be reduced accordingly if the order picker is to beused in conditions of extreme dust, temperature fluctuations or multiple shifts.The following maintenance checklist states the tasks and intervals after which theyshould be carried out. Maintenance intervals are defined as:W = Every 50 service hours, at least weeklyA = Every 250 operating hoursB = Every 500 operating hours, or at least annuallyC = Every 2000 operating hours, or at least annuallyW service intervals are to be performed by the customer.In the run-in period - after approx. 100 service hours - or after repair work, the ownermust check the wheel nuts/bolts and re-tighten if necessary.

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5.3.1 Maintenance Checklist

Maintenanceinterval ●W A B C

Braking Check magnetic brake air gap. ●

Electricalsystem

Test instruments, displays and control switches. ●Test warning and safety device. ●Make sure wire connections are secure and check fordamage.

●

Test micro switch setting. ●Check contactors and relays. ●Fix the motor and cable. ●

Powersupply

Visually inspect battery. ●Visually inspect battery plug. ●Check battery cable connections are secure, greaseterminals if necessary.

●

Travel Check transmission for noise and leakage. ●Check travel mechanism, adjust and lubricate ifnecessary.

●

Check wheels for wear and damage. ●Check wheel suspension and attachments. ●Check drive support plate. ●

Truckframe

Check chassis for damage. ●Check labels. ●Check mast attachment. ●Check screw connections. ●Check gates and panels are secure and free of damage. ●

Hydraulicoperations

Test hydraulic system. ●Check that hose and pipe lines and their connections aresecure, check for leaks and damage.

●

Check cylinders and piston rods for damage and leaks,and make sure they are secure.

●

Check hydraulic oil level. ●Replace hydraulic oil. ●

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Maintenanceinterval ●W A B C

Lifting Check lifting chains and chain guides for wear, adjust andgrease

●

Check Load handler and Pallet for wear and damage. ●Perform sight check of rollers, sliding elements, and stops ●

Steeringsystem

Test electric steering. ●Check steering toothed for wear and lubricate. ●

Lubrication Grease the vehicle in accordance with the lubricationschedule.

●

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5.3.2 Lubrication Schedule

31

ConsumablesHandling consumables type material: Consumables must always be handledcorrectly. Follow the manufacturer’s instructions.

Improper handling is hazardous to health, life and the environment. Consumablesmust only be stored in appropriate containers. They may be flammable and musttherefore not come into contact with hot components or naked flames.

Only use clean containers when filling up with consumables. Do not mix consumablesof different grades. The only exception to this is when mixing is expressly stipulated inthe Operating Instructions.

Avoid spillage. Spilled liquids must be removed immediately with suitable bondingagents and the bonding agent/consumable mixture must be disposed of inaccordance with regulations.Code Description Used for

AL-HM46

Hydraulic oilL-HV32(Low temperature)

B Lubrication grease Lubrication surfaceC GL-80W-90 Gear case

5.3.3 Maintenance Instructions

Prepare the order picker for maintenanceand repairsAll necessary safety measures must betaken to avoid accidents when carrying outmaintenance and repairs. The followingpreparations must be made:• Park the order picker securely (See 3.5Parking the order picker securely ).• Remove the key to prevent the order pickerfrom accidentally starting.• When working under a raised lift truck,secure it to prevent it from tipping or slidingaway.

Open the cover• Remove the two screws (1).• Carefully open the cover (2) up.

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Replacing the drive wheelThe drive wheel must only be replaced by authorized service personnel.

Check the hydraulic oil level

It is going to add hydraulic oil when you heard explosion sound from pipe duringlifting.• Prepare the order picker for maintenance andrepairs ( See 5.3.3 Maintenance Instructions ).• Opening the cover.• Add hydraulic oil of the correct grade ( See5.3.2 Lubrication Schedule ) .Add hydraulic oil till you cant hear explosion sound during lifting.Installation is the reverse order.

Checking electrical fuses

• Prepare the truck for maintenance and repairs(See 5.3.3 Maintenance Instructions ).• Open the cover.• Check rating of all fuses in accordance with table,replace if necessary.

Item To protect: Rating1 Traction / Lift / Steer motor Fuse 200A2 Controller Fuse 10A

5.3.4 Recommissioning

The order picker may only be recommissioned after cleaning or repair work, once thefollowing operations have been performed.• Test horn.• Test Emergency brake switch.• Test brake.• Lubricate the order picker in accordance with the maintenance schedule.

Warning!Forbid adding hydraulic oil withinimpurity.

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5.4 Decommissioning the order picker

If the order picker is to be decommissioned for more than two months , e.g. Foroperational reasons,it must be parked in a frost-free and dry location and allnecessary measures must be taken before, during and after decommissioning asdescribed.On decommissioning the order picker must be jacked up so that all the wheels areclear of the ground. This is the only way of ensuring that the wheels and wheelbearings are not damaged.If the order picker is to be out of service for more than 6 months , further measuresmust be taken in consultation with the manufacturer’s service department.

5.4.1Prior to decommissioning

• Thoroughly clean the order picker.• Check the brakes.• Check the hydraulic oil level and replenishas necessary (See 5.3.3 MaintenanceInstructions ).• Apply a thin layer of oil or grease to anynon-painted mechanical components.• Lubricate the order picker in accordancewith the maintenance schedule (See 5.3.2Lubrication Schedule ).• Charge the battery (See 4.2Charging thebattery).• Disconnect the battery, clean it and apply grease to the terminals.In addition, follow the battery manufacturer’s instructions.• Spay all exposed electrical contacts with a suitable contact spray.

5.4.2 Restoring the order picker to operation after decommissioning

• Thoroughly clean the order picker.• Lubricate the order picker in accordance with the maintenance schedule (See 5.3.2Lubrication Schedule ).• Clean the battery, grease the terminals and connect the battery.• Charge the battery (See 4.2 Charging the battery ).• Check hydraulic oil for condensed water and replace if necessary.• Run the order picker (see 3.3 Run the truck ).

Battery powered trucks:If there are switching problems in the electrical system, apply contact spray to theexposed contacts and remove any oxide layers on the contacts of the operatingcontrols by applying them repeatedly.Perform several brake tests immediately after re-commissioning the truck.

Warning！Charge every months:• Charge the battery.Battery powered trucks:The battery must be charged atregular intervals to avoid depletion ofthe battery through self-discharge.The sulfatisation would destroy thebattery.

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5.5 Safety checks to be performed at regular intervals and following any

unusual incidentsCarry out a safety check in accordance with national regulations. We have a specialsafety department with trained personnel to carry out such checks. The order pickermust be inspected at least annually (refer to national regulations) or after any unusualevent by a qualified inspector. The inspector shall assess the condition of the orderpicker from purely a safety viewpoint, without regard to operational or economiccircumstances. The inspector shall be sufficiently instructed and experienced to beable to assess the condition of the order picker and the effectiveness of the safetymechanisms based on the technical regulations and principles governing theinspection of order pickers.

A thorough test of the order picker must be undertaken with regard to its technicalcondition from a safety aspect. The order picker must also be examined for damagecaused by possible improper use. A test report shall be provided. The test resultsmust be kept for at least the next 2 inspections.

The owner is responsible for ensuring that faults are immediately rectified.A test plate is attached to the order picker as proof that it has passed the safetyinspection. This plate indicates the due date for the next inspection.

5.6 Final de-commissioning, disposalFinal, proper decommissioning or disposal of the order picker must be performed inaccordance with the regulations of the country of application. In particular, regulationsgoverning the disposal of batteries, fuels and electronic and electrical systems mustbe observed.

35

6.TroubleshootingThis chapter is designed to help the user identify and rectify basic faults or the resultsof incorrect operation. When locating a fault, proceed in the order shown in the table.If the fault cannot be rectified after carrying out the remedial procedure, notify the

manufacturer ’ s service department ,as any further troubleshooting can only beperformed by specially trained and qualified service personnel.The manufacturer hasa customer service department specially trained for these tasks.

Fault Possible cause Actionorderpickerdoes notstart.

• Battery connector notconnected.• Key switch in “OFF” position• Safety gates open• EMERGENCY DISCONNECTswitch pressed

• Foot switch not pressed• Battery charge too low

• Faulty fuse• order picker in charge mode

• Check the battery connector andconnect if necessary.• Set key switch to “ON”• Close the safety gates• Unlatch EMERGENCYDISCONNECT switch

• Press foot switch• Check battery charge, chargebattery if Necessary• Test fuses• Interrupt charging

Load cannot belifted

• Hydraulic oil level too low• Excessive load

• Fuse blown

• Check the hydraulic oil level• Note maximum capacity (seedata plate)• Check fuses

To provide targeted and rapid response to faults, the following details are usefuland important to provide for the customer service department:• Order picker serial number• Display unit error number (if present)(see 6.1 Error Message)• Error description• Current location of order picker.

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6.1 Error Message

COMBIACX CONTROLLER

Error Message Possible cause Fault elimination

Code Error text

99 SLIP PROFILEThere is an error on the choice ofthe parameters of the slip profile.

Check in the hardware settingmenu the value of thoseparameters.

80 FORW+BACKThis alarm occurs when both thetravel demands (Fwd and Bwd)are active at the same time.

Check the wiring of the Fwdand Rev travel demand inputs(use the readings in theTESTER to facilitate thetroubleshooting). Check themicroswitches for failures.A failure in the logic is possibletoo. So, when you have verifiedthe travel demand switches arefine working and the wiring isright, it is necessary to replacethe controller.

79INCORRECTSTART

This is a warning for an incorrectstarting sequence.

The possible reasons for thisalarm are (use the readings inthe TESTER tofacilitate the troubleshooting):A) A travel demand active atkey onB) Presence man sensor activeat key onCheck the wirings. Check themicro-switches. It could be alsoan error sequence made by theoperator. A failure in the logic ispossible too; so when all of theabove conditions were checkedand nothing was found, replacethe controller.

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78 VACC NOT OK

The test is made at key-on andafter 20sec that both the traveldemands have been turned off.This alarm occurs if theACCELERATOR reading in theTESTER menu’ is 1,0V higherthan PROGRAM VACC minacquisition when the accelerator isreleased.

Check the mechanicalcalibration and the functionalityof the potentiometer.

62TH.PROTECTION

This alarm occurs when thetemperature of the base plate ishigher than 85°. Then themaximum current decreasesproportionally with the temperatureincreases from 85° up to 105°. At105° the Current is limited to 0Amps.

Improve the air cooling of thecontroller. If the alarm issignalled when the controller iscold, the possible reasons area thermal sensor failure or afailure in the logic card. In thiscase, it is necessary to replacethe controller.

65 BATTERY LOW

It occurs when the battery chargeis calculated being less than orequal to 10% of the full charge andthe BATTERY CHECK setting isother than 0 (refer to SET OPTIONmenu).

Get the battery charged. If itdoesn’t work, measure with avoltmeter the battery voltageand compare it with the value inthe BATTERY VOLTAGEparameter. If they are differentadjust the value of the ADJUSTBATTERY function.

71 EEPROM KO

It’s due to a HW or SW defect ofthe non-volatile embeddedmemory supporting the controllerparameters. This alarm does notinhibit the machine operations, butthe truck will work with the defaultvalues.

Try to execute a CLEAREEPROM operation (refer toConsole manual). Switch thekey off and on to check theresult. If the alarm occurspermanently, it is necessary toreplace the controller. If thealarm disappears, thepreviously stored parameterswill have been replaced by thedefault parameters.

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65MOTORTEMPERATURE

This warning occurs when thetemperature sensor is opened (ifdigital) or has overtaken thethreshold of 150°C (if analog).

Check the thermal sensorinside the motor (use theMOTOR TEMPERATUREreading in the TESTER menu);check the sensor ohmic valueand the sensor wiring. If thesensor is OK, improve the aircooling of the motor. If thewarning is present when themotor is cool, then the problemis inside the controller.

61THERMICSENSOR KO

The output of the controllerthermal sensor is out of range.

This type of fault is not relatedto external components;replace the controller.

CHECK UPNEEDED

This is just a warning to call for thetime programmed maintenance.

It is just enough to turn theCHECK UP DONE option tolevel ON after the maintenanceis executed.

DATAACQUISITION

Acquisition of the current gains.The alarm ends when theacquisition is done.

86 PEDAL WIRE KO

The SW continuously checks forthe connection of the two supplyends of the potentiometer in theaccelerator. The test consists ofreading the voltage drop on asense diode, connected betweenNPOT (CNA#30) and GND andcascaded with the potentiometer:if the potentiometer getsdisconnected on PPOT (CNA#25)or NPOT, no current flows in thissense diode and the voltage onthe NPOT connection collapsesdown. When the NPOT voltage isless than 0.3V this alarm occurs.This alarm occurs also when theNPOT voltage is higher than 2Vdc(to detect also the condition of abroken sense diode).

Check the voltage on NPOTand the potentiometerconnections.

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51 TILLER OPEN

Warning: when the tiller isreleased, after a fixed period oftime of standby (30 seconds) themain contactor open.

At the next travel request thewarning disappear.

92 CURRENT GAIN

The Maximum current gainparameters are at the defaultvalues, which means themaximum current adjustmentprocedure has not been carriedout yet.

Ask the assistance of a Zapitechnician to do the correctadjustment procedure of thecurrent gain parameters.

68WAITING FORNODE

The controller receives from theCAN the message that anothercontroller in the net is in faultcondition; as a consequence theACE0 controller itself cannot enteran operative status, but has toWAIT for the other controllercoming out from the fault status.

76VALVE COILSHORTED

This alarm occurs when there is ashort circuit on an on/off valve coil.

A) If the fault is present at startup, it is very likely that the hwovercurrent protection circuit isdamaged, it is necessary toreplace the controller.B) If the fault is present whenthe controller drives theoutputs, the problem is locatedin the harness and in the coils.

74EV1 DRIVERSHORTED

Electrovalve EV1 driver is shorted.

Check if there is a short or alow impedence between thenegative of one of those coilsand –BATT. Otherwise thedriver circuit is damaged andthe controller must be replaced.

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74EV2 DRIVERSHORTED


Check if there is a short or alow impedance between thenegative of this coil and –BATT.This warning occurs also if theexternal load is not present andthe parameter EV2 in the “SetOptions” menu is set“PRESENT”, in this case thewarning disappears setting theEV2 parameter “ABSENT”.Otherwise the driver circuit isdamaged and the controllermust be replaced.

74EV3 DRIVERSHORTED


Check if there is a short or alow impedance between thenegative of this coil and –BATT.This warning occurs also if theexternal load is not present andthe parameter EV3 in the “SetOptions” menu is set“PRESENT”, in this case thewarning disappears setting theEV3 parameter “ABSENT”.Otherwise the driver circuit isdamaged and the controllermust be replaced.

56 PUMP I NO ZERO

In standby condition (pump motornot driven), the feedback comingfrom the current sensor in thepump chopper gives a value out ofa permitted range,

This type of fault is not relatedto external components;replace the controller.

52 PUMP I=0 EVER

This test is carried out when thepump motor is running, and itverifies that the current feedbacksensor is not constantly stuck to 0.

A) Check the motor connection,that there is continuity. If themotor connection is opened,the current cannot flow, so thetest fails and the error code isdisplayed.B) If everything is ok for what itconcerns the motor, theproblem could be in the currentsensor or in the related circuit.

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75 CONT. DRV. EV1The EV1 valve driver is not able todrive the load (cannot close).

The device or its driving circuitis damaged, replace thecontroller.





89PUMP VACC NOTOK

The minimum of the liftpotentiometer is not correctly set.

It is suggested to repeat a“PROGRAM VACC” procedure.

67SENS.MOT.TEMP. KO

A) The motor temperature sensoris not correctly connected to A22.B) The motor temperature sensoris damaged.

- Check the correct connectionof the motor temperaturesensor.- If the current sensor iscorrectly connected, replace it.- If the problem persist, it is dueto the controller.

85VACC OUTRANGE

The voltage on CNC#4 is outsideof the parameters’ range.

Please re-acquire the VACCparameters with a PROGRAMVACC procedure.

11 STALL ROTORThe traction rotor is stuck or theencoder signal is not correctlyreceived by the controller.

Please check if the sign ofFREQUENCY and ENCODERon the tester menu are thesame and different than zeroduring a traction request.

48EVP DRIVEROPEN

The EVP driver is damaged or theEVP coil impedance is too law.

Please check the EVP coilimpedance. If the EVPimpedance is OK, the problemis inside the controller.

49MANY PUMPREQS

More than one pump functionswere requested at the same time.

Just one pump function at atime can be requested. Pleasereset all the requests and tryagain.

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79PUMP INCSTART

This is a warning for a pumpincorrect starting sequence.

The possible reasons for thisalarm are:A) Pump request active atkeyon.B) Pump request active withoutman presence.Check the wirings. Check themicro-switches. It could also bean error sequence made by theoperator. A failure logic ispossible too. When all of theabove conditions were checkedand nothing was found, replacethe controller.

90PUMP VACCRANGE

The voltage on CNC#9 is outsideof the parameters range.

If the EVP TYPE parameter isset to ANALOG, please acquireagain the values of MINLOWER and MAX LOWER.If the controller is in Combiacxconfiguration and thePROPORTION. LIFTparameter is set to ON, pleaseacquire again also the values ofMIN LIFT and MAX LIFT.

13PARAMRESTORE

This warning appears when thecontroller restored the defaultvalues.

If a CLEAR EEPROM wasmode before the lastkeyon-recycle, this warning justmeans that the EEPROM wascorrectly cleared. A traveldemand or a pump requestcancel the alarm.If this alarm appears at keyonwithout any CLEAR EEPROMrequest by the operator, therecould be a problem inside thecontroller.

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EPS-AC0 CONTROLLER

Error MessagePossible cause Fault elimination

Error Error text

6 SERIAL ERR #1

Main uC and Slave uCcommunicate via a localserial interface. This alarmoccurs when the slave uCdoes not receive thecommunication from themain uC through this serialinterface.

It is necessary toreplace the controller.

13 EEPROM KO

It occurs if a test to writeand read one location inEEPROM fails. The SWexpects to read the writtenvalue. It occurs also whenthe hour counter givesdifferent values between thethree redundant locations inwhich it is recorded. Itoccurs also when the busybit of the EEPROM does notrise within 12 msec.


16 LOGIC FAILURE #4

This alarm occurs in the reststate if the output of thevoltage amplifier of thephase Vw-Vv have a driftlarger than ±0.25 V.


17 LOGIC FAILURE #3

This alarm occurs in the reststate if the output of thevoltage amplifier of thephase Vu-Vw have a driftlarger than ±0.25 V.


18 LOGIC FAILURE #2

This alarm occurs when thereal voltage betweenphases W and V of themotor is different from thedesired.


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19 LOGIC FAILURE #1

This alarm occurs when thereal voltage betweenphases W and U of themotor is different from thedesired.


32 VMN NOT OK

This alarm occurs in theinitial rest state after key onif the outputs of the motorvoltage amplifiers are not inthe window from 2.2 to 2.8Vdc.


48 MAIN CONT. OPEN

This alarm occurs onlywhen the setting CAN BUSis PRESENT. Then theeps-ac0 waits for a via CANinformation that the tractioncontroller has closed themain contactor. If thisinformation lacks more thanabout 1.5 secs, this alarmoccurs.

Find, on the tractioncontroller, the reason forkeeping the maincontactor open.

53 STBY I HIGH

This alarm occurs two ways:1) In the initial rest stateafter key on, if the outputs ofthe current amplifiers arenot comprised in thewindow 2.2 to 2.8 Vdc.2) After the initial diagnosisthis alarm occurs when theoutputs of the currentamplifiers at rest have a driftlarger than ±0.15 V.


61 HIGH TEMPERATURE

This alarm occurs if thetemperature of thecontroller base plateovertakes 75 degrees.

Improve the cooling ofthe controller; otherwiseit is necessary toreplace the controller.

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65 MOTOR TEMPERAT.

This alarm occurs onlywhen DIAG MOTOR TEMPis on and the thermalsensor inside the motormeasures a temperaturehigher than 150 degrees. Itoccurs also when trying toacquire the motorresistance with atemperature in the motorhigher than 150 degree(still with DIAG MOTORTEMP to ON).

Check the thermalsensor in the motor isright working. If it is,improve the cooling ofthe motor.

70 HIGH CURRENT

This alarm occurs if thecircuit to limit via hardwarethe current in the motor iseither always active atkey-on or repeatedly activewhen the motor is turning.

Check the motor issuited to work with theeps-ac0 (not oversized).Otherwise it isnecessary to replacethe controller.

71 POWER FAILURE #3

This alarm occurs when thecurrent in the phase V of themotor is zero and the motoris commanded for moving.

Check the power fuse isOK. Check the batterypositive arrives to thecontroller. Check thecontinuity of the wire inthe phase V of themotor. Otherwise it isnecessary to replacethe controller.

72 POWER FAILURE #2

This alarm occurs when thecurrent in the phase U of themotor is zero and the motoris commanded for moving.

Check the power fuse isOK. Check the batterypositive arrives to thecontroller. Check thecontinuity of the wire inthe phase U of themotor. Otherwise it isnecessary to replacethe controller.

46

73 POWER FAILURE #1

This alarm occurs when thecurrent in the phase W ofthe motor is zero and themotor is commanded formoving.

Check the power fuse isOK. Check the batterypositive arrives to thecontroller. Check thecontinuity of the wire inthe phase W of themotor. Otherwise it isnecessary to replacethe controller.

83 BAD ENCODER SIGN

It occurs in applications withtoggle switches when theapplied frequency(FREQUENCY) and themotor speed (ENC SPEED)have opposite sign.

Swap in between thetwo encoder channels(CNB#7 with CNB#8).

84 STEER SENSOR KO

This alarm occurs if thecommand potentiometer(CPOC1 on CNA#9 orCPOC2 on CNA#8)changes with a jerk largerthan MAX SP SLOPE (see12.4.6.3). This alarm isused to catch a discontinuityin the voltages of thecommand potentiometer.

Change the twin pot.

85 STEER HAZARD

This is just a warning toinform that the steeringcontroller is limiting theangle in the steeringdirection. No speedreduction occurs on thetraction.

——

218 CLOCK PAL NOT OK

The main uC sends ananalog signal towards theslave uC to reset the slaveuC on demand. When theslave uC detects this analogsignal external to a windowfrom 2.2 to 2.8 and not inthe range to generate thereset on demand, the slaveuC raises this alarm.


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99 INPUT ERROR #1

It occurs when the voltageon CNA#4 (NK1: LowerPotential Terminal of theSafety Contacts (see 7.6) ishigher than 12 V before toturn the safety contactsclosed.

When the safetycontacts are open, thevoltage on CNA#4 isexpected to be close to0 Vdc and this isindependent fromwhether the safetycontacts are connectedto a plus battery or to aminus battery . In thefirst case (safetycontacts connected to aplus battery), when thesafety contacts areopen, CNA#4 isconnected to a minusbattery through a load.Only a harness mistakemay connect NK1 to ahigher than 12 Vvoltage.

212 MICRO SLAVE #8

It occurs when the encodercounting of the main uC isnot matched with theencoder counting of theslave uC.


219 STEPPER MOTOR MISM

This alarm occurs if thefrequency and theamplitude of the voltagesfrom the stepper motor linesare mismatched in betweenIn normal condition whenthe amplitude of the steppermotor lines increases, thefrequency of the steppermotor lines must increasetoo.


220 MOTOR LOCKED

This alarm occurs if thecurrent in the steering motorstays close to the maximumcurrent longer than 1 sec.

Search for a mechanicalproblem locking themotor. To make easierthe fault catching, setDEBUG OUTPUT tolevel 11.

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221 MICRO SLAVE #4

It occurs in one of thefollowing conditions:(Open loop application only)If the slave uC detects thestator voltage phasorrotates in the oppositedirection respect to the signof the stepper motor speed,this alarm occurs. (Closedloop application only) If theslave uC detects the statorvoltage phasor rotates inthe opposite directionrespect to the commandedposition, this alarm occurs.


222 FB POT LOCKED

In application with afeedback potentiometer, thisalarm occurs if the feedbackpotentiometer (CPOT onCNB#6) does not change(or changes in the oppositedirection) its value even ifcommanded to change.In application with toggleswitches with ENCODERCONTROL to off, this alarmoccurs if the feedbackencoder counting does notchange its value even ifcommanded to change.

In application with thefeedback potentiometer,verify the feedbackpotentiometer is notmechanically loosened.Check there is not amechanical block of thesteered wheel. Be surethe wiper has notreached its ownelectrical limit becauseof too much angle of thesteered wheel. Besides,this alarm may occur atthe installation when themotor rotates in thewrong direction turningaway from the wished

223 JERKING FB POT

This alarm occurs if thefeedback potentiometer(CPOT onCNB#6) changes with a jerklarger than 0.3 V in 16msec. Thisalarm is used to catch adiscontinuity in the voltagesof thefeedback potentiometer.

Change the feedbackpotentiometer.

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225 CURRENT GAIN

This alarm occurs when theparameters to compensatefor the gain of the currentamplifiers (ADJUSTMENT#03 and ADJUSTMENT#04) have the default values

It is necessary to sendthe controller to Zapi toperform the maximumcurrent regulation.

226 NO SYNC

Every 16msec, inside thecode cycle, the main uCrises and then lowers aninput for the slave uC(SYNC). When the slave uCdetects no edge for morethan 100 msec on this input,this alarm occurs. This isjust a watch dog function:when the main uC does notexecute the code cycle itdoes not update the SYNCsignal and the slave uC cutsoff the steer and traction.


227 SLAVE COM. ERROR

Main uC and Slave uCcommunicate via a localserial interface. This alarmoccurs when the main uCdoes not receive thecommunication from theslave uC through this serialinterface.


237 WAITING DATA

This warning occurs only ifCAN BUS is PRESENT. Atkey-on the eps-ac0 asks tothe traction controller tosend a list of parametersvia CAN Bus. From therequest until the parametersare correctly relieved, thiswarning occurs. The steer isnot activated yet, and thesafety relays remain openwhen this warning ispresent.

——

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228 POSITION ERROR

This alarm occurs for anerror in the redundant testof the feedback sensors.

Check thepotentiometerconnected to CNB#6 isright working. If toggleswitches are connectedto CNA#2 and CNA#3,verify they are rightworking and the settingAUX FUNCTION 11 iscorrect. Verify also thesensor bearing in themotor (encoder) has nota slip (the sensorbearing has two rings:one is connected to therotor shaft; the other isconnected to the motorframe. Check these tworings are strictlyconnected to theirstructure without slip.

238 EPS NOT ALIGNED

This is a real alarm that cutoff the traction. It occurs atthe initial alignment if thestraight-ahead condition isnot matched within 6sec.Throughout this 6 secsdelay, the steer is notactivated yet, the safetyrelays are open and thetraction is stopped.

——

239 WAITING FOR TRAC

At key-on the eps-ac0needs an assent from thetraction controller to closethe safety contacts and toturn onto operational mode.Until this assent is notrelieved, this warningoccurs. The steer is notactivated yet and the safetyrelays remain open whenthis warning is present.

——

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241 ENCODER ERROR

It occurs when ENCODERCONTROL is set ON andthe real frequency does notpursuit the commandedfrequency

This condition is severaltimes due to either, amismatching betweenthe Encoder resolutionused in the SW and thereal encoder resolution,or a wrong connectionbetween the twoencoder channels. Inthis latest caseexchange in betweenthe two encoderchannels.

242 Q LINE SENSOR KO

This alarm occurs when themean voltage on theQuadrature line of thestepper motor (connectionCNA#8) is not null: thevoltage on every steppermotor line is a sine wavewith null mean voltage.

Check the continuity ofthe stepper motorconnections. Inparticular the resistancebetween CNA#8 andthe minus battery (withthe stepper motor atrest) is expected beingvery low (close to 30ohms).

243 D LINE SENSOR KO

This alarm occurs when themean voltage on the Directline of the stepper motor(connection CNA#9) is notnull: the voltage on everystepper motor line is a sinewave with null meanvoltage.

Check the continuity ofthe stepper motorconnections. Inparticular the resistancebetween CNA#9 andthe minus battery (withthe stepper motor atrest) is expected beingvery low (close to 30ohms).

245 DATAACQUISITION

This alarm occurs when theacquiring the motorresistance or whenadjusting the parameters tocompensate for the gain ofthe current amplifiers(maximum current factoryadjusted).

Recycle the key.

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244 GAIN EEPROM KO

The parameters tocompensate for the gain ofthe current amplifiers(ADJUSTMENT #03 andADJUSTMENT #04) arerecorded in a not volatilememory (eeprom) with aredundant handling. In factevery adjustment isrecorded in three eepromlocations. If the values inthese three locations aredifferent in between thisalarm occurs.

It is necessary to sendthe controller to Zapi toexecute the maximumcurrent regulation.

246 MICRO SLAVE KO

In stepper motorapplication, this alarmoccurs if the main uC isdetecting a direction of thestepper motor not matchedwith the one that the slaveuC is detecting.In closed loop application,this alarm occurs if the mainuC is detecting a directionof the steering error notmatched with the one thatthe slave uC is detecting.Furthermore, this alarmoccurs also if the main uC isdetecting no steeringlimitation meanwhile theslave uC is detecting esteering limitation.


247 CAN BUS KO

This alarm occurs onlywhen the setting CAN BUSis PRESENT. Then theeps-ac0 must receive theevent messages from thetraction controller. If thesemessages lack more thanabout 1 sec, this alarmoccurs.

Check the CAN Buscommunication systemand analyse theframes from the tractioncontroller to the steercontrollers.

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248 S.P OUT OF RANGE

This alarm occurs for a faulton the commandpotentiometer (CPOC1 onCNA#9, CPOC2 onCNA#8). When a singlecommand pot is chosen, thealarm occurs if its wiper(CPOC1) exits the rangefrom 0.8 Vdc to 4.2 Vdc.When the twin pot ischosen, the alarm occurs ifthe sum of the two wipervoltages (CPOC1+CPOC2)exits the range from 4.5 Vdcto 5.5 Vdc.

Check the connectionsof the potentiometer.This alarm occurs whenone connection of thecommandpotentiometer is broken.

249 F.B OUT OF RANGE

This alarm occurs for a faulton the feedbackpotentiometer (CPOT onCNB#6). This alarm occursif CPOT exits the rangefrom 0.3 Vdc to 4.7 Vdc.

Check the connectionsof the feedbackpotentiometer. Thisalarm occurs when oneconnection of thefeedback potentiometeris broken.

250 MICRO SLAVE

It occurs when theinformation on the statusbus between the main uCand the slave uC is frozento the 0xFF value (the slaveuC does not update thestatus bus configuration).


251 KM OPEN

This alarm occurs if theslave uC detects the safetycontact, of the main uC,open when expected beingclosed.


252 KS OPEN

This alarm occurs if themain uC detects the safetycontact, of the slave uC,open when expected beingclosed.


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253 KM CLOSED

This alarm occurs at key onif the slave uC detects thesafetycontact, of the main uC,closed prior to becommanded.

This alarm occurs if theconnection CNA#5 (K1)is around a voltage of12 Vdc when switchingon the key. In fact, whenthe safety contacts areopen, K1 is expectedbeing connected to abattery voltage (not 12V). Search for a harnessproblem or replace thecontroller.

254 KS CLOSED

This alarm occurs if themain uC detects the safetycontact, of the slave uC,closed prior to becommanded.

This alarm occurs if theconnection CNA#4(NK1) is around avoltage of 12 Vdc whenswitching on the key. Infact, when the safetycontacts are open, NK1is expected beingconnected to a minusbattery voltage (not 12V). Search for a harnessproblem or replace thecontroller.

h:jx3 operation manual - ep equipment new zealand€¦ · – place directional control in neutral...

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