We build a better

future
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Introduction Hyundai’s production plant (Ulsan)
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New AC front drive battery models:

15/18/20BT-9 16/18/20B-9

22/25/30/32/35B-9 22/25/30/35BH-9

40/45/50B-9
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Table of contents

GENERAL MACHINE INTRODUCTION

DRIVE UNITS AND INTEGRATED WET BRAKES
HYDRAULIC SYSTEMS
ELECTRIC SYSTEMS
NEW CLUSTER
CONTROLLERS AND PARAMETERS
ERROR CODE LIST
MAINTENANCE
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GENERAL MACHINE INTRODUCTION 15/18/20BT-9

ZAPI DUAL AC2 drive controller 330A+330A/48V

ZAPI AC2 pump controller 450A/48V
2 x HHI (Prestolite) drive motor 4,7 kW
1 x HHI (Prestolite) pump motor 14 kW
MS Precision transmissions + wet brake
Calibration through calibrator or display
3 user modes selectable (H, N, E)
Travel speed 16 km/h
Load weight indicator - option
Automatic tilt positioning system - option
Fingertip control available - option
Battery side loading system
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GENERAL MACHINE INTRODUCTION 15/18/20BT-9

1 Lift cylinder
2 Mast
3 Steering unit
4 Backrest
5 Tilt cylinder
6 Priority valve
7 Forks
8 Front wheel
9 Drive unit
10 Drive motor
11 Pump motor
12 Hydraulic pump
13 Main control valve
14 Battery
15 Rear wheel
16 Steering axle
17 Counterweight
18 Traction controller
19 Pump controller
20 Seat
21 Overhead guard
22 Steering wheel
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GENERAL MACHINE INTRODUCTION 15/18/20BT-9
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GENERAL MACHINE INTRODUCTION 16/18/20B-9

ZAPI DUAL AC2 drive controller 330A+330A/48V

ZAPI AC2 pump controller 450A/48V
2 x HHI (Prestolite) drive motor 4,7 kW
1 x HHI (Prestolite) pump motor 14 kW
MS Precision transmissions + wet brake
Calibration through calibrator or display
3 user modes selectable (H, N, E)
Travel speed 16 km/h
Load weight indicator - option
Automatic tilt positioning system - option
Fingertip control available - option
Battery side loading system
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GENERAL MACHINE INTRODUCTION 16/18/20B-9

1 Lift cylinder
2 Mast
3 Steering unit
4 Backrest
5 Tilt cylinder
6 Priority valve
7 Forks
8 Front wheel
9 Drive unit
10 Drive motor
11 Pump motor
12 Hydraulic pump
13 Main control valve
14 Battery
15 Rear wheel
16 Steering axle
17 Steering cylinder
18 Counterweight
19 Traction controller
20 Pump controller
21 Seat
22 Overhead guard
23 Steering wheel
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GENERAL MACHINE INTRODUCTION 16/18/20B-9
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GENERAL MACHINE INTRODUCTION 22/25/30/32/35B-9

ZAPI DUAL AC2 drive controller 450A+450A/48V

ZAPI AC3 pump controller 600A/48V
2 x HHI (Prestolite) drive motor 2x7.0 kW
1 x HHI (Prestolite) pump motor 17.0 kW
SEIL Industrial transmissions + wet brake
Calibration through calibrator or display
3 user modes selectable (H, N, E)
Travel speed 18 km/h (unloaded)
Battery side loading system
Options: Load weight indicator
Automatic tilt leveling system
Fingertip control
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GENERAL MACHINE INTRODUCTION 22/25/30/32/35B-9

1 Lift cylinder
2 Mast
3 Backrest
4 Steering unit
5 Tilt cylinder
6 Main control valve
7 Forks
8 Front wheel
9 Drive unit
10 Drive motor
11 Hyd gear pump
12 Pump motor
13 Battery
14 Rear wheel
15 Steering axle
16 Steering cylinder
17 Counterweight
18 Traction controller
19 Pump controller
20 Seat
21 Overhead guard
22 Steering wheel
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GENERAL MACHINE INTRODUCTION 22/25/30/32/35B-9
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GENERAL MACHINE INTRODUCTION 22/25/30/35BH-9

Dual AC2 Power traction controller 80V, 300+300A

AC2 Power Pump controller 80V, 400A
2 x HHI (Prestolite) drive motor 8.0 kW
1 x HHI (Prestolite) pump motor 19.7 kW
SEIL Industrial transmissions + wet brake
Calibration through calibrator or display
3 user modes selectable (H, N, E)
Travel speed 19 km/h
Load weight indicator option
Automatic tilt positioning system option
Fingertip control available as option
Battery side loading system
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GENERAL MACHINE INTRODUCTION 22/25/30/35BH-9

1 Lift cylinder
2 Mast
3 Backrest
4 Steering unit
5 Tilt cylinder
6 Main control valve
7 Forks
8 Front wheel
9 Drive unit
10 Drive motor
11 Hyd gear pump
12 Pump motor
13 Battery
14 Rear wheel
15 Steering axle
16 Steering cylinder
17 Counterweight
18 Traction controller
19 Pump controller
20 Seat
21 Overhead guard
22 Steering wheel
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GENERAL MACHINE INTRODUCTION 22/25/30/35BH-9
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GENERAL MACHINE INTRODUCTION 40/45/50B-9

2xAC3 Power traction controller 80V, 2x600A

AC3 Power Pump controller 80V, 600A
2 x HHI (Prestolite) drive motor 10.0 kW
1 x HHI (Prestolite) pump motor 28.7 kW
PRO-MEC (ITA) transmissions + wet brake
Calibration through calibrator or display
3 user modes selectable (H, N, E)
Travel speed 19 km/h
Load weight indicator option
Automatic tilt positioning system option
Fingertip control available as option
Battery side loading system
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GENERAL MACHINE INTRODUCTION 40/45/50B-9

1 Lift cylinder
2 Mast
3 Backrest
4 Steering unit
5 Tilt cylinder
6 Main control valve
7 Drive motor
8 Forks
9 Front wheel
10 Drive unit
11 Pump motor
12 Battery
13 Rear wheel
14 Steering axle
15 Steering cylinder
16 Counterweight
17 Traction controller
18 Pump controller
19 Seat
20 Overhead guard
21 Steering wheel
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GENERAL MACHINE INTRODUCTION 40/45/50B-9
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DRIVE UNITS BRAKES 15/18/20BT-9 16/18/20B-9

1 Brake pedal & bracket assy AZOLLA ZS32

2 Parking lever assy
3 Reservoir tank assy
4 Brake master cylinder

AZOLLA ZS32

Mobilfluid 424
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DRIVE UNITS BRAKES 15/18/20BT-9 16/18/20B-9
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DRIVE UNITS BRAKES 15/18/20BT-9 16/18/20B-9
1 Drive unit assembly (LH) 9 Dowel pin
2 Drive unit assembly (RH) 10 Socket bolt
3 Housing sub assembly (LH) 11 Input pinion
4 Housing sub assembly (RH) 12 Ball bearing
5 Cover out sub assembly (LH)
6 Cover out sub assembly (RH)
7 Parking sub assembly (LH)
8 Parking sub assembly (RH)

13 Snap ring (for shaft)

14 Snap ring (for hole)
15 Air breather
16 Breather
17 Rubber cap
18 O-ring
19 Brake plug
20 Plug
21 Magnetic plug
22 Set screw
23 Hex nut
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DRIVE UNITS BRAKES 15/18/20BT-9 16/18/20B-9

15 Planetary carrier 21 Special bolt

16 Lock nut 22 Back plate
17 Thrust washer 23 Friction disc
18 Needle bearing 24 Plate
19 Planetary gear 25 Set screw
20 Snap ring 26 Thrust washer

3 Housing carrier (LH) 9 Taper roller bearing

4 Housing carrier (RH) 10 Needle bearing
5 Oil seal 11 Shim
6 Gamma seal 12 Shim
7 Wheel hub 13 Shim
8 Hub bolt 14 Shim Improvement
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DRIVE UNITS BRAKES –
15/18/20BT-9 16/18/20B-9
IMPROVEMENT
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DRIVE UNITS BRAKES 15/18/20BT-9 16/18/20B-9

1 Cover out assembly (LH)

2 Cover out assembly (RH)
3 Cover out (LH)
4 Cover out (RH)
5 Parallel pin 1 Parking sub assembly (LH)
6 Friction block 2 Parking sub assembly (RH)
7 Ring gear (83T) 3 Parking cover (LH)
8 Ball bearing 4 Parking cover (RH)
9 Snap ring 5 Piston
10 Actuator 6 Quad ring
11 Return spring 7 Backup ring
8 Quad ring
12 Sun pinion 9 Backup ring
13 Socket bolt 10 Shaft
11 Lever
12 Snap ring
13 O-ring
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DRIVE UNITS BRAKES 15/18/20BT-9 16/18/20B-9

Tips during drive unit assembly

For detailed information please see Service Manual

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DRIVE UNITS BRAKES 15/18/20BT-9 16/18/20B-9

Tips during drive unit assembly

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DRIVE UNITS BRAKES –
15/18/20BT-9 16/18/20B-9
IMPROVEMENT

Hand brake lever

#0086 - 15BT-9 1400

#0111 - 18BT-9 1410
#0129 - 20BT-9
XKCF-01240
#0184 - 16B-9 3900
#0064 - 18B-9 4000
#0199 - 20B-9

Drive unit serial numbers

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DRIVE UNITS BRAKES 22/25/30/32/35B-9 22/25/30/35BH-9

SEIL Industrial Co
Korea
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DRIVE UNITS BRAKES 22/25/30/32/35B-9 22/25/30/35BH-9

ADJUSTMENT OF BRAKE PEDAL

Height
Pedal height from floor plate adjust with stopper bolt.
·Pedal height : 133 mm (5.2 in)
Play
Adjust with rod of master cylinder.
·Pedal play : 4~6 mm (0.15~0.23 in)

Azolla ZS32

AZOLLA ZS32

Mobilfluid 424 1ltr/side

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DRIVE UNITS BRAKES 22/25/30/32/35B-9 22/25/30/35BH-9
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DRIVE UNITS BRAKES 22/25/30/32/35B-9 22/25/30/35BH-9
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DRIVE UNITS BRAKES 40/45/50B-9
ADJUSTMENT OF BRAKE PEDAL
Height
Pedal height from floor plate adjust with stopper
bolt.
·Pedal height : 130 mm (5.2 in)
Play
Adjust with rod of master cylinder.
·Pedal play : 4~6 mm (0.15~0.23 in)
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DRIVE UNITS BRAKES 40/45/50B-9

1 Spacer bearing 35 Helix pinion 53 Piston seal

2 Wheel hub 18 Retaining ring 36 Ball bearing 54 Piston
3 Wheel fixing 19 Ring gear 37 Retaining ring 55 Step seal
screw carrier disc 38 Retaining ring 56 Piston
4 Needle cage 20 Ring gear 39 Locking pin 57 Disk pusher
5 Shaft seal 21 Stud 40 Sun pinion 58 Friction disk
6 Taper roller 22 Washer 41 Feather key 59 Steel disk
bearing 23 Hexagon nut 42 Elastic pin 60 Support disk
7 Spacer 24 Planet carrier 43 Lever 61 Spring
8 Breather plug 25 Retaining ring 44 Pin 62 Fixing screw
9 Cap screw 26 Planet gear 45 Cap screw 63 Locking pin
10 Cap screw 27 Roller bearing 46 Screw plug 64 Spring
11 Cap screw 28 Retaining ring 47 Washer
12 Housing 29 Lock nut 48 Connection
13 Screw plug 30 Retaining ring 49 Bleeder nipple
14 Magnetic plug 31 Helix gear cap
15 Locking pin 32 Retaining ring 50 Bleeder nipple
16 Needle cage 33 Ball bearing 51 Brake housing
17 Taper roller 34 Cover 52 Seal
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DRIVE UNITS BRAKES 40/45/50B-9
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DRIVE UNITS BRAKES - general
Model Initial(50~250hrs) 2000hrs Drive Unit(Axle) Spec Q-ty [l] Brake
Gear oil
10~15BTR-9 • • ZF SAE 80W-90 6 VG 32
replacement 15~20BT-9; 16~20B-9 • • MSP MF 424 0.6 VG 32
interval 22~35B-9; 22~35BH-9 • • SI MF 424 1 VG 32
40~50B-9 • • PRO-MEC MF 424 1.5 DOT 3

Brake oil
specification
change
©GN-HHIE

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©GN-HHIE

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HYDRAULIC SYSTEMS 15/18/20BT-9
Tilt lock valves - ALL BATTERY MODELS
40 l/min; 350bar; 50ms; 12V; 1150mA
31HE-70010 - Manifold Assy-Auto Tilt

1 Hydraulic gear pump

2 Priority valve
3 Main control valve
4 Steering unit
5 Hydraulic motor
6 Tilt cylinder
7 Lift cylinder
8 Suction strainer
9 Return filter
10 Down safety valve
Steering: 100 Bar 11 Down control valve
Main: 12 Hydraulic oil tank
15BT-9 = 160 Bar 13 Main relief valve
18BT-9 = 180 Bar 14 Aux relief valve
20BT-9 = 190 Bar 15 OPSS valve
Auxiliary: +/- 130Bar 16 Holding valve
17 Emergency valve
Emergency descending valve unscrew max 2 turns
©GN-HHIE

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HYDRAULIC SYSTEMS 15/18/20BT-9 16/18/20B-9

OPSS active OPSS inactive

Pressure from lift Pressure from lift

cylinders and spring cylinders is higher on
in holding valve close the „right side” and
the holding valve and wins with spring –
stop lowering holding valve is open
function

Down safety v/v Down control v/v

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HYDRAULIC SYSTEMS 15/18/20BT-9 16/18/20B-9

Lift Lower Tilt forward Tilt backwards

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HYDRAULIC SYSTEMS 15/18/20BT-9 16/18/20B-9
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HYDRAULIC SYSTEMS 16/18/20B-9

1 Hydraulic gear pump 9 Down safety valve

2 Main control valve 10 Return filter
3 Steering unit 11 Hydraulic oil tank
4 Steering cylinder 12 Priority valve Steering: 100 Bar
5 Tilt cylinder 13 OPSS valve Main:
6 Lift cylinder 14 Holding valve 16B-9 = 160 Bar
7 Suction strainer 15 Emergency valve 18B-9 = 180 Bar
8 Down control valve 20B-9 = 190 Bar
Auxiliary: +/- 130Bar
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HYDRAULIC SYSTEMS | STEERING 15/18/20BT-9

1 Hydraulic gear pump

2 Priority valve
4 Steering unit
5 Hydraulic motor
8 Suction strainer
9 Return filter
12 Hydraulic tank
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HYDRAULIC SYSTEMS | STEERING 16/18/20B-9
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HYDRAULIC SYSTEMS 22/25/30/32/35B-9

Steering: 90 Bar 1 Hydraulic gear pump with 7 Suction strainer

Main: priority valve 8 Down control valve
22B-9 = 170 Bar 2 Main control valve 9 Down safety valve
25B-9 = 190 Bar 3 Steering unit 10 Return filter
30B-9 = 190 Bar 4 Steering cylinder 11 Hydraulic oil tank
32B-9 = 200 Bar 5 Tilt cylinder
35B-9 = 210 Bar 6 Lift cylinder
Auxiliary: +/- 130Bar
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HYDRAULIC SYSTEMS 22/25/30/32/35B-9

1 Hydraulic gear
pump with priority
valve
3 Steering unit
4 Steering cylinder
7 Suction strainer
10 Return filter
11 Hydraulic oil tank
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HYDRAULIC SYSTEMS 22/25/30/35BH-9

Before - double pump

Model S/N
22B-9 #1~
25B-9 #1~
30B-9 #1~
35B-9 #4~
22BH-9 #1~
25BH-9 #5~
30BH-9 #5~
35BH-9 #6~

After - single pump

31B1-01000

Steering: 90 Bar 1 Hydraulic gear pump 9 Down safety valve

with priority valve 10 Return filter
Main: 2 Main control valve 11 Hydraulic oil tank
22BH-9 = 170 Bar 3 Steering unit 12 Main relief valve
4 Steering cylinder 13 AUX relief valve
25BH-9 = 190 Bar 5 Tilt cylinder 14 Emergency valve
30BH-9 = 190 Bar 6 Lift cylinder 15 OPSS Valve
35BH-9 = 210 Bar 7 Suction strainer 16 Holding valve
8 Down control valve
Auxiliary: +/- 130Bar
Older configuration
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HYDRAULIC SYSTEMS 22/25/30/35BH-9

1 Hydraulic gear pump 9 Down safety valve

with priority valve 10 Return filter
2 Main control valve 11 Hydraulic oil tank
Steering: 90 Bar 3 Steering unit 12 Main relief valve
Main: 4 Steering cylinder 13 AUX relief valve
5 Tilt cylinder 14 Emergency valve
22BH-9 = 170 Bar 6 Lift cylinder 15 OPSS Valve
25BH-9 = 190 Bar 7 Suction strainer 16 Holding valve
30BH-9 = 190 Bar 8 Down control valve
35BH-9 = 210 Bar
Current configuration Auxiliary: +/- 130Bar
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HYDRAULIC SYSTEMS 22/25/30/35BH-9

1 Hydraulic gear pump with priority valve

3 Steering unit
4 Steering cylinder
7 Suction strainer
10 Return filter
11 Hydraulic oil tank
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HYDRAULIC SYSTEMS 40/45/50B-9

1 Hydraulic gear 8 Down safety

pump valve
2 Priority valve 9 Down flow Steering: 125 Bar
3 Main control regulator Main:
valve 10 Suction strainer 40B-9 = 170 Bar
4 Steering unit 11 Return filter 45B-9 = 190 Bar
5 Steering cylinder 12 Hydraulic oil 50B-9 = 210 Bar
6 Lift cylinder tank Auxiliary: +/- 150Bar
7 Tilt cylinder
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HYDRAULIC SYSTEMS 40/45/50B-9
Qlift =100L/min
Fingertip Qtilt =40L/min

100 Reducing v/v tp control

pilot pressure. Pressure
can be set as 20bar and
40 bar.
Qaux =40L/min 101 3-way controller. It will
be relieved when
pressure reaches 9bar.
102 Pilot operated relief v/v.
Controls main relief
pressure.
103 Damping screw. To
prevent hydraulic shock
in the system. It makes
smooth cylinder
operation.
104 Shuttle v/v. Delivers
highest load detected
from each v/v section to
maun block.
105 Lifting solenoid.
106 Lowering solenoid.
107 2-way controller.
Controls inlet and outlet
pressure of spool as 6bar
for constant flow.
108 Secondary relief v/v.
Controls LS line of A and B
ports.
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HYDRAULIC SYSTEMS 40/45/50B-9
Fingertip

neutral lift lower

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HYDRAULIC SYSTEMS 40/45/50B-9
Function Aux.valves fingertip

1. 2-way Flow control valve

2. Pressure relief valves A B R
3. Load sense line LS
4. Side-shift cylinder (example)

1
1
LS
P
R
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HYDRAULIC SYSTEMS 40/45/50B-9

Steering pot.
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58
ELECTRIC SYSTEMS 15/18/20BT-9
1 Combination switch
2 Display
3 DC-DC converter
4 Beacon lamp
5 Tilt switch assy
6 Pressure sensor
7 Fan
8 Pump controller
9 SBR switch assy
10 Contactor
11 Main fuse cover
12 Back buzzer
13 Steering sensor
14 Traction controller
15 Fuse & relay cover assy
16
17 Relay
18 Flasher unit assy
19 Pump motor
20 Traction motor
21 Fan
22 Horn high
23 Accelerator assy
24 Parking switch assy
25 Key switch assy
26 Head lamp switch
27 Work lamp switch
28 Beacon switch
29 Emergency switch
30 Socket assy
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ELECTRIC SYSTEMS 16/18/20B-9
1 Combination switch
2 Display
3 DC-DC converter
4 Beacon lamp
5 Tilt switch assy
6 Pressure sensor
7 Fan
8 Pump controller
9 SBR switch assy
10 Main fuse cover
11 Contactor
12 Fuse & relay cover assy
13 Traction controller
14 Fuse box assy
15 Fan
16 Back buzzer
17 Relay
18 Flasher unit assy
19 Pump motor
20 Traction motor
21 Fan
22 Horn high
23 Accelerator assy
24 Parking switch assy
25 Key switch assy
26 Head lamp switch
27 Work lamp switch
28 Beacon switch
29 Emergency switch
30 Socket assy
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ELECTRIC SYSTEMS 15/18/20BT-9 16/18/20B-9
1 Rotor assy 9 Bearing
2 Stator assy 10 Oil seal
3 Endbell De 11 O-ring
4 Endbell 12 Flange nut
5 Block-Terminal A 13 Wave washer
6 Speed sensor kit PUMP MOTOR
7 Stud bolt
8 Protector-Terminal
Temperature
sensor not
DRIVE MOTOR available as
separate part.
4 Endbell
5 Block-Terminal A
6 Oil seal
7 Speed sensor kit
8 Stud bolt
9 Protector-Terminal
1 Rotor assy 10 Bearing
2 Stator assy 11 Flange nut
3 Endbell De 12 Wave washer
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ELECTRIC SYSTEMS 15/18/20BT-9 16/18/20B-9

12V

48V
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ELECTRIC SYSTEMS 15/18/20BT-9 16/18/20B-9

12V

48V
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ELECTRIC SYSTEMS 15/18/20BT-9 16/18/20B-9

48V
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ELECTRIC SYSTEMS 15/18/20BT-9 16/18/20B-9
If the new fingertip console will be
installed to a existing machine some
things need to be changed:
- If you use the latest
main harness 21HE-
95119
- If you use the
fingertip extension
426
harness 21FY-95920
425

Old configuration New configuration

CN-162
Resistor must be removed
and plug CN-313 must be
120 connected instead
Ὠ CN-313
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ELECTRIC SYSTEMS 22/25/30/32/35B-9

1 Combination switch
2 Parking micro switch
3 Accelerator assy
4 Fan assy
5 High horn
6 Drive motor
7 E/M contactor
8 Fuse box assy
9 Pump motor
10 Pump controller
11 Traction controller
12 SBR switch assy
13 Fan assy
14 Contactor
15 Back up alarm
16 Flasher unit assy
17 Relay
18 Working lamp (opt)
19 Beacon lamp switch (opt)
20 Head lamp switch (opt)
21 Working lamp switch (opt)
22 Beacon switch (opt)
23 Socket assy
24 Emergency switch assy
25 Display
26 DC-DC converter
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ELECTRIC SYSTEMS 22/25/30/32/35B-9
1 Rotor assy 10 Bearing
2 Stator assy 11 Oil seal
3 Endbell De 12 Nut flange
4 Endbell 13 Wave washer
5 Block-Terminal A
6 Speed sensor kit PUMP MOTOR
7 Stud bolt
8 Protector-Terminal
9 Bearing

5 Block-Terminal A
6 Speed sensor kit
7 Stud bolt
8 Protector-Terminal
DRIVE MOTOR 1 Rotor 9 Bearing
2 Stator 10 Oil seal
3 Endbell De 11 Flange nut
4 Endbell 12 Wave washer
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ELECTRIC SYSTEMS 22/25/30/32/35B-9

12V

48V
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68
ELECTRIC SYSTEMS 22/25/30/32/35B-9

12V

48V
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69
ELECTRIC SYSTEMS 22/25/30/32/35B-9

48V
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ELECTRIC SYSTEMS 22/25/30/32/35B-9
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ELECTRIC SYSTEMS 22/25/30/35BH-9

1 Combination switch
2 Accelerator assy
3 Parking micro switch
4 High horn
5 Drive motor
6 Pump motor
7 Fan assy
8 Pump controller
9 Traction controller
10 Back up alarm
11 Contactor
12 Fuse box assy
13 SBR switch assy
14 Working lamp(opt)
15 Beacon lamp(opt)
16 Display
17 Working lamp switch(opt)
18 Beacon lamp switch(opt)
19 DC-DC converter
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ELECTRIC SYSTEMS 22/25/30/35BH-9

1 Rotor assy 10 Bearing

2 Stator assy 11 Oil seal
3 Endbell De 12 Nut flange
4 Endbell 13 Wave washer
5 Block-Terminal A
6 Speed sensor kit
7 Stud bolt
8 Protector-Terminal
9 Bearing
DRIVE MOTOR PUMP MOTOR

5 Block-Terminal A
6 Speed sensor kit
7 Stud bolt
8 Protector-Terminal
1 Rotor 9 Bearing
2 Stator 10 Oil seal
3 Endbell De 11 Flange nut
4 Endbell 12 Wave washer
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ELECTRIC SYSTEMS 22/25/30/35BH-9

12V

80V
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ELECTRIC SYSTEMS 22/25/30/35BH-9

12V

80V
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ELECTRIC SYSTEMS 22/25/30/35BH-9

80V
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ELECTRIC SYSTEMS 40/45/50B-9

1 Combination switch
2 Parking micro switch
3 Accelerator assy
4 Fan assy
5 High horn
6 Drive motor
7 E/M contactor
8 Fuse box assy
9 Pump motor
10 Pump controller
11 Traction controller
12 SBR switch assy
13 Fan assy
14 Contactor
15 Back up alarm
16 Flasher unit assy
17 Relay
18 Working lamp (opt)
19 Beacon lamp (opt)
20 Beacon switch (opt)
21 Working lamp switch (opt)
22 Head lamp switch (opt)
23 Socket assy
24 Emergency switch assy
25 Display
26 DC-DC converter
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ELECTRIC SYSTEMS 40/45/50B-9

1 Rotor assy 10 Bearing

2 Stator assy 11 Oil seal
3 Endbell De 12 Nut flange
4 Endbell 13 Wave washer
5 Block-Terminal A
6 Speed sensor kit
7 Stud bolt
8 Protector-Terminal
9 Bearing
DRIVE MOTOR PUMP MOTOR

5 Block-Terminal A
6 Speed sensor kit
7 Stud bolt
8 Protector-Terminal
1 Rotor 9 Bearing
2 Stator 10 Oil seal
3 Endbell De 11 Flange nut
4 Endbell 12 Wave washer
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ELECTRIC SYSTEMS 40/45/50B-9
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ELECTRIC SYSTEMS 40/45/50B-9

12V

80V
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ELECTRIC SYSTEMS 40/45/50B-9

80V
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81
ELECTRIC SYSTEMS 22/25/30/32/35B-9 22/25/30/35BH-9
AUTO TILT SYSTEM 15/16/18/20B(T)-9 40/45/50B-9

Due to missing 12V output from

controller, 36V has been used >
Solid State Relay applied

15/16/18/20B(T)-9 22/25/30/32/35B-9

22/25/30/35BH-9 40/45/50B-9
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ELECTRIC SYSTEMS NEW CLUSTER
Blinks when the ESC and This LED blinks
brake oil level in ENTER Roll up when the
the reservoir is handbrake is
below the lower Roll left + Roll right + activated.
limit. menu power mode
Roll down + This LED blinks
This LED blinks when the seat belt
turtle mode
when an electric is not correctly
device (controller, fastened.
motor, cable, etc.)
is in alarm This LED blinks
condition. when the operator
is not on the seat.
This LED blinks
when the
controller or motor Simulator-press here
temperature is
high.

1. Current time
2. Turtle mode
3. Truck speed pointer
4. Accelerator level
5. Truck speed
6. Hour meter
7. Wheel position and running direction
8. Power mode
9. BDI (battery's state of charge)
10. Load weight (option)
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ELECTRIC SYSTEMS NEW CLUSTER

To enter, press
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ELECTRIC SYSTEMS NEW CLUSTER

password
To enter,
press long 98282
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ELECTRIC SYSTEMS NEW CLUSTER

How to check alarms:

1. First yellow capital letter shows in which controller

the alarm happens as below;
M : Traction-Master
S : Traction-Slave
P : Pump
V : Mhyrio CB
2. Following two letters or digits show alarm code.
Please refer to ALARM CODE list
3. This shows a name of ALARM.
- 5 latest error codes are displayed -
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ELECTRIC SYSTEMS NEW CLUSTER

1. Code of alarm
2. Name of alarm

To clear
controller
alarm history
Step 5-1

3. Count of alarm
4 .Temperature of controller as alarm occurs.
5. Hour-meter of controller as alarm occurs
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ELECTRIC SYSTEMS NEW CLUSTER
VASS SETUP USING DISPLAY MENU

This function searches and memorizes the minimum and

maximum potentiometer wiper voltage of the accelerator
pedal, lift lever, steering sensor which use potentiometer
sensors and load sensor. The below show how to use the VASS
function of DISPLAY.
(All figures in below are just example.)
While even a motor is running, VASS can not be configured
properly, so please be sure that all motors are not running
before entering configuration process & saving.
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ELECTRIC SYSTEMS NEW CLUSTER
VASS SETUP USING DISPLAY MENU
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ELECTRIC SYSTEMS NEW CLUSTER
SETUP LOAD SENSOR

TRUCK menu→TRACTION Save the Parameter in the

→ADJUSTMENT→LOAD SENSOR memory (Confirmation screen)

1 5

Set to ‘ON’ Move to ‘OVER LOAD WEIGHT’

It sets overload warning weight. Refer to the
upper ‘REF LOAD WEIGHT’ setting steps.
2 6 Warning: weight depends on residual capacity.

Move to ‘REF LOAD WEIGHT’

Move to ‘OVER LOAD TYPE’-NONE
* Selectable options]
NONE : No warning of overload.
3 7
Option #1 : Overload warning and operation stops
except Lift down & Steering.
Option #2 : Overload warning only

Enter the value as the

actual load weight.
(Ex 2,800Kg)
4
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ELECTRIC SYSTEMS NEW CLUSTER
VASS SETUP USING DISPLAY MENU

Move to SETTING→V.A.S.S→‘LOAD’
“Enter” on condition of No load (direction lever - Neutral & all motor
stop).
8

“Enter” on condition of READY and Red indication (on No

load).

Red indication on ‘ADJ REF’ item means a starting of setting.

Lift the reference weight (step 4) 50cm from ground and wait (5~10sec) until the value is
10 stable.

“Enter” to save the setting parameters. ☞ To get more accurate setting

parameters, heavier reference weight is
11 recommended.
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ELECTRIC SYSTEMS NEW CLUSTER
VASS SETUP USING DISPLAY MENU

Do Tilt-out to full.
“Enter” in condition of full Tilt out.

1 4

* Do Tilt-in to full.

* Level forks horizontally.

3
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ELECTRIC SYSTEMS NEW CLUSTER

OPTION VASS “ FINGER TIP ” SETUP USING DISPLAY MENU
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OPTION FINGERTIP ADJUSTMENT USING DISPLAY MENU

Enter password 98282 => Settings => Mhyrio => Parameter change
MIN EVP & MAX EVP= not used

MIN EVP 1= lowering function MAX EVP 1= lowering function MIN EVP 1 OPEN DELAY MIN EVP 1 CLOSE DELAY
Here the min. opening of the Here the max. opening of the = lowering function, valve = lowering function,valve
valve will be set. valve will be set. opening delay after fingertip closing delay after fingertip
Opening value smaller = activation. release
smoother start Example: to prevent
accidental opening of clamp
MIN/MAX EVP 2 = lift function => open / close delay
MIN/MAX EVP 3 = tilt forward => open / close delay
MIN/MAX EVP 4 = tilt backwards => open / close delay
MIN/MAX EVP 5 = Side shift right => open / close delay
MIN/MAX EVP 6 = Side shift left => open / close delay
These values have influence of
MIN/MAX EVP 7 = Aux => open / close delay carriage stopping response time
MIN/MAX EVP 8 = Aux => open / close delay after releasing the fingertip
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9

Model Model Application Type Power Current limit

16/18/20B-9 DUAL AC2 Power Traction MOSFET 36-48V, 330+330A 330A/3min
15/18/20BT-9 AC2 Pump MOSFET 36-48V, 450A 450A/3min
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Model Model Application Type Power Current limit

16/18/20B-9 DUAL AC2 Power Traction MOSFET 36-48V, 330+330A 330A/3min
15/18/20BT-9 AC2 Pump MOSFET 36-48V, 450A 450A/3min
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Traction

Master Slave

Standard ZAPI menu

structure.
Different outlook by
display and console.
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
Traction MASTER

PARAMETER CHANGE E MODE N MODE H MODE

It determines the acceleration ramp. [sec]
Acceler. delay 5 4 3
Less value means better acceleration performance.
It controls the deceleration ramp when the travel request is released. [sec]
Release braking 3.6 3.1 2.6
Less value means better braking performance.
It controls the deceleration ramp when the direction switch is inverted during travel.
Invers. Braking [sec] 5 3.6 3.1
Less value means better braking performance.
It determines the deceleration ramp when the travel request is released and the
Pedal braking brake pedal switch is closed. [sec] 0.8 0.8 0.8
Less value means better braking performance.
Deceleration ramp when the pedal position is changed but not completely
Speed limit brk. 3.8 3.8 3.8
released.[sec]
It determines the deceleration ramp when the speed reduction input becomes active
Brake cutback and the motor slow down. [sec] 3 3 3
Less value means better braking performance.
Max speed forw It determines the maximum speed in forward direction. 99Hz 119Hz 135Hz
Max speed back It determines the maximum speed in backward direction. 99Hz 119Hz 135Hz
Cutback speed 1 Speed reduction when the cutback switch is active. E13 in pump controller. 60% 60% 60%
Turtle speed Hz. It determines the truck maximum speed when the turtle mode is activated. 70Hz 70Hz 70Hz

ANY DIFFERENCES IN PARAMETERS’ UNITS? PLEASE REFER TO CONVERSION TABLE

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Traction MASTER

PARAMETER CHANGE E MODE N MODE H MODE

Speed reduction when the truck is doing a curve. The parameter sets the speed
setpoint when the maximum steering angle is reached (4 wheels truck, the internal
Curve cutback 30% 30% 30%
wheel is stopped). In intermediate steering angles, the speed setpoint will be within a
range b
Minimum speed when the forward or reverse switch is closed, but the accelerator is
Frequency creep 0.30Hz 0.30Hz 0.30Hz
on a minimum position.
Maximum current This changes the maximum current of the inverter. 84% 84% 84%
Acc. smooth It gives a parabolic shape to the acceleration ramp (up to "stop smooth"Hz). 2.5 2 1
Inv. smooth It gives a parabolic shape to the acceleration ramp after a direction inversion. 2.5 2 1

Stop smooth Hz. It sets the frequency where the smooth effect of the parabolic acceleration ends. 15Hz 10Hz 10Hz
It determines the delay time between the opening of the seat switch and the start of
Seat delay time 2 2 2
the truck electrical braking (OPSS for traction only)
It sets the maximum delay time between the accelerator is pressed and the direction
Sequence de. Time lever is moved out of the neutral position. 2 2 2
If this time is expired the truck stops with warning : “SEQUENCE FAULT”.
After no travel or pump request is active for the chat time the line contactor is
CHAT TIME automatically opened. To restart, the the operator needs to press the accelerator 10 10 10
pedal or activate the hydraulic levers.
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
Traction MASTER

SET OPTION E MODE N MODE H MODE

RUNNING: The counter registers travel time only
Hour counter RUNNING RUNNING RUNNING
KEY ON: The counter registers when the "key" switch is closed
ON: The battery discharge level check is carried out; when the battery level reaches
10%, an alarm is signalled and the maximum current is reduced to the half of the
Battery check ON ON ON
programmed value.
OFF: The battery discharge level check is carried out but no alarm is signalled
When the alarm "BATTERY LOW" appears, if this option is programmed to ON, the
Traction cutout ON ON ON
traction maximum speed is reduced to 60Hz.
When the alarm "BATTERY LOW" appears, if this option is programmed to ON, the lift
Lift cutout ON ON ON
function is disabled.
If this option is set to ON the static return to off is requested for starting the truck.
The required sequence is :
- Seat- direction lever neutral -accelerator pedal or
S.R.O. - Seat-accelerator pedal- direction lever neutral within the seq. delay time. ON ON ON
If this option is set to OFF the required sequence to start the truck is :
·Seat-accelerator pedal or :
·Accelerator pedal-Seat within the seq. delay time
ON / OFF : If this option is programmed ON the traction inverter manages an
Hydro key on OFF OFF OFF
hydraulic steering function when the "key" is switched ON.
- ON : The stop on ramp feature (truck electrically hold on a ramp) is managed for a
Stop on ramp fixed time (6sec.). OFF OFF OFF
- OFF: The stop on ramp feature is not performed.
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
Traction MASTER

SET OPTION E MODE N MODE H MODE

- EXCLUSIVE HYDRO : input C10 activates hydraulic steering function,
output C31 is activated.
Aux input #1 - OPTION #1 : Input C10 is the input for an handbrake device, active low (open OPTION #1 OPTION #1 OPTION #1
switch).
- OPTION #2 : Input C10 is the input for a speed reduction device, active

- DIGITAL : A digital (ON/OFF) motor thermal sensor is connected to C25 (C35) input.
- ANALOG : An analog motor thermal sensor is connected to C25 (C35) (the curve can
Set temperature ANALOG ANALOG ANALOG
be customized on a customer request).
- NONE : No motor thermal sensor switch is connec

This parameter is used to set the correct steering table.

Steer table OPTION #1 OPTION #1 OPTION #1
- OPTION #2 : The steering table is the one for 4 wheels truck.
Display If this option is set to on the communication with HHI graphic display is enabled. ON ON ON
Pedal type #1pedal position shown on display #2 speed point OPTION #1 OPTION #1 OPTION #1
This parameter defines how truck drive if accel pedal & brake pedal is pressed
simultaneously.
Pedal brake stop OFF OFF OFF
If set to ON, truck is stopped when pedal brake is pressed.
If set to OFF, the traction current is reduced to half of the maximum current.
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
Traction MASTER

SET MODEL E MODE N MODE H MODE

CONNECTED TO 3 3 3

ADJUSTMENTS E MODE N MODE H MODE

Set battery type It selects the nominal battery voltage. 48V 48V 48V
Fine adjustment of the battery voltage measured by the controller. Please increase or
Adjust battery 46.17V 46.27V 46.17V
decrease the value 1 by 1 and check the voltage.
Max steer right (only This is the function to record in the controller EEPROM the steering poti output
3.2V 3.2V 3.2V
available on console) voltage when the wheels are fully turned right (maximum of the steering poti range).
Max steer left (only This is the function to record in the controller EEPROM the steering poti output
0.0V 0.0V 0.0V
available on console) voltage when the wheels are fully turned left (minimum of the steering poti range).
Set steer 0-pos. (only This is the function to record in the controller EEPROM the steering poti output
1.4V 1.4V 1.4V
available on console) voltage when the wheels are straight.
Set steer right This parameter sets the max steering angle in right direction. 90⁰ 90⁰ 90⁰
Set steer left This parameter sets the max steering angle in left direction. 90⁰ 90⁰ 90⁰
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
Traction MASTER

ADJUSTMENTS E MODE N MODE H MODE

Throttle 0 zone It establishes a deadband in the accelerator input curve (see also curve below). 5% 5% 5%
Throttle X point This parameter changes the characteristic of the accelerator input curve. 63% 63% 63%
Throttle Y point This parameter changes the characteristic of the accelerator input curve.

36.00% 36.00% 36.00%

VACC MIN and VACC MAX are values programmable by the "Program Vacc"
function.
Cooling fans installed on nearby motors and controllers will work as follows;
Option #1: fans work always
Cooling fan work Option #2: fans work in case a temperature of controller exceeds a temperature set OPTION#2 OPTION#2 OPTION#2
in START TEMP FAN menu
Option #3: fans work when motors work
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
Traction MASTER

ADJUSTMENTS E MODE N MODE H MODE

if COOLING FAN WORK menu is set as option #2, this menu is used to set a
Start TEMP. FAN temperature limitation which allows fans to work when a temperature of controller 50⁰ 50⁰ 50⁰
or motor exceeds the limitation.
It adjusts the lower level of the battery discharge table. Higher level means higher
Adjustment #2 bdi LEVEL=3 LEVEL=3 LEVEL=3
voltage.
It adjusts the upper level of the battery discharge table. Higher level means higher
Adjustment #1 bdi LEVEL=3 LEVEL=3 LEVEL=3
voltage.
Set an increment of battery charge above actual value. If battery voltage exceed this
Adjustment #03 total value the software recognize charging, and battery charge percentage increase 20.00% 20.00% 20.00%
to correct value also if battery isn't fully charged.
Main cont. voltage This parameters adjusts the line contactor coil voltage (PWM output C26). 36V 36V 36V
Aux output voltage This parameters adjusts the solenoid coil voltage (PWM output C28). Not in use. 36V 36V 36V
This parameter determines the motor temperature level at which the "Motor
Adjustment #04 temperature" alarm is signalled. This parameter must be adjusted only if the "Set 145℃ 145℃ 145℃
temperature" (menu "Set option") parameter is programmed "Analog".
It adjusts the speed coefficient to have the correct speed indication on the display.
This coefficient has to be regulated depending on truck mechanic characteristics. It
results from the following formula :
Speed factor 81 81 81
Speed factor = 88 * rr * p /Ø
where : rr = total gearbox ratio; Ø= traction wheel diameter (cm); P = number of pair
poles of the motor
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Traction MASTER

ADJUSTMENTS E MODE N MODE H MODE

ON : Load Sensing Function is activated
Load sensor (option) OFF OFF OFF
OFF : Load Sensing Function is disactivated
ADJ MIN LOAD Sensor voltage setting for empty forks - from calibration 1.3V 1.3V 1.3V
ADJ REF LOAD Sensor voltage setting for reference load - from calibration 3.3V 3.3V 3.3V
REF. load weight Test load weight - necessary for calibration 1600Kg 1600Kg 1600Kg
Rated load weight This parameter is used to show and configurate the rated load weight - DUMMY 1800Kg 1800Kg 1800Kg
This parameter is used to show and configurate the trigger condition for OVER LOAD alarm.
Overload weight
If the loaded weight exceeds the weight indicated in this paramter, OVER LOAD alarm and 2100Kg 2100Kg 2100Kg
(option) function limitation will occur accroding to OVERLOAD TYPE paramter.
This parameter is used to show and configurate the trigger condition for LOAD SENSOR alarm.
If the loaded weight exceeds the weight indicated in this paramter, the TIP OVER accident can occur,
Max load weight which is fatal for driver' safety, so LOAD SENSOR alarm will be displayed and followed by traction & 6375Kg 6375Kg 6375Kg
pump limitation except lift down function. * The figures in this parameter should be higher than
OVERLOAD WEIGHT paratmer
This option specifies how overload alarm works in overloaded situation.
NONE : There would'n be any kind of alarms or limitations.
If re-configuration of V.A.S.S LOAD is required, please set this parameter as NONE, then proceed re-
configuration.
Overload type
Option #1 : If the weight of load filed on forks exceeds the overload weight set in overload parameter, NONE NONE NONE
(option) OVER LOAD alarm will be displayed and followed by traction & pump limitation except lift down &
steering function.
Option #2 : If the weight of load filed on forks exceeds the overload weight set in overload parameter,
OVER LOAD alarm will be displayed.

Load speed UPD (option) For accuracy, Load Sensor only works when the pump motor speed is lower than as set in this parameter. 10Hz 10Hz 10Hz
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Traction MASTER
TESTER MENU
This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full
MOTOR VOLTAGE
voltage (which depends of the battery voltage).
FREQUENCY This is the frequency of the voltage and current supplied to the motor.
ENCODER This is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.
SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor, expressed in the same unit of the frequency.
CURRENT RMS Ampere value. Root Mean Square value of the line current in the motor.
TEMPERATURE °C value. This is the temperature of the inverter base plate. This temperature is used for the HIGH TEMPERATURE alarm detection.
Temperature #1 This is the temperature of the right motor; if the option is programmed "None" it shows 0°.
Temperature #2 This is the temperature of the left motor; if the option is programmed "None" it shows 0°.
Accelerator The voltage of the accelerator potentiometer's wiper (CPOT).
Steer angle This is the indication of the angular position of the steered wheel.
Internal wheel cutback This is the indication of the speed reduction applied to the internal wheel; in other words, it shows the ratio of the two speeds.
- ON / +VB = Input active, switch closed.
Forward switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Backward switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Enable switch
- OFF / GND = Input non active, switch open.
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
Traction MASTER
TESTER MENU
- ON / +VB = Input active, switch closed.
Seat switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Cutback switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Brake switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Exclusive hydro
- OFF / GND = Input non active, switch open.
Brake pedal pot. Voltage of the brake potentiometer's wiper (CPOTB). The parameter is active only if the PEDAL BRAKING parameter is set ANALOG.
The level of the speed reduction microswitch.
Hand brake - ON / GND = Input active, switch opened.
- OFF / +VB = Input non active, switch closed.
Voltage booster This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.
Battery voltage Level of battery voltage measured at the input of the key switch.
Battery charge The percentage Charge level of the battery.
Load pot Voltage value of load sensor.
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
Traction SLAVE

PARAMETER CHANGE E MODE N MODE H MODE

It controls the deceleration ramp when the travel request is released.
Release braking LEVEL = 2 LEVEL = 3 LEVEL = 4
Less value means better braking performance.
It determines the delay time between the opening of the seat switch on CNC#5 digital
Seat delay time 2 2 2
input and

SET OPTION not available E MODE N MODE H MODE

SET MODEL E MODE N MODE H MODE

CONNECTED TO 4 4 4

ADJUSTMENTS E MODE N MODE H MODE

Set battery type It selects the nominal battery voltage. 48V 48V 48V
Fine adjustment of the battery voltage measured by the controller. Please increase or
Adjust battery 51.64V 51.64V 51.64V
decrease the value 1 by 1 and check the voltage.
This parameter adjusts the voltage of the auxiliary output coil, PWM output C31 -
Aux output voltage 12V 12V 12V
fan rely
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
Traction SLAVE
TESTER MENU
This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full
MOTOR VOLTAGE
voltage (which depends of the battery voltage).
FREQUENCY This is the frequency of the voltage and current supplied to the motor.
ENCODER This is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.
SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor, expressed in the same unit of the frequency.
CURRENT RMS Ampere value. Root Mean Square value of the line current in the motor.
TEMPERATURE °C value. This is the temperature of the inverter base plate. This temperature is used for the HIGH TEMPERATURE alarm detection.
Voltage booster This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.
Battery voltage Level of battery voltage measured at the input of the key switch.
- ON / +VB = Input active, switch closed.
Seat switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Forward switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Backward switch
- OFF / GND = Input non active, switch open.
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
PUMP

Standard ZAPI menu

structure.
Different outlook by
display and console.
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
PUMP

PARAMETER CHANGE E MODE N MODE H MODE

It determines the acceleration ramp.
Acceler. delay LEVEL=0 LEVEL=0 LEVEL=0
Less value means better acceleration performance.
It determines the acceleration ramp.
Deceler delay LEVEL=0 LEVEL=0 LEVEL=0
More value means better deceleration performance.
Max speed up Determines the maximum lifting speed with a potentiometer control. 85Hz 90Hz 105Hz
Determines the minimum lifting speed with a potentiometer control when the lifting
Min speed up 18.00Hz 18.00Hz 18.00Hz
enable switch is closed.
Determines the lift speed reduction in percentage when the speed reduction switch is
Cutback speed 25Hz 25Hz 25Hz
activated.
Tilt speed Tilt speed, fine regulation. 30Hz 30Hz 30Hz
Shift speed Shift speed, fine regulation. 30Hz 30Hz 30Hz
Aux speed Auxiliary function speed, fine regulation. 50Hz 50Hz 50Hz
Hyd speed fine Hydro speed, fine regulation. 16Hz 16Hz 16Hz
Maximum current The maximum current of the inverter. LEVEL=9 LEVEL=9 LEVEL=9
Idle time Time delay when an hydraulic steering function request is switched off. 1.5 1.5 1.5
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
PUMP

SET OPTION E MODE N MODE H MODE

Cutback mode E13 input NONE NONE NONE
RUNNING: The counter registers travel time only
Hour counter RUNNING RUNNING RUNNING
KEY ON: The counter registers when the "k ey" switch is closed

- DIGITAL : A digital (ON/OFF) motor thermal sensor is connected to C25 (C35) input.
- ANALOG : An analog motor thermal sensor is connected to C25 (C35) (the curve can
Set temperature ANALOG ANALOG ANALOG
be customized on a customer request).
- NONE : No motor thermal sensor switch is connec

- OFF : The truck model includes mechanical lever distributor (default)

Joystick (Option) - ON : The truck model includes electro-hydraulic distributor and finger tips. Can OFF OFF OFF
communication with Can tiller and Hydro CB zapi modules is enabled.
- ON : Fingertip Side Shift function is activated.
Shift function
- OFF : Fingertip Side Shift function is disactivated.
- ON : Fingertip Aux function is activated.
Aux function
- OFF : Fingertip Aux function is disactivated.
- OFF : The lift sensor includes a lift switch and an analogue lift sensor. Lift speed can
be controlled proportionally with lever position.
Digital lift OFF OFF OFF
- ON : The lift sensor includes a lift switch only. Lift speed cannot be controlled
proportionally.
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
PUMP

ADJUSTMENTS E MODE N MODE H MODE

Set battery type It selects the nominal battery voltage. 48V 48V 48V
Fine adjustment of the battery voltage measured by the controller. Please increase or
Adjust battery 50.9V 50.9V 50.9V
decrease the value 1 by 1 and check the voltage.
Throttle 0 zone It establishes a deadband in the accelerator input curve (see also curve below). 5% 5% 5%
Throttle X point This parameter changes the characteristic of the accelerator input curve. 63% 63% 63%
Throttle Y point This parameter changes the characteristic of the accelerator input curve.

36.00% 36.00% 36.00%

VACC MIN and VACC MAX are values programmable by the "Program Vacc"
function.
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CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
PUMP

ADJUSTMENTS E MODE N MODE H MODE

This parameter determines the motor temperature level at which the "Motor
Adjustment #04 temperature" alarm is signalled. This parameter must be adjusted only if the "Set 145℃ 145℃ 145℃
temperature" (menu "Set option") parameter is programmed "Analog".
PWM on main - OFF: The inverter applies the battery voltage to the coil on F2, F8 output.
ON ON ON
contactor - ON: The PWM reduces the voltage to the set value. Fork leveling
- OFF: The inverter applies the battery voltage to the coil on F3, F9 output.
PWM on aux output ON ON ON
- ON: The PWM reduces the voltage to the set value. OPSS
It sets the PWM level in % on the outputs F8 and F9. Here is used to drive a main
MC/AUX PWM 25% 25% 25%
contact for pump.
- ON : AUTO TILT LEVELING function is activated.
Fork leveling OFF OFF OFF
- OFF : AUTO TILT LEVELING function is disactivated.
FORK LEVEL MIN. 1.3V 1.3V 1.3V
FORK LEVEL MAX. 9.2V 9.2V 9.2V
FORK LVL. CENTER 3.7V 3.7V 3.7V
FORK MIN. SPEED 49.80% 49.80% 49.80%
FORK APPR. RANGE LEVEL=5 LEVEL=5 LEVEL=5
FORK CENTER DEAD LEVEL=5 LEVEL=5 LEVEL=5

SET MODEL E MODE N MODE H MODE

CONNECTED TO 5 5 5
©GN-HHIE

116
CONTROLLERS AND PARAMETERS 15/18/20BT-9 16/18/20B-9
PUMP

TESTER MENU
This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full
MOTOR VOLTAGE
voltage (which depends of the battery voltage).
FREQUENCY This is the frequency of the voltage and current supplied to the motor.
ENCODER This is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.
SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor, expressed in the same unit of the frequency.
CURRENT RMS Ampere value. Root Mean Square value of the line current in the motor.
TEMPERATURE °C value. This is the temperature of the inverter base plate. This temperature is used for the HIGH TEMPERATURE alarm detection.
Temperature This is the temperature of the motor; if the option is programmed "None" it shows 0°.
- ON / +VB = Active entry of closed switch.
Lifting switch
- OFF / GND = Non active entry of open switch.
- ON / +VB = Active entry of closed switch.
Security switch
- OFF / GND = Non active entry of open switch.
- ON / +VB = Active entry of closed switch.
Hydro speed req.
- OFF / GND = Non active entry of open switch.
Lift/lower req. Level of the lift and lower analogue signal.
Tilt request Voltage of the tilt analogue signal.
Shift request Voltage of the shift analogue signal.
Aux request Voltage of the auxiliary analogue signal.
- ON / GND = Active entry of open switch.
Cutback switch
- OFF / +VB = Non active entry of closed switch.
Voltage booster This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.
Battery voltage Level of battery voltage measured at the input to the key switch.
©GN-HHIE

117
CONTROLLERS AND PARAMETERS 22/25/30/32/35B-9

Model Model Application Type Power Current limit

DUAL AC2 Power Traction MOSFET 36-48V, 450+450A 450A/3min
22/25/30/32/35B-9
AC3 Pump MOSFET 36-48V, 600A 600A/3min
©GN-HHIE

118
CONTROLLERS AND PARAMETERS 22/25/30/32/35B-9

Model Model Application Type Power Current limit

DUAL AC2 Power Traction MOSFET 36-48V, 450+450A 450A/3min
22/25/30/32/35B-9
AC3 Pump MOSFET 36-48V, 600A 600A/3min
©GN-HHIE

119
CONTROLLERS AND PARAMETERS 22/25/30/32/35B-9
Traction

Master Slave

Standard ZAPI menu

structure.
Different outlook by
display and console.
©GN-HHIE

120
CONTROLLERS AND PARAMETERS 22/25/30/32/35B-9
Traction MASTER

PARAMETER CHANGE E MODE N MODE H MODE SET OPTIONS E MODE N MODE H MODE
ACCELER. DELAY LEVEL = 5 LEVEL = 3 LEVEL = 1 HOUR COUNTER RUNNING RUNNING RUNNING
RELEASE BRAKING LEVEL = 2 LEVEL = 3 LEVEL = 4 BATTERY CHECK ON ON ON
INVERS. BRAKING LEVEL = 1 LEVEL = 3 LEVEL = 4 TRACTION CUT OUT ON ON ON
PEDAL BRAKING LEVEL = 9 LEVEL = 9 LEVEL = 9 LIFT CUT OUT ON ON ON
SPEED LIMIT BRK. LEVEL = 4 LEVEL = 4 LEVEL = 4 S.R.O. ON ON ON
BRAKE CUTBACK LEVEL = 5 LEVEL = 5 LEVEL = 5 HYDRO KEY ON OFF OFF OFF
MAX SPEED FORW 100 Hz 120 Hz 143 Hz STOP ON RAMP OFF OFF OFF
MAX SPEED BACK 100 Hz 120 Hz 143 Hz AUX INPUT #1 OPTION#1 OPTION#1 OPTION#1
CUTBACK SPEED 1 60% 60% 60% SET TEMPERATURE ANALOG ANALOG ANALOG
TURTLE SPEED 70 Hz 70 Hz 70 Hz STEERTABLE OPTION#1 OPTION#1 OPTION#1
CURVE CUTBACK 30% 30% 30% DISPLAY ON ON ON
FREQUENCY CREEP 0.30 Hz 0.30 Hz 0.30 Hz PEDAL TYPE OPTION#1 OPTION#1 OPTION#1
MAXIMUM CURRENT LEVEL = 9 LEVEL = 9 LEVEL = 9 PEDAL BRK STOP OFF OFF OFF
ACC. SMOOTH 2.5 2 1
INV. SMOOTH 2.5 2 1
STOP SMOOTH 15 Hz 10 Hz 10 Hz
SEAT DELAY TIME 2 2 2
SEQUENCE DE.TIME 2 2 2
CHAT TIME 10 10 10
©GN-HHIE

121
CONTROLLERS AND PARAMETERS 22/25/30/32/35B-9
Traction MASTER

ADJUSTMENTS E MODE N MODE H MODE ADJUSTMENTS E MODE N MODE H MODE

SET BATTERY TYPE 48V 48V 48V LOAD SENSOR OFF OFF OFF
ADJUST BATTERY 51.07V 51.07V 51.40V ADJ MIN LOAD 1.3V 1.3V 1.3V
MAX STEER RIGHT 1.1V 1.1V 1.1V ADJ REF LOAD 3.3V 3.3V 3.3V
MAX STEER LEFT 3.9V 3.9V 3.9V REF. LOAD WEIGHT 3000Kg 3000Kg 3000Kg
SET STEER 0-POS. 2.7V 2.7V 2.7V RATED LOAD W. 3000Kg 3000Kg 3000Kg
SET STEER RIGHT 90? 90? 90? OVER LOAD WEIGHT 3250Kg 3250Kg 3250Kg
SET STEER LEFT 65? 65? 65? MAX LOAD WEIGHT 3500Kg 3500Kg 3500Kg
THROTTLE 0 ZONE 5% 5% 5% OVERLOAD TYPE NONE NONE NONE
THROTTLE X POINT 63% 63% 63% LOAD SPEED UPD. 10Hz 10Hz 10Hz
THROTTLE Y POINT 36% 36% 36%
COOLING FAN WORK OPTION#2 OPTION#2 OPTION#2
START TEMP.FAN 50⁰ 50⁰ 50⁰
ADJUSTMENT#2 BDI LEVEL=3 LEVEL=3 LEVEL=3
ADJUSTMENT#1 BDI LEVEL=4 LEVEL=4 LEVEL=4
ADJUSTMENT #03 20% 20% 20%
MAIN CONT. VOLT. 36V 36V 36V
AUX OUTPUT VOLT. 12V 12V 12V
ADJUSTMENT #04 145? 145? 145? SET MODEL E MODE N MODE H MODE
SPEED FACTOR 79 79 79 CONNECTED TO 3 3 3
©GN-HHIE

122
CONTROLLERS AND PARAMETERS 22/25/30/32/35B-9
Traction MASTER
TESTER MENU
This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full
MOTOR VOLTAGE
voltage (which depends of the battery voltage).
FREQUENCY This is the frequency of the voltage and current supplied to the motor.
ENCODER This is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.
SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor, expressed in the same unit of the frequency.
CURRENT RMS Ampere value. Root Mean Square value of the line current in the motor.
TEMPERATURE °C value. This is the temperature of the inverter base plate. This temperature is used for the HIGH TEMPERATURE alarm detection.
Temperature #1 This is the temperature of the right motor; if the option is programmed "None" it shows 0°.
Temperature #2 This is the temperature of the left motor; if the option is programmed "None" it shows 0°.
Accelerator The voltage of the accelerator potentiometer's wiper (CPOT).
Steer angle This is the indication of the angular position of the steered wheel.
Internal wheel cutback This is the indication of the speed reduction applied to the internal wheel; in other words, it shows the ratio of the two speeds.
- ON / +VB = Input active, switch closed.
Forward switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Backward switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Enable switch
- OFF / GND = Input non active, switch open.
©GN-HHIE

123
CONTROLLERS AND PARAMETERS 22/25/30/32/35B-9
Traction MASTER
TESTER MENU
- ON / +VB = Input active, switch closed.
Seat switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Cutback switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Brake switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Exclusive hydro
- OFF / GND = Input non active, switch open.
Brake pedal pot. Voltage of the brake potentiometer's wiper (CPOTB). The parameter is active only if the PEDAL BRAKING parameter is set ANALOG.
The level of the speed reduction microswitch.
Hand brake - ON / GND = Input active, switch opened.
- OFF / +VB = Input non active, switch closed.
Voltage booster This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.
Battery voltage Level of battery voltage measured at the input of the key switch.
Battery charge The percentage Charge level of the battery.
Load pot Voltage value of load sensor.
©GN-HHIE

124
CONTROLLERS AND PARAMETERS 22/25/30/32/35B-9
Traction SLAVE

PARAMETER CHANGE E MO DE N MO DE H MO DE
RELEASE BRAKING LEVEL = 2 LEVEL = 3 LEVEL = 4
SEAT DELAY TIME 2 2 2

SET MO DEL
CONNECTED TO 4 4 4

ADJUSTMENTS
SET BATTERY TYPE 48V 48V 48V
ADJUST BATTERY 51.64V 51.64V 51.64V
AUX OUTPUT VOLT. 12V 12V 12V
©GN-HHIE

125
CONTROLLERS AND PARAMETERS 22/25/30/32/35B-9
Traction SLAVE
TESTER MENU
This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full
MOTOR VOLTAGE
voltage (which depends of the battery voltage).
FREQUENCY This is the frequency of the voltage and current supplied to the motor.
ENCODER This is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.
SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor, expressed in the same unit of the frequency.
CURRENT RMS Ampere value. Root Mean Square value of the line current in the motor.
TEMPERATURE °C value. This is the temperature of the inverter base plate. This temperature is used for the HIGH TEMPERATURE alarm detection.
Voltage booster This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.
Battery voltage Level of battery voltage measured at the input of the key switch.
- ON / +VB = Input active, switch closed.
Seat switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Forward switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Backward switch
- OFF / GND = Input non active, switch open.
©GN-HHIE

126
CONTROLLERS AND PARAMETERS 22/25/30/32/35B-9
PUMP

Standard ZAPI menu

structure.
Different outlook by
display and console.
©GN-HHIE

127
CONTROLLERS AND PARAMETERS 22/25/30/32/35B-9
PUMP

PARAMETER CHANGE E MO DE N MO DE H MO DE SET MO DEL E MO DE N MO DE H MO DE

ACCELER. DELAY LEVEL=0 LEVEL=0 LEVEL=0 CONNECTED TO PUMP PUMP PUMP
DECELER. DELAY LEVEL=0 LEVEL=0 LEVEL=0
MAX SPEED UP 72Hz 81Hz 90Hz ADJUSTMENTS E MO DE N MO DE H MO DE
MIN SPEED UP 16.50Hz 16.50Hz 16.50Hz SET BATTERY TYPE 48V 48V 48V
CUTBACK SPEED 25Hz 25Hz 25Hz ADJUST BATTERY 50.9V 50.9V 50.9V
TILT SPEED 50Hz 50Hz 50Hz THROTTLE 0 ZONE 5% 5% 5%
SHIFT SPEED 30Hz 30Hz 30Hz THROTTLE X POINT 63% 63% 63%
AUX SPEED 50Hz 50Hz 50Hz THROTTLE Y POINT 36% 36% 36%
HYD SPEED FINE 18Hz 18Hz 18Hz ADJUSTMENT #04 145⁰ 145⁰ 145⁰
MAXIMUM CURRENT LEVEL=8 LEVEL=8 LEVEL=8 PWM ON MAIN CONT ON ON ON
IDLE TIME 1.5 1.5 1.5 PWM ON AUX OUT. OFF OFF OFF
MC/AUX PWM 75% 75% 75%
SET O PTIO N E MO DE N MO DE H MO DE FORK LEVELING OFF OFF OFF
CUTBACK MODE NONE NONE NONE FORK LEVEL MIN. 1.3V 1.3V 1.3V
HOUR COUNTER RUNNING RUNNING RUNNING FORK LEVEL MAX. 9.2V 9.2V 9.2V
SET TEMPERATURE ANALOG ANALOG ANALOG FORK LVL. CENTER 3.7V 3.7V 3.7V
JOYSTICK OFF OFF OFF FORK MIN. SPEED 49.80% 49.80% 49.80%
DIGITAL LIFT OFF OFF OFF FORK APPR. RANGE LEVEL=5 LEVEL=5 LEVEL=5
MOTOR TYPE STANDARDPUMP STANDARDPUMP STANDARDPUMP FORK CENTER DEAD LEVEL=5 LEVEL=5 LEVEL=5
©GN-HHIE

128
CONTROLLERS AND PARAMETERS 22/25/30/32/35B-9
PUMP

TESTER MENU
This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full
MOTOR VOLTAGE
voltage (which depends of the battery voltage).
FREQUENCY This is the frequency of the voltage and current supplied to the motor.
ENCODER This is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.
SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor, expressed in the same unit of the frequency.
CURRENT RMS Ampere value. Root Mean Square value of the line current in the motor.
TEMPERATURE °C value. This is the temperature of the inverter base plate. This temperature is used for the HIGH TEMPERATURE alarm detection.
Temperature This is the temperature of the motor; if the option is programmed "None" it shows 0°.
- ON / +VB = Active entry of closed switch.
Lifting switch
- OFF / GND = Non active entry of open switch.
- ON / +VB = Active entry of closed switch.
Security switch
- OFF / GND = Non active entry of open switch.
- ON / +VB = Active entry of closed switch.
Hydro speed req.
- OFF / GND = Non active entry of open switch.
Lift/lower req. Level of the lift and lower analogue signal.
Tilt request Voltage of the tilt analogue signal.
Shift request Voltage of the shift analogue signal.
Aux request Voltage of the auxiliary analogue signal.
- ON / GND = Active entry of open switch.
Cutback switch
- OFF / +VB = Non active entry of closed switch.
Voltage booster This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.
Battery voltage Level of battery voltage measured at the input to the key switch.
©GN-HHIE

129
CONTROLLERS AND PARAMETERS 22/25/30/35BH-9

Model Model Application Type Power Current limit

DUAL AC2 Power Traction MOSFET 80V, 300+300A 300A/3min
22/25/30/35BH-9
AC2 Power Pump MOSFET 80V, 400A 400A/3min
©GN-HHIE

130
CONTROLLERS AND PARAMETERS 22/25/30/35BH-9

Model Model Application Type Power Current limit

DUAL AC2 Power Traction MOSFET 80V, 300+300A 300A/3min
22/25/30/35BH-9
AC2 Power Pump MOSFET 80V, 400A 400A/3min
©GN-HHIE

131
CONTROLLERS AND PARAMETERS 22/25/30/35BH-9
Traction

Master Slave

Standard ZAPI menu

structure.
Different outlook by
display and console.
©GN-HHIE

132
CONTROLLERS AND PARAMETERS 22/25/30/35BH-9
Traction MASTER

PARAMETER CHANGE E MO DE N MO DE H MO DE SET O PTIO N E MO DE N MO DE H MO DE

ACCELER. DELAY LEVEL=5 LEVEL=3 LEVEL=1 HOUR COUNTER RUNNING RUNNING RUNNING
RELEASE BRAKING LEVEL=4 LEVEL=4 LEVEL=5 BATTERY CHECK ON ON ON
INVERS. BRAKING LEVEL=1 LEVEL=3 LEVEL=4 TRACTION CUTOUT ON ON ON
PEDAL BRAKING LEVEL=9 LEVEL=9 LEVEL=9 LIFT CUTOUT ON ON ON
SPEED LIMIT BRK. LEVEL=9 LEVEL=9 LEVEL=9 S.R.O. ON ON ON
BRAKE CUTBACK LEVEL=5 LEVEL=5 LEVEL=5 HYDRO KEY ON OFF OFF OFF
MAX SPEED FORW 102Hz 125Hz 150Hz STOP ON RAMP OFF OFF OFF
MAX SPEED BACK 102Hz 125Hz 150Hz AUX INPUT #1 OPTION#1 OPTION#1 OPTION#1
CUTBACK SPEED 1 60% 60% 60% SET TEMPERATURE ANALOG ANALOG ANALOG
TURTLE SPEED 70Hz 70Hz 70Hz STEER TABLE OPTION#1 OPTION#1 OPTION#1
CURVE CUTBACK 30% 30% 30% DISPLAY ON ON ON
FREQUENCY CREEP 0.30Hz 0.30Hz 0.30Hz PEDAL TYPE OPTION#1 OPTION#1 OPTION#1
MAXIMUM CURRENT LEVEL=8 LEVEL=8 LEVEL=8 PEDAL BRK STOP OFF OFF OFF
ACC. SMOOTH 2.5 2.5 1
INV. SMOOTH 2.5 2.5 1
STOP SMOOTH 15Hz 15Hz 10Hz
SEAT DELAY TIME 2 2 2
SEQUENCE DE.TIME 2 2 2
CHAT TIME 10 10 10
©GN-HHIE

133
CONTROLLERS AND PARAMETERS 22/25/30/35BH-9
Traction MASTER

ADJUSTMENTS E MO DE N MO DE H MO DE LOAD SENSOR OFF OFF OFF

SET BATTERY TYPE 80V 80V 80V ADJ MIN LOAD 1.3V 1.3V 1.3V
ADJUST BATTERY 85.68V 85.68V 85.68V ADJ REF LOAD 3.3V 3.3V 3.3V
MAX STEER RIGHT 1.3V 1.3V 1.3V REF. LOAD WEIGHT 3000Kg 3000Kg 3000Kg
MAX STEER LEFT 4.0V 4.0V 4.0V RATED LOAD W. 3000Kg 3000Kg 3000Kg
SET STEER 0-POS. 2.9V 2.9V 2.9V OVER LOAD WEIGHT 3500Kg 3500Kg 3500Kg
SET STEER RIGHT 90? 90? 90? MAX LOAD WEIGHT 6375Kg 6375Kg 6375Kg
SET STEER LEFT 65? 65? 65? OVERLOAD TYPE NONE NONE NONE
THROTTLE 0 ZONE 3% 3% 3% LOAD SPEED UPD. 10Hz 10Hz 10Hz
THROTTLE X POINT 63% 63% 63%
THROTTLE Y POINT 36% 36% 36%
COOLING FAN WORK OPTION#2 OPTION#2 OPTION#2
START TEMP.FAN 50⁰C 50⁰C 50⁰C
ADJUSTMENT#2 BDI LEVEL=2 LEVEL=2 LEVEL=2
ADJUSTMENT#1 BDI LEVEL=3 LEVEL=3 LEVEL=3
ADJUSTMENT #03 20% 20% 20%
MAIN CONT. VOLT. 36V 36V 36V
AUX OUTPUT VOLT. 36V 36V 36V
ADJUSTMENT #04 145⁰C 145⁰C 145⁰C SET MODEL E MODE N MODE H MODE
SPEED FACTOR 76 76 76 CONNECTED TO 3 3 3
©GN-HHIE

134
CONTROLLERS AND PARAMETERS 22/25/30/35BH-9
Traction MASTER
TESTER MENU
This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full
MOTOR VOLTAGE
voltage (which depends of the battery voltage).
FREQUENCY This is the frequency of the voltage and current supplied to the motor.
ENCODER This is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.
SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor, expressed in the same unit of the frequency.
CURRENT RMS Ampere value. Root Mean Square value of the line current in the motor.
TEMPERATURE °C value. This is the temperature of the inverter base plate. This temperature is used for the HIGH TEMPERATURE alarm detection.
Temperature #1 This is the temperature of the right motor; if the option is programmed "None" it shows 0°.
Temperature #2 This is the temperature of the left motor; if the option is programmed "None" it shows 0°.
Accelerator The voltage of the accelerator potentiometer's wiper (CPOT).
Steer angle This is the indication of the angular position of the steered wheel.
Internal wheel cutback This is the indication of the speed reduction applied to the internal wheel; in other words, it shows the ratio of the two speeds.
- ON / +VB = Input active, switch closed.
Forward switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Backward switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Enable switch
- OFF / GND = Input non active, switch open.
©GN-HHIE

135
CONTROLLERS AND PARAMETERS 22/25/30/35BH-9
Traction MASTER
TESTER MENU
- ON / +VB = Input active, switch closed.
Seat switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Cutback switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Brake switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Exclusive hydro
- OFF / GND = Input non active, switch open.
Brake pedal pot. Voltage of the brake potentiometer's wiper (CPOTB). The parameter is active only if the PEDAL BRAKING parameter is set ANALOG.
The level of the speed reduction microswitch.
Hand brake - ON / GND = Input active, switch opened.
- OFF / +VB = Input non active, switch closed.
Voltage booster This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.
Battery voltage Level of battery voltage measured at the input of the key switch.
Battery charge The percentage Charge level of the battery.
Load pot Voltage value of load sensor.
©GN-HHIE

136
CONTROLLERS AND PARAMETERS 22/25/30/35BH-9
Traction SLAVE

PARAMETER CHANGE E MO DE N MO DE H MO DE
RELEASE BRAKING LEVEL=2 LEVEL=2 LEVEL=3
SEAT DELAY TIME 2 2 2

SET MO DEL
CONNECTED TO 4 4 4

ADJUSTMENTS
SET BATTERY TYPE 80V 80V 80V
ADJUST BATTERY 85.44V 85.92V 85.44V
AUX OUTPUT VOLT. 12V 12V 12V
©GN-HHIE

137
CONTROLLERS AND PARAMETERS 22/25/30/35BH-9
Traction SLAVE
TESTER MENU
This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full
MOTOR VOLTAGE
voltage (which depends of the battery voltage).
FREQUENCY This is the frequency of the voltage and current supplied to the motor.
ENCODER This is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.
SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor, expressed in the same unit of the frequency.
CURRENT RMS Ampere value. Root Mean Square value of the line current in the motor.
TEMPERATURE °C value. This is the temperature of the inverter base plate. This temperature is used for the HIGH TEMPERATURE alarm detection.
Voltage booster This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.
Battery voltage Level of battery voltage measured at the input of the key switch.
- ON / +VB = Input active, switch closed.
Seat switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Forward switch
- OFF / GND = Input non active, switch open.
- ON / +VB = Input active, switch closed.
Backward switch
- OFF / GND = Input non active, switch open.
©GN-HHIE

138
CONTROLLERS AND PARAMETERS 22/25/30/35BH-9
PUMP

Standard ZAPI menu

structure.
Different outlook by
display and console.
©GN-HHIE

139
CONTROLLERS AND PARAMETERS 22/25/30/35BH-9
PUMP

PARAMETER CHANGE E MO DE N MO DE H MO DE ADJUSTMENTS

ACCELER. DELAY LEVEL=0 LEVEL=0 LEVEL=0 SET BATTERY TYPE 80V 80V 80V
DECELER. DELAY LEVEL=0 LEVEL=0 LEVEL=0 ADJUST BATTERY 85.7V 85.7V 85.7V
MAX SPEED UP 81Hz 90Hz 98Hz THROTTLE 0 ZONE 5% 5% 5%
MIN SPEED UP 18.00Hz 18.00Hz 18.00Hz THROTTLE X POINT 63% 63% 63%
CUTBACK SPEED 25Hz 25Hz 25Hz THROTTLE Y POINT 36% 36% 36%
TILT SPEED 30Hz 30Hz 30Hz ADJUSTMENT #04 145⁰C 145⁰C 145⁰C
SHIFT SPEED 30Hz 30Hz 30Hz PWM ON MAIN CONT OFF OFF OFF
AUX SPEED 50Hz 50Hz 50Hz PWM ON AUX OUT. ON ON ON
HYD SPEED FINE 30Hz 30Hz 30Hz MC/AUX PWM 15% 15% 15%
MAXIMUM CURRENT LEVEL=9 LEVEL=9 LEVEL=9 FORK LEVELING OFF OFF OFF
IDLE TIME 1.5 1.5 1.5 FORK LEVEL MIN. 1.3V 1.3V 1.3V
FORK LEVEL MAX. 9.2V 9.2V 9.2V
SET O PTIO N FORK LVL. CENTER 3.7V 3.7V 3.7V
CUTBACK MODE NONE NONE NONE FORK MIN. SPEED 49.80% 49.80% 49.80%
HOUR COUNTER RUNNING RUNNING RUNNING FORK APPR. RANGE LEVEL=5 LEVEL=5 LEVEL=5
SET TEMPERATURE ANALOG ANALOG ANALOG FORK CENTER DEAD LEVEL=5 LEVEL=5 LEVEL=5
JOYSTICK OFF OFF OFF
DIGITAL LIFT OFF OFF OFF

SET MO DEL
CONNECTED TO PUMP PUMP PUMP
©GN-HHIE

140
CONTROLLERS AND PARAMETERS 22/25/30/35BH-9
PUMP
TESTER MENU
This is the voltage supplied to the motor by the inverter; it is expressed as a percentage of the full
MOTOR VOLTAGE
voltage (which depends of the battery voltage).
FREQUENCY This is the frequency of the voltage and current supplied to the motor.
ENCODER This is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.
SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor, expressed in the same unit of the frequency.
CURRENT RMS Ampere value. Root Mean Square value of the line current in the motor.
TEMPERATURE °C value. This is the temperature of the inverter base plate. This temperature is used for the HIGH TEMPERATURE alarm detection.
Temperature This is the temperature of the motor; if the option is programmed "None" it shows 0°.
- ON / +VB = Active entry of closed switch.
Lifting switch
- OFF / GND = Non active entry of open switch.
- ON / +VB = Active entry of closed switch.
Security switch
- OFF / GND = Non active entry of open switch.
- ON / +VB = Active entry of closed switch.
Hydro speed req.
- OFF / GND = Non active entry of open switch.
Lift/lower req. Level of the lift and lower analogue signal.
Tilt request Voltage of the tilt analogue signal.
Shift request Voltage of the shift analogue signal.
Aux request Voltage of the auxiliary analogue signal.
- ON / GND = Active entry of open switch.
Cutback switch
- OFF / +VB = Non active entry of closed switch.
Voltage booster This is the booster of the voltage supplied to the motor in load condition; it is expressed in a percentage of the full voltage.
Battery voltage Level of battery voltage measured at the input to the key switch.
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CONTROLLERS AND PARAMETERS 40/45/50B-9

Traction MASTER
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CONTROLLERS AND PARAMETERS 40/45/50B-9

Traction SLAVE
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CONTROLLERS AND PARAMETERS 40/45/50B-9

PUMP
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CONTROLLERS AND PARAMETERS 40/45/50B-9
Traction

Master Slave

Standard ZAPI menu

structure.
Different outlook by
display and console.
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CONTROLLERS AND PARAMETERS 40/45/50B-9
PUMP

Standard ZAPI menu

structure.
Different outlook by
display and console.
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CONTROLLERS AND PARAMETERS 40/45/50B-9
Traction MASTER

PARAMETER CHANGE E MO DE N MO DE H MO DE SET O PTIO N E MO DE N MO DE H MO DE

ACCELER. DELAY LEVEL=3 LEVEL=2 LEVEL=1 HOUR COUNTER RUNNING RUNNING RUNNING
RELEASE BRAKING LEVEL=2 LEVEL=2 LEVEL=1 BATTERY CHECK ON ON ON
INVERS. BRAKING LEVEL=3 LEVEL=5 LEVEL=6 TRACTION CUTOUT ON ON ON
PEDAL BRAKING LEVEL=7 LEVEL=7 LEVEL=7 LIFT CUTOUT ON ON ON
SPEED LIMIT BRK. LEVEL=6 LEVEL=6 LEVEL=6 HYDRO KEY ON OFF OFF OFF
BRAKE CUTBACK LEVEL=5 LEVEL=5 LEVEL=5 STOP ON RAMP OFF OFF OFF
MAX SPEED FORW 91Hz 113Hz 135Hz AUX INPUT #1 OPTION#2 OPTION#2 OPTION#2
MAX SPEED BACK 91Hz 113Hz 135Hz SET PEDAL BRAKE DIGITAL DIGITAL DIGITAL
CUTBACK SPEED 100% 100% 100% SET TEMPERATURE ANALOG ANALOG ANALOG
TURTLE SPEED 76Hz 76Hz 76Hz STEER TABLE OPTION#1 OPTION#1 OPTION#1
CURVE CUTBACK 30% 30% 30% DISPLAY ON ON ON
FREQUENCY CREEP 0.30Hz 0.30Hz 0.30Hz S.R.O. ON ON ON
MAXIMUM CURRENT LEVEL=5 LEVEL=5 LEVEL=5 PEDAL TYPE OPTION#1 OPTION#1 OPTION#1
ACC. SMOOTH 1.5 1.5 1.5 PEDAL BRK STOP OFF OFF OFF
INV. SMOOTH 1.5 1.5 1.5
STOP SMOOTH 15Hz 10Hz 10Hz
SEAT DELAY TIME 2 2 2
SEQUENCE DE.TIME 2 2 2
CHAT TIME 10 10 10
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CONTROLLERS AND PARAMETERS 40/45/50B-9
Traction MASTER

ADJUSTMENTS E MO DE N MO DE H MO DE SET MODEL E MODE N MODE H MODE

SET POT BRK MIN 0.5V 0.5V 0.5V CONNECTED TO 3 3 3
SET POT BRK MAX 4.5V 4.5V 4.5V
SET BATTERY TYPE 80V 80V 80V
ADJUST BATTERY 78.5V 78.5V 78.5V
MAX STEER RIGHT 0.7V 0.7V 0.7V
MAX STEER LEFT 2.9V 2.9V 2.9V
SET STEER 0-POS. 2.0V 2.0V 2.0V
SET STEER RIGHT 85° 85° 85°
SET STEER LEFT 63° 63° 63°
THROTTLE 0 ZONE 0% 0% 0%
THROTTLE X POINT 63% 63% 63%
THROTTLE Y POINT 25% 25% 25%
ADJUSTMENT#2 BDI LEVEL=3 LEVEL=3 LEVEL=3
ADJUSTMENT#1 BDI LEVEL=3 LEVEL=3 LEVEL=3
ADJUSTMENT #03 20% 20% 20%
PWM ON MAIN CONT ON ON ON
PWM ON AUX OUT. OFF OFF OFF
ADJUSTMENT #04 145°C 145°C 145°C
SPEED FACTOR 75 75 75
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CONTROLLERS AND PARAMETERS 40/45/50B-9
Traction SLAVE

PARAMETER CHANGE E MO DE N MO DE H MO DE ADJUSTMENTS E MO DE N MO DE H MO DE

MAXIMUM CURRENT LEVEL=5 LEVEL=5 LEVEL=5 SET BATTERY TYPE 80V 80V 80V
ADJUST BATTERY 78.0V 78.0V 78.0V
SET O PTIO N E MO DE N MO DE H MO DE PWM ON AUX OUT.2 12V 12V 12V
HOUR COUNTER RUNNING RUNNING RUNNING PWM ON AUX OUT. OFF OFF OFF
AUX OUTPUT #1 BRAKE BRAKE BRAKE LOAD SENSOR OFF OFF OFF
SET TEMPERATURE ANALOG ANALOG ANALOG ADJ MIN LOAD 1.3V 1.3V 1.3V
OPSS COIL ON ON ON ADJ REF LOAD 3.3V 3.3V 3.3V
REF. LOAD WEIGHT 4515Kg 4515Kg 4515Kg
SET MO DEL E MO DE N MO DE H MO DE RATED LOAD W. 5460Kg 5460Kg 5460Kg
CONNECTED TO 4 4 4 OVER LOAD WEIGHT 4830Kg 4830Kg 4830Kg
MAX LOAD WEIGHT 8925Kg 8925Kg 8925Kg
OVERLOAD TYPE NONE NONE NONE
LOAD SPEED UPD. 10Hz 10Hz 10Hz
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CONTROLLERS AND PARAMETERS 40/45/50B-9
PUMP

PARAMETER CHANGE E MO DE N MO DE H MO DE ADJUSTMENTS

ACCELER. DELAY LEVEL=0 LEVEL=0 LEVEL=0 SET BATTERY TYPE 80V 80V 80V
DECELER. DELAY LEVEL=0 LEVEL=0 LEVEL=0 ADJUST BATTERY 78.5V 78.5V 78.5V
MAX SPEED UP 82Hz 90Hz 100Hz THROTTLE 0 ZONE 9% 9% 9%
MIN SPEED UP 18.00Hz 18.00Hz 18.00Hz THROTTLE X POINT 72% 72% 72%
CUTBACK SPEED 25Hz 25Hz 25Hz THROTTLE Y POINT 15% 15% 15%
TILT SPEED 40Hz 40Hz 40Hz COOLING FAN WORK OPTION#1 OPTION#1 OPTION#1
SHIFT SPEED 35Hz 35Hz 35Hz START TEMP.FAN 50°C 50°C 50°C
AUX SPEED 40Hz 40Hz 40Hz PWM ON MAIN CONT ON ON ON
HYD SPEED FINE 18Hz 18Hz 18Hz PWM ON AUX OUT. OFF OFF OFF
MAXIMUM CURRENT LEVEL=9 LEVEL=9 LEVEL=9 ADJUSTMENT #04 145? 145? 145?
IDLE TIME 1.5 1.5 1.5 FORK LEVELING OFF OFF OFF
FORK LEVEL MIN. 1.3V 1.3V 1.3V
SET O PTIO N FORK LEVEL MAX. 9.2V 9.2V 9.2V
CUTBACK MODE OFF OFF OFF FORK LVL. CENTER 3.7V 3.7V 3.7V
HOUR COUNTER RUNNING RUNNING RUNNING FORK MIN. SPEED 49.80% 49.80% 49.80%
SET TEMPERATURE ANALOG ANALOG ANALOG FORK APPR. RANGE LEVEL=5 LEVEL=5 LEVEL=5
DIGITAL LIFT OFF OFF OFF FORK CENTER DEAD LEVEL=5 LEVEL=5 LEVEL=5
JOYSTICK OFF OFF OFF

SET MODEL
CONNECTED TO 5 5 5
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ERROR CODE LIST Master and slave
DUAL TRACTION AND PUMP

Master and slave

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ERROR CODE LIST DUAL TRACTION AND PUMP

Master and slave Pump

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ERROR CODE LIST DUAL TRACTION AND PUMP

Pump
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ERROR CODE LIST SINGE MASTER SLAVE AND PUMP

Master
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ERROR CODE LIST SINGE MASTER SLAVE AND PUMP

Master Slave
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ERROR CODE LIST SINGE MASTER SLAVE AND PUMP

Slave Pump
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ERROR CODE LIST SINGE MASTER SLAVE AND PUMP

Pump
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MAINTENANCE 15/18/20BT-9 16/18/20B-9
Please refer also to SB-2013-046

AZOLLA ZS32
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MAINTENANCE 22/25/30/32/35B-9
Please refer also to SB-2013-046

AZOLLA ZS32
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MAINTENANCE 22/25/30/35BH-9
Please refer also to SB-2013-046

AZOLLA ZS32
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MAINTENANCE 40/45/50B-9
Please refer also to SB-2013-046

45 l
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MAINTENANCE
Please refer also to SB-2013-046
A B C D E
Daily maintenance checks 8-10h Periodical maintenance checks 50-250h 450-500h 900-1000h 2000h
daily monthly 3 months 6 months yearly
C heck truck visually and inspect components ●
Check truck for obvious damages and leaks. ●
Test drive truck/check functional performance ●
Check clean battery terminals. ●
C heck torque on critical fasteners ●
Check electrolyte level. ● C heck battery cables/truck receptacle ●
Check capacity, warning plates and decals. ● Fill battery electrolyte level ●
Check condition of tires and wheels. Remove embedded objects. ●
Perform battery load test ●
Test ground ●
Check for missing or loose wheel lug nuts. ●
C lean drive axle air vent ●
Check hydraulic sump oil level. ● C heck drive axle fluid level ●
Check display. ● Drain and replace drive axle fluid ●
Check warning lights and hourmeter. ● Drain and replace drive axle fluid (initial) ●
C heck drive axle mounting and fasteners ●
Check overhead guard condition and bolts. ●
C heck brake condition and wear ●
Check horn operation and other warning devices. ●
Lubricate steering axle linkage ●
Check steering operation. ● C heck/lubricate steering axle wheel bearings ●
Check service brake operation. ● Replace hydraulic sump fluid and strainer ●
Check parking brake operation. ●
Fill hydraulic sump fluid ●
Replace hydraulic sump filter and breather ●
Check directional and speed controls operation. ●
Lubricate tilt cylinder rod ends ●
Check accelerator. ● Lubricate mast fitting ●
Check lift, tilt and auxiliary operation. ● C heck lift chain adjustment and wear ●
Check mast, lift chains and fasteners. ● C heck/lubricate lift chains ●
Lubricate mast rollers ●
Check carriage or attachments and forks. ●
C heck contactor (Replace contactor tips if roughness is remarkable) ●
Check seat deck holddown latch for correct locking. ●
Replace brake fluid ●
Check optional safety equipment.(Alarms, Lights etc.) ● C heck controller ●

For details please refer to manuals on-line

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