Part No.

508000003121
I V1 08/2019
EP EQUIPMENT CO.,LTD. is one of the catalogs.
world’s leading companies manufacture,
With business all over the world, EP has
design material handling equipment and
thousands of employees and hundreds
provide related service. With over
of agents worldwide to provide our
100,000m2 plant it produces over
global customers with prompt local
100,000 trucks per year, and provides
service.
professional, effective and optimized
material handling solutions worldwide,
Based on the concept of sharing
until now it has developed three major
economy , EP also offer rental service
kinds of business:
for various logistics equipment. Adhering
· Material handling equipment: Focus
to the idea “Making the leasing of logistic
on electric forklift and warehouse
equipment more simple”, EP is devoted
equipment
to providing customized one-stop
·OEM parts: Global parts supply
leasing solutions for our customers with
·Imow industry,online: One stop
our high quality, reasonable price and
industrial products supply
prompt rental service.
Guided by our customer-oriented
EP’s mission&vision is “ Let more people
concept, EP has developed service
apply the electrical material handling
centers in more than 30 countries
equipment to relieve the intensity of
around the world, from which customers
labour” and “Let’s grow together”.
are able to receive timely local service.
Moreover, 95% of warranty parts can be
EP EQUIPMENT CO., LTD
shipped out within 24 hours after been
Address: XIAQUAN, DIPU, ANJI,
ordered. Through our online after-sales
ZHEJIANG, CHINA
service system, customers can process
Tel: + 86-0571-28023920
their warranty claims, order spare parts
Fax: + 86-0571-28035616
and consult the operation manuals,
Website: www.ep-ep.com
maintenance materials and spare parts
Email: service@ep-ep.com

I
 Foreword
The present original operating instructions are designed to provide sufficient
instruction for the safe operation and maintenance of the Reach Truck. Please be
sure to read this operator manual carefully if you are operator or are in charge of the
Reach Truck,before you operate and service the Reach Truck. Only in this way can
you protect yourself and make the Reach Truck play a role as much as possible.
Our Reach Trucks are subject to ongoing development, so maybe there are some
differences between your product and the description in this manual. And the operator
manual details will be different because of customer's special requirements.
If you have any questions ,please keep in touch with the sales department or let the
dealer know.
Notes:
1. This manual is used for operation and maintenance , the detail parameters, size
and specifications in context is only for reference , the real parameters will depend on
sale files.
2. Manual pictures for reference only, the real car shall prevail, and shall not affect the
manual use.
3.Manual pictures only sign for one of the models in this series models.

COPYRIGHT OF THESE OPERATING INSTRUCYIONS REMAINS WITH EP

CO.,LTD

OM2412 08.19

II
 WARNING!
TO PREVENT SETIOUS RISK OF INJURY TO
YOUORSELF AND OTHERS OBSERVE THE
FOLLOWING SAFETY INSTRUCTIONS.
These Reach Truck may become hazardous if adequate maintenance is neglected.
Therefore, adequate maintenance facilities, trained personnel and procedures should
be provided.

Maintenance and inspection shall be performed in conformance with the following

practices:

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

followed.

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

adjust, and inspect Reach Truck.

3. Before leaving the Reach Truck:

– Do not park the Reach Truck on an incline.
– Fully lower the load forks.
– Press the emergency brake switch .
– Set the key switch to the "OFF" position and remove the key.

4. Before starting to operate Reach Truck:

– Be in operating position
– Place directional control in neutral
– Before operating Reach Truck, check functions of lift systems, directional
control,speed control,steering, warning devices and brakes.

5. Avoid fire hazards and have fire protection equipment present. 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 shall

be inspected regularly and maintained in legible condition.

7. Capacity, operation and maintenance instruction plates or decals shall be

maintained in legible condition.

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

9. All hydraulic systems shall be regularly inspected and maintained in conformance

III
with good practice. Cylinders, valves and other similar parts shall be checked to
assure that "drift" has not developed to the extent that it would create a hazard.

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

11. Modifications and additions which affect capacity and safe Reach Truck operation
shall not be performed by the customer or user without manufacturers prior written
approval. Capacity, operation and maintenance plates or decals shall be changed
accordingly.

IV
 Catalog

Correct use and Application................................................................................................... 1

1. Reach Truck Description.................................................................................................... 2

1.1Application....................................................................................................................2
1.2 Reach Truck Assemblies.......................................................................................... 3
1.2.1 Control Handle................................................................................................ 4
1.2.2 Key switch........................................................................................................ 4
1.2.3 Battery discharge indicator............................................................................5
1.3 Standard Version Specifications..............................................................................6
1.3.1 Performance data for standard Reach Trucks........................................... 6
1.3.2 Dimensions...................................................................................................... 6
1.4 Identification points and data plates..................................................................... 11
1.4.1Reach Truck data plate.................................................................................12
1.4.2 Capacity chart............................................................................................... 13
2. Commissioning.................................................................................................................. 14
2.1Using the Reach Truck for the First Time............................................................. 14
2.2During brake-in..........................................................................................................14
3.Operation............................................................................................................................. 15
3.1Safety Regulations for the Operation of Reach Trucks...................................... 15
3.2 Operate and run the Reach Truck........................................................................ 16
3.2.1 Preparing....................................................................................................... 16
3.2.2 Travel, Steering, Braking............................................................................. 16
3.2.3 Lifting, transporting and depositing loads................................................. 18
3.2.4 Parking the Reach Truck securely............................................................. 19
4.Battery Maintenance & Charging..................................................................................... 20
4.1 Safety regulations for handling acid batteries.....................................................20
4.2 Battery type & dimension....................................................................................... 20
4.3Charging the battery.................................................................................................21
4.4 Battery removal and installation............................................................................ 21
4.5Battery maintenance................................................................................................ 22
4.6Battery Disposal........................................................................................................22
5.Reach Truck Maintenance................................................................................................ 23
5.1Operational safety and environmental protection................................................23
5.2Maintenance Safety Regulations........................................................................... 23
5.3 Servicing and inspection........................................................................................ 24
5.3.1 Maintenance Checklist.................................................................................25
5.3.2 Lubrication Schedule................................................................................... 26
5.3.3 Maintenance Instructions............................................................................ 27
5.4 Decommissioning the Reach Truck...................................................................... 29
5.4.1Prior to decommissioning............................................................................. 29

V
 5.4.2 Restoring the Reach Truck to operation after decommissioning..........30
5.5 Safety checks to be performed at regular intervals and following any unusual
incidents...........................................................................................................................30
5.6 Final de-commissioning, disposal.........................................................................30
6.Troubleshooting.................................................................................................................. 31
6.1 Error Message..........................................................................................................32

VI
 Correct use and Application

The Reach Truck described in the present operator manual is an industrial Reach
Truck designed for lifting 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 to
personnel, the Reach Truck or property. In particular, avoid overloading the Reach
Truck with loads which are too heavy or placed on one side. The data plate attached
to the Reach Truck or the load diagram are binding for the maximum load capacity.
The Reach Truck must not be used in fire or explosion endangered areas, or areas
threatened by corrosion or excessive dust.

Proprietor responsibilities
For the purposes of the present operator manual the “proprietor” is defined as any
natural or legal person who either uses the Reach 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 of the Reach Truck, is charged with operational duties.
The proprietor must ensure that the Reach Truck is used only for the purpose it is
intended for and 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 all
Reach Truck users have read and understood this operator manual.
Failure to comply with the operator manual shall invalidate the warranty. The same
applies if improper work is carried out on the Reach Truck by the customer or third
parties without the permission of the manufacturer’s customer service department.

Adding accessories
The mounting or installation of additional equipment which affects or enhances the
performance of the Reach Truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval.

1
1. Reach Truck Description

1.1Application
The Reach Truck is reach electric Reach Truck with a steered drive wheel.
It is designed for use on level floors to lift and transport palletised goods. Open
bottom pallets or roll cages can be lifted.
The capacity can be obtained from the data plate.
The capacity with respect to lift height and load center of gravity is indicated on the
capacity plate.

2
1.2 Reach Truck Assemblies

Item Component Item Component

1 Control shaft with control shaft 8 Lifting device
head Drive wheel
2 Key switch 9 Blocking Shelf
3 Combined instrument 10 Hoist frame
(battery discharge monitor and
operating hour meter)
4 Up Cover 11 Plug
5 Rear Cowl 12 Battery
6 Driving Wheel 13 Pedal （CQE12 Optional）
7 Scissors 13 Pedal （CQE15S）

3
 1.2.1 Control Handle

Item Component Function

"Tilting Tilting the mast backward or forward
14
backward&forward" button
"Reach Reach the mast backward or forward
15
backward&forward" button
16 “Lower&Lift” switch Lowers or Raises load forks.
17 Sides way Switch Sides way the fork
18 Warning signal button Triggers a warning signal.
Safety function which, when activated, forces the Reach
19 Collision safety switch
Truck to reverse until the switch restored to neutral.
20 Travel switch Controls the driving speed and direction

1.2.2 Key switch

Switches control current on and off.
Removing the key prevents the Reach Truck
from being switched on by unauthorised
personnel.

4
1.2.3 Battery discharge indicator

The LEDs (1) represent battery residual

capacity, The LCD (2) displays the
operating hours.

Battery Discharge Indicator(1)

When the Reach Truck has been
released via the key switch, the battery
charge status is displayed.
The colours of the LEDs (1) represent the
following conditions:
Component LED colour value
Green 70-100%
Standard battery residual capacity Orange 50-60%
Flashing Red 0-20%

Battery Discharge for 70%, A flashing red show on storage battery charge warning.
Battery Discharge for 80%, Two flashing reds show on battery charge used up
warning, Lifting is now inhibited. The battery must be charged.

Operating hours display(2)

Display range between 0.0 and 99,999.0 hours. Travel and lifting are logged. This is a
backlit display.

Power up test
On power up the display shows:
• the operating hours
• the charge status

5
 1.3 Standard Version Specifications
Technical specification details in accordance with VDI2198. Technical modifications
and additions reserved.
1.3.1 Performance data for standard Reach Trucks
Item Description CQE12 CQE15S Unit
Drive unit Battery Battery
Operator type pedestrian standing
Q Load capacity 2645 3300 lb.
c Load center 23.6 23.6 in.
Travel speed, laden/ unladen 3.4/3.7 mph
Lifting speed, laden/ unladen 17.7/26.6 fpm
Lowering speed, laden/ unladen 31.5/29.5 fpm
Reaching speed, laden / unladen 15.7/15.7 fpm
Maximum gradeability, laden/ unladen 6/10 °
Service weight (Duplex Mast,With battery) 4045 4110 lb.
Unladen, Front / Rear, fork 2510/1535 2535/1575 lb.
Loadin Unladen, Front / Rear, fork retracted 2730/1315 2755/1355 lb.
g Laden, Front / Rear, fork advanced 630/6060 685/6730 lb.
Laden, Front / Rear, fork 2065/4625 2370/5045 lb.
Drive motor rating S2 60 min. 1.7/2 4.4 kW
Lift motor rating at S3 15% 4 kW
Battery voltage/ rated capacity (5h) 24/210 24/280 V/Ah
Battery weight 418.9 507 lb.

1.3.2 Dimensions

Item Description CQE12 CQE15S Unit

y Wheelbase 53.7 in.
h1 Height, mast lowered 82.3 in.
h2 Free lift 0 in.
h3 Lift height 118.1 in.
h4 Height, mast extended 155.9 in.
h7 Seat height/standing height -- 5.9
h8 Height of wheel arms 5.3 5.3 in.
l1 Overall length 86.3 90.5 in.
l2 Length to face of forks 44.1 48.4 in.
b1/ b2 Overall width 33.5/43.3 in.
s/e/l Fork dimensions 1.5/3.9/42.1 in.

6
b3 Fork Frame width 31.5 in.
b5 Distance between fork-arms 7.8-30.7 in.
Distance between wheel
b4 35.4 in.
arms/loading surfaces
Tilt of mast/fork carriage
α/β 2/4 °
forward/backward
l4 Reach distance 23.2 in.
Ground clearance, laden, below
m1 2.75 in.
mast
The minimum ground clearance
m2 2.75 in.
of frame
Aisle width1）, 1000×1200 pallet
Ast 102 106 in.
crossways
Aisle width1 , 800×1200 pallet
）

Ast 103.7 107.6 in.

lengthways
Wa Outer turning radius 61.4 65.3 in.
Length across wheel arms
l7 66.1 70.5 in.
（exclusive fork ）
Tyre type PU/PU
Tyre size, driving wheels Φ9×3 Φ10.2×4.1 in.
Tyre size, loading wheels Φ4×2.8 in.
Tyre size, caster wheels -- Φ3.9×2.8 in.
Wheels, number driving，
1x /4 1x 2/4
caster/loading (x=drive wheels)
b10 Track width, front,driving side 0 0 in.
b11 Track width,rear,loading side 39.3 39.3 in.

1） Including safety distance a = 200 mm

2） Sound pressure level at the driver’s ear 74 dB(A)

7
 Standard Mast Types （mm）
Close Mast Extended Mast
Free height lift height
Mast types height Height
h1 h2 h3 h4
1940 0 2700 3660
2090 0 3000 3960
2240 0 3300 4260
Two Stage Mast
2390 0 3600 4560
2590 0 4000 4960
2740 0 4300 5260
1960 1000 4000 4955
2130 1170 4500 5455
Three Stage Mast 2230 1270 4800 5760
2295 1335 5000 5960
2460 1500 5500 6460
Service weight （include battery）(kg)
Mast height Service weight（kg）
Mast types
（mm） CQE12 CQE15S
2700 1825 1855
3000 1835 1865
3300 1845 1875
Two Stage Mast
3600 1855 1885
4000 1865 1895
4300 1875 1905
4000 2065 2095
4500 2080 2110
Three Stage Mast 4800 2090 2120
5000 2095 2125
5500 2110 2140

8
Length across wheel arms
CQE12 CQE15S
Mast types Two Stage Three Stage Two Stage Three Stage
Mast Mast Mast Mast
Overall length
l1 2191 2203 2310 2320
（minimum）（mm）
Aisle width for pallets
1000 × 1200 Ast 2592 2600 2692 2700
crossways（mm）
Aisle width for pallets
800 × 1200 Ast 2633 2644 2734 2744
lengthways（mm）
Aisle width for pallets
1000 × 1200 Ast 2683 2693 2784 2794
lengthways（mm）
Aisle width for pallets
800 × 1200 Ast 2468 2475 2569 2575
crossways（mm）

9
10
1.4 Identification points and data plates

Item Description Item Description

“Never put your hands in
1 Reach Truck data plate 6
inner and outer
2 AC Power Decal 7 “Never stand ” warning
3 “Never sit ” warning
4 Operator Warning Decal
5 Key Switch Decal

11
1.4.1Reach Truck data plate

Item Description Item Description

1 Manufacturer 6 Fork length
2 Type 7 Lift height
3 Load capacity（kg） 8 Battery nominate capacity
4 Load center 9 Service weight with battery
5 Fork width 10 Serial no.

For queries regarding the Reach Truck or ordering spare parts please quote the
Reach Truck serial number(10).

MODEL NUMBER EXAMPLE

CQE 12&15 S

Reach Reach Truck Load capacity：12=1200Kg;

15=1500Kg

12
1.4.2 Capacity chart

The chart given above shows the relation

between the load center and the weight
of loads.

13
2. Commissioning

2.1Using the Reach Truck for the First Time

Only operate the Reach Truck with battery current.
Preparing the Reach 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 "4.4 Battery removal and
installation" ) do not damage battery cable.
• Charge the battery, (see "4.3 Charging the battery" ).
When the Reach Truck is parked the surface of the tyres will flatten. The flattening will
disappear after a short period of operation.

2.2During brake-in
We recommended operating the machine under light load conditions for the first stage
of operation to get the most from it. Especially the requirements given below should
be observed while the machine is in a stage of 100 hours of operation.
• Must prevent the new battery from over discharging when early used. Please
charging 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.

14
3.Operation

3.1Safety Regulations for the Operation of Reach Trucks

Driver authorisation: The Reach Truck may only be used by suitably trained
personnel, who have demonstrated to the proprietor or his representative that they
can drive and handle loads and have been authorised to operate the Reach Truck by
the proprietor or his representative.

Driver’s rights, obligations and responsibilities: The driver must be informed of

his duties and responsibilities and be instructed in the operation of the Reach Truck
and shall be familiar with the operator manual . The driver shall be afforded all due
rights . Safety shoes must be worn with pedestrian operated Reach Trucks.

Unauthorised Use of Reach Truck: The driver is responsible for the Reach Truck
during the time it is in use. He shall prevent unauthorised persons from driving or
operating the Reach Truck. It is forbidden to carry passengers or lift personnel.

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

Repairs: The driver must not carry out any repairs or alterations to the Reach Truck
without the necessary training and authorisation to do so. The driver must never
disable or adjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is at

risk due to Reach Truck movement, lifting operations, the load handler (e.g. forks or
attachments) or the load itself. This also includes areas which can be reached by
falling loads or lowering operating equipment.

· Unauthorised persons must be kept away from the hazardous area.

· Where there is anger to personnel, a warning must be sounded with sufficient notice.
· If unauthorised personnel are still within the hazardous area the Reach Truck shall
be brought to a halt immediately.

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

15
3.2 Operate and run the Reach Truck

3.2.1 Preparing
Before the Reach Truck can be commissioned, operated or a load unit lifted, the
driver must ensure that there is nobody within the hazardous area.
Checks and operations to be performed before starting daily work
– Make sure the Emergency brake switch
is depressed(6). Warning!
– Make sure the battery is connected Before operating the truck, check all
– Insert the key in the key switch ( 14) and controls and warning devices for
turn it to the right as far as it will go. proper operation. If any damage of
– Test the warning signal switch (13). fault is found, don’t operate truck until
corrected.
• Visually inspect the entire Reach Truck
(in particular wheels and load handler) for obvious damage.

3.2.2 Travel, Steering, Braking

Do not drive the Reach Truck unless the panels are closed and properly locked.

16
1.Driving

Driving in low speed

Push the control shaft into the slow speed range(S)and set the driving switch to the
desired driving direction(front or back).The bigger angle it swivels,the higher speed
will it get.

Driving in high speed

Push the control shaft into the quick speed range(K)and set the driving switch to the
desired driving direction(front or back). The bigger angle it swivels,the higher speed
will it get.
It will get different speed though the switch swivels the same angle in the different
range,the speed in the quick range(K) is quicker than in the slow range(S).

2.Steering
Apply the control handle(2) to the

left or right.

3.Braking
The brake pattern of the Reach
Truck depends largely on the
ground conditions. The driver
must take this into account when
operating the Reach Truck.
The driver must be looking ahead
when travelling. If there is no
hazard, brake
moderately to avoid moving the load .
The Reach Truck can brake in four different Warning!
ways: If the control handle moves slowly or
• Emergency braking not at all to the upper brake zone, the
• Automatic braking Reach Truck must be taken out of
• Regenerative braking service until the cause of this fault is
• Inversion braking be rectified.
• Emergency braking Replace the gas pressure spring if
Press Emergency brake switch(1), all necessary.
electrical functions are cut out and the
Warning!
Reach Truck automatically brakes.
If the travel switch moves slowly or not
at all to 0, the Reach Truck must be
• Automatic braking
taken out of service until the cause of
When the control handle(2) is released it
this fault is be rectified.
automatically sets itself to the upper brake
Replace the control handle if necessary.
zone (B) and automatic braking ensues.

17
• Regenerative braking
If the travel switch is set to "0", the Reach Warning!
Truck automatically brakes regeneratively. In hazardous situations set the control
When the speed below 1Km/h, the brake handle to the brake position or set the
then applies and motor brake stop. travel switch to the opposite direction.

• Inversion braking
You can set the travel switch to the opposite direction when travelling. The Reach
Truck brakes regeneratively until it starts to move in the opposite direction.

3.2.3 Lifting, transporting and depositing loads

Unsecured and incorrectly positioned
loads can cause accidents Warning!
·Instruct other people to move out of the Before lifting a load unit the driver
hazardous area of the Reach Truck. Stop must make sure that it has been
working with the Reach Truck if people do not correctly stowed and does not exceed
leave the hazardous. the Reach Truck’s capacity.
·Only carry loads that have been correctly Do not lift long loads at an angle.
secured and positioned. Use suitable
precautions to prevent parts of the load from
tipping or falling down. Warning!
·Do not transport witch bad handbarrow ( as Don't lift to tiptop, to avoid shorted life
Reach Truck and stock ) . of oil cylinder.
·Never stand underneath a raised load
handler.
·Do not stand on the load handler.
·Do not lift other people on the load handler.
·Insert the forks as far as possible
underneath the load.

Lift
Pull “Lift&Lower” switch(16) until the height
you need.

Lower
Push “Lift&Lower” switch(16)
Warning!
until the lowest position.
·Never tilt the mast with loads upraised 1.5m or more.
·Don’t lift the load when the mast was tilted forward.

18
Tilt forward
Press “Tilting forward&backward” button(15) until the angle you need.

Tilt backward
Press “Tilting forward&backward” button(15) until the angle you need.

3.2.4 Parking the Reach Truck securely

When you leave the Reach Truck it must be securely parked even if you only intend to
leave it for a short time.

• Pull “Lower” switch(3), fully lower the load Warning!

handler. Parking the Reach Truck securely.
• Fully lower the forks. Forbid parking on an incline.
• Press Emergency brake switch(1). Always fully lower the forks.
• Turn off the key switch and remove the key(2).

19
 4.Battery Maintenance & Charging

4.1 Safety regulations for handling acid batteries

Park the Reach Truck securely before carrying out any work on the batteries.

Maintenance personnel : Batteries may only be charged, serviced or replaced by

trained personnel .The present operator manual and the manufacturer ’s instructions
concerning batteries and charging stations must be observed when carrying out the
work.
Fire protection :
• Smoking and naked flames must be
avoided when working with batteries.
• Wherever a Reach Truck is parked for
charging there shall be no inflammable
material or operating fluids capable of
creating sparks within 2 meters around the
Reach Truck.
• 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 Battery type & dimension

Battery type & dimension as follow :

voltage/ rated Battery height Battery length Battery width
Tuck type Battery type
capacity（V/Ah） (in) (in) (in)
24 / 210 22.4 25.6 7.8
Industry 24 / 224 26.9 26.2 7.4
CQE12/15
battery 24 / 280 24.8 32.1 8.2
24 / 360 24.8 32.1 8.2

When replacing or installing batteries, ensure that the battery is correctly secured in
the battery compartment of the Reach Truck.

20
4.3Charging the battery

Safety regulations for Charging the battery

• To charge the battery, the Reach Truck must be parked in a closed and properly
ventilated room.
• Do not place any metal objects on the battery.
• Before charging, check all cables and plug connections for visible signs of damage.
• Before start and finish charging to make sure power is turn OFF.
• It is essential to follow the safety regulations of the
battery and charging station manufacturers.

Charging step
• Check whether the condition is according with
"Safety regulations for Charging the battery".
• Park the Reach Truck securely(See 3.2.4 Parking
the Reach Truck securely ).
• Remove the battery plug (1).
• Connect the battery plug (1) with the charging lead
of the stationary charger (2) and turn on the
charger.
NOTE:This picture is just a sample.

4.4 Battery removal and installation

• Park the Reach Truck securely(See 3.2.4 Parking

the Reach Truck securely ).
• Place the battery plug(1) or the battery cable in
such a way that they will not get caught on the
Reach Truck when the battery(3) is removed.
• The hooks must be attached to the eyes of the
battery in such a way.
• Remove the baffle(2).Pull the battery out from the
side.
• Installation is in the reverse order of operations.

NOTE:This picture is just a sample.

Warning!
The Reach Truck must be parked on level ground. To prevent short circuits, batteries
with exposed terminals or connectors must be covered with a rubber mat.
When transporting batteries using a crane, ensure that the crane is of adequate
Capacity. The lifting gear must exert a vertical pull so that the battery container is not
compressed. Forbid falling lift tool on battery surface.

21
4.5Battery maintenance

Do not overuse battery:

• If you use up the energy of battery till the forklift immovability, you will shorten its
working hours.
• Shower for battery appears need for charge，please charge it quickly.

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

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

Battery storage：
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room. To ensure the battery is always ready
for use a choice of charging methods can be made:
• a monthly equalizing charge as in point 4.3(see Page 18)

4.6Battery Disposal

Batteries may only be disposed of in accordance with national environmental

protection regulations or disposal laws.The manufacturer’s disposal instructions must
be followed.
Batteries contain an acid solution which is poisonous and corrosive . Therefore ,
always wear protective clothing and eye protection when carrying out work on
batteries . Above all avoid any contact with battery acid.
Nevertheless, should clothing, skin or eyes come in contact with acid the affected
parts should be rinsed with plenty of clean water-where the skin or eyes are affected
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 operational
safety of the Reach Truck. Battery equipment may only be replaced with the
agreement of the manufacturer.

22
5.Reach Truck Maintenance

5.1Operational safety and environmental protection

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

5.2Maintenance Safety Regulations

Maintenance personnel
Reach Trucks must only be serviced and maintained by the manufacturer’s trained
personnel.
The manufacturer’s service department has field technicians specially trained for
these tasks. We therefore recommend a maintenance contract with the
manufacturer’s local service center.

Lifting and jacking up

When a Reach Truck is to be lifted, the lifting gear must only be secured to the points
specially provided for this purpose.
When jacking up the Reach Truck, take appropriate measures to prevent the Reach
Truck from slipping or tipping over (e.g. wedges, wooden blocks).
You may only work underneath a raised load handler if it is supported by a sufficiently
strong chain.

Cleaning
Do not use flammable liquids to clean the Reach Truck.
Prior to cleaning, all safety measures required to prevent sparking (e.g. through short
circuits) must be taken. For battery-operated Reach Trucks, the battery connector
must be removed.
Only weak suction or compressed air and non-conductive antistatic brushes may be
used for cleaning electric or electronic assemblies.
If the Reach Truck is to be cleaned with a water jet or a high-pressure cleaner, all
electrical and electronic components must be carefully covered beforehand as
moisture can cause malfunctions.

23
After cleaning the Reach Truck, carry out the activities detailed in the
“Recommissioning
” section.

Electrical System
Only suitably trained personnel may operate on the Reach Truck’s electrical system.
Before working on the electrical system, take all precautionary measures to avoid –
electric shocks.
For battery-operated Reach Trucks, also de-energise the Reach Truck by removing
the battery connector.

Welding
To avoid damaging electric or electronic components, remove these from the Reach
Truck before performing welding operations.

Settings
When repairing or replacing electric or electronic components or assemblies, always
note the Reach Truck-specific settings.

Tyres
The quality of tyres affects the stability and performance of the Reach Truck. When
replacing factory fitted tyres only used original manufacturer’s spare parts, as
otherwise the data plate specifications will not be kept.
When changing wheels and tyres, ensure that the Reach Truck does not slew (e.g.
when replacing wheels always left and right simultaneously).

5.3 Servicing and inspection

Thorough and expert servicing is one of the most important requirements for the safe
operation of the Reach Truck. Failure to perform regular servicing can lead to Reach
Truck failure and poses a potential hazard to personnel and equipment.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the Reach Truck is to be
used in conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they
should be carried out. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly
A = Every 250 operating hours
B = Every 500 operating hours, or at least annually
C = Every 2000 operating hours, or at least annually
W service intervals are to be performed by the customer.
In the run-in period - after approx. 100 service hours - or after repair work, the owner
must check the wheel nuts/bolts and re-tighten if necessary.

24
 5.3.1 Maintenance Checklist
Maintenance
interval ●
W A B C
Braking Check magnetic brake air gap. ●
Electrical Test instruments, displays and control switches. ●
system Test warning and safety device. ●
Make sure wire connections are secure and check for
●
damage.
Test micro switch setting. ●
Check Controller and EPS Controller. ●
Fix the motor and cable ●
Power Visually inspect battery ●
supply Visually inspect battery plug ●
Check battery cable connections are secure, grease
●
terminals if necessary.
Travel Check the transmission for noise and leakage. ●
Check travel mechanism, adjust and lubricate if ●
necessary.Check control handle recuperating function.
Check driving wheel and loading wheel for wear and ●
damage.
Check wheel bearings and attachments. ●
Reach Check Reach Truck frame for damage. ●
Truck Check labels are present and complete ●
frame Check mast attachment ●
Hydraulic Test hydraulic system. ●
operations Check that hose and pipe lines and their connections are
●
secure, check for leaks and damage.
Check cylinders and piston rods for damage and leaks,
●
and make sure they are secure.
Check load chain setting and tension if necessary. ●
Visually inspect mast rollers and check contact surface
●
wear level
Check forks,load handler for wear and damage ●
Check hydraulic oil level. ●
Replace hydraulic oil. ●

25
5.3.2 Lubrication Schedule

26
Consumables
Handling consumables type material: Consumables must always be handled
correctly. Follow the manufacturer’s instructions.

Improper handling is hazardous to health, life and the environment. Consumables

must only be stored in appropriate containers. They may be flammable and must
therefore not come into contact with hot components or naked flames.

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

Avoid spillage. Spilled liquids must be removed immediately with suitable bonding
agents and the bonding agent/consumable mixture must be disposed of in
accordance with regulations.
Code Description Used for
A HM32# Hydraulic system
B GL-5 85W-90 gear case

5.3.3 Maintenance Instructions

Prepare the Reach Truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
• Park the Reach Truck securely (See 3.2.4 Parking the Reach Truck securely ).
• Remove the key to prevent the Reach Truck from accidentally starting.
• When working under a raised lift Reach Truck, secure it to prevent it from tipping or
sliding away.

Open the cover

• Remove the two screws (1).
• Carefully open the panel (2).

Replacing the drive wheel

The drive wheel must only be replaced by
authorised service personnel.

27
Check the hydraulic oil level
It is going to add hydraulic oil when you heard
explosion sound from pipe during lifting.
Warning!
• Prepare the Reach Truck for maintenance
Forbid adding hydraulic oil within
and repairs ( See 5.3.3 Maintenance
impurity.
Instructions ).
• Opening the front cover
• Add hydraulic oil of the correct grade ( See 5.3.2 Lubrication Schedule ) .
Add hydraulic oil till you cant hear explosion sound during lifting.
Installation is the reverse order.

Check transmission oil level

• Prepare the Reach Truck for maintenance and
repairs (See 5.3.3 Maintenance Instructions ). Warning!
• Open the panel (See 5.3.3 Maintenance Forbid adding transmission oil within
Instructions ). impurity.
• Turn the control handle to the right limited
position.
• Check the transmission oil level, it should be at the control plug level (See 5.3.2
Lubrication Schedule ).
• Add transmission oil every 800-1000 operating hours,
or at least annually (See 5.3.2 Lubrication Schedule ).
Installation is the reverse order.

Checking electrical fuses

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

28
 Item To protect: Rating
1 Traction/ lifting motor Fuse 200A
2 Battery Control Fuse 10A
3 Control system Control Fuse 10A

Recommissioning
The Reach Truck may only be recommissioned after cleaning or repair work, once the
following operations have been performed.
• Test horn.
• Test Emergency brake switch.
• Test brake.
• Lubricate the Reach Truck in accordance with the maintenance schedule.
5.4 Decommissioning the Reach Truck
If the Reach Truck is to be decommissioned for more than two months , e.g. For
operational reasons,it must be parked in a frost-free and dry location and all
necessary measures must be taken before, during and after decommissioning as
described.
On decommissioning the Reach Truck must be jacked up so that all the wheels are
clear of the ground. This is the only way of ensuring that the wheels and wheel
bearings are not damaged.
If the Reach Truck is to be out of service for more than 6 months , further measures
must be taken in consultation with the manufacturer’s service department.

5.4.1Prior to decommissioning
• Thoroughly clean the Reach Truck.
• Check the brakes.
• Check the hydraulic oil level and replenish Warning！
as necessary (See 5.3.3 Maintenance Charge every months:
Instructions ). – Charge the battery.
• Apply a thin layer of oil or grease to any Battery powered Reach Trucks:
non-painted mechanical components. The battery must be charged at
• Lubricate the Reach Truck in accordance regular intervals to avoid depletion of
with the maintenance schedule (See 5.3.2 the battery through self-discharge.
Lubrication Schedule ). The sulfuration would destroy the
• Charge the battery (See 4.3Charging the battery.
battery ).
• 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.

29
5.4.2 Restoring the Reach Truck to operation after decommissioning
• Thoroughly clean the Reach Truck.
• Lubricate the Reach Truck in accordance with the maintenance schedule (See 5.3.2
Lubrication Schedule ).
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery (See 4.3Charging the battery ).
• Check hydraulic oil for condensed water and replace if necessary.
• Start up the Reach Truck (see 3.2Operate and run the Reach Truck ).
If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the operating
controls by applying them repeatedly.
Perform several brake tests immediately after re-commissioning the Reach Truck.

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

unusual incidents
Carry out a safety check in accordance with national regulations. EP has a special
safety department with trained personnel to carry out such checks. The Reach Truck
must be inspected at least annually (refer to national regulations) or after any unusual
event by a qualified inspector. The inspector shall assess the condition of the Reach
Truck from purely a safety viewpoint, without regard to operational or economic
circumstances. The inspector shall be sufficiently instructed and experienced to be
able to assess the condition of the Reach Truck and the effectiveness of the safety
mechanisms based on the technical regulations and principles governing the
inspection of Reach Trucks.

A thorough test of the Reach Truck must be undertaken with regard to its technical
condition from a safety aspect. The Reach Truck must also be examined for damage
caused by possible improper use. A test report shall be provided. The test results
must 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 Reach Truck as proof that it has passed the safety
inspection. This plate indicates the due date for the next inspection.

5.6 Final de-commissioning, disposal

Final, proper decommissioning or disposal of the Reach Truck must be performed in
accordance with the regulations of the country of application. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.

30
6.Troubleshooting
This chapter is designed to help the user identify and rectify basic faults or the results
of incorrect operation. When locating a fault, proceed in the order shown in the table.
Fault Possible cause Action
Reach • Key switch in “OFF” position • Set key switch to “I”
Truck does • Battery charge too low • Check battery charge, charge
not start. • Faulty fuse battery if Necessary
•Reach Truck in charge mode • Test fuses
• Interrupt charging
Load can • Hydraulic oil level too low • Check the hydraulic oil level
not be • Excessive load • Note maximum capacity (see
lifted data plate)

If the fault cannot be rectified after carrying out the remedial procedure, notify the
manufacturer ’ s service department ,as any further troubleshooting can only be
performed by specially trained and qualified service personnel.

31
 6.1 Error Message

COMBIAC0 CONTROLLER

Error Message

Possible cause Fault elimination

Code Error text

Check in the hardware setting

There is an error on the choice of
99 SLIP PROFILE menu the value of those
the parameters of the slip profile.
parameters.

Check the wiring of the Fwd

and Rev travel demand inputs
(use the readings in the
TESTER to facilitate the
troubleshooting). Check the
This alarm occurs when both the
microswitches for failures.
80 FORW+BACK travel demands (Fwd and Bwd)
A failure in the logic is possible
are active at the same time.
too. So, when you have verified
the travel demand switches are
fine working and the wiring is
right, it is necessary to replace
the controller.
The possible reasons for this
alarm are (use the readings in
the TESTER to
facilitate the troubleshooting):
A) A travel demand active at
key on
B) Presence man sensor active
INCORRECT This is a warning for an incorrect at key on
79
START starting sequence. Check the wirings. Check the
micro-switches. It could be also
an error sequence made by the
operator. A failure in the logic is
possible too; so when all of the
above conditions were checked
and nothing was found, replace
the controller.

32
 The test is made at key-on and
after 20sec that both the travel
demands have been turned off.
This alarm occurs if the Check the mechanical
78 VACC NOT OK ACCELERATOR reading in the calibration and the functionality
TESTER menu’ is 1,0V higher of the potentiometer.
than PROGRAM VACC min
acquisition when the accelerator is
released.

This alarm occurs when the Improve the air cooling of the
temperature of the base plate is controller. If the alarm is
higher than 85°. Then the signalled when the controller is
HIGH maximum current decreases cold, the possible reasons are
62
TEMPERATURE proportionally with the temperature a thermal sensor failure or a
increases from 85° up to 105°. At failure in the logic card. In this
105° the Current is limited to 0 case, it is necessary to replace
Amps. the controller.

Get the battery charged. If it

It occurs when the battery charge doesn’t work, measure with a
is calculated being less than or voltmeter the battery voltage
equal to 10% of the full charge and and compare it with the value in
65 BATTERY LOW
the BATTERY CHECK setting is the BATTERY VOLTAGE
other than 0 (refer to SET OPTION parameter. If they are different
menu). adjust the value of the ADJUST
BATTERY function.

Try to execute a CLEAR

EEPROM operation (refer to
It’s due to a HW or SW defect of Console manual). Switch the
the non-volatile embedded key off and on to check the
memory supporting the controller result. If the alarm occurs
71 EEPROM KO parameters. This alarm does not permanently, it is necessary to
inhibit the machine operations, but replace the controller. If the
the truck will work with the default alarm disappears, the
values. previously stored parameters
will have been replaced by the
default parameters.

33
 Check the thermal sensor
inside the motor (use the
MOTOR TEMPERATURE
reading in the TESTER menu);
This warning occurs when the
check the sensor ohmic value
MOTOR temperature sensor is opened (if
65 and the sensor wiring. If the
TEMPERATURE digital) or has overtaken the
sensor is OK, improve the air
threshold of 150°C (if analog).
cooling of the motor. If the
warning is present when the
motor is cool, then the problem
is inside the controller.

This type of fault is not related

THERMIC The output of the controller
61 to external components;
SENSOR KO thermal sensor is out of range.
replace the controller.

It is just enough to turn the

CHECK UP This is just a warning to call for the CHECK UP DONE option to
NEEDED time programmed maintenance. level ON after the maintenance
is executed.

DATA The alarm ends when the

Acquisition of the current gains.
ACQUISITION acquisition is done.

The SW continuously checks for

the connection of the two supply
ends of the potentiometer in the
accelerator. The test consists of
reading the voltage drop on a
sense diode, connected between
NPOT (CNA#30) and GND and
cascaded with the potentiometer:
if the potentiometer gets Check the voltage on NPOT
86 PEDAL WIRE KO disconnected on PPOT (CNA#25) and the potentiometer
or NPOT, no current flows in this connections.
sense diode and the voltage on
the NPOT connection collapses
down. When the NPOT voltage is
less than 0.3V this alarm occurs.
This alarm occurs also when the
NPOT voltage is higher than 2Vdc
(to detect also the condition of a
broken sense diode).

34
 Warning: when the tiller is
released, after a fixed period of At the next travel request the
51 TILLER OPEN
time of standby (30 seconds) the warning disappear.
main contactor open.

The Maximum current gain

parameters are at the default Ask the assistance of a Zapi
values, which means the technician to do the correct
92 CURRENT GAIN
maximum current adjustment adjustment procedure of the
procedure has not been carried current gain parameters.
out yet.

The controller receives from the

CAN the message that another
controller in the net is in fault
WAITING FOR condition; as a consequence the
68
NODE ACE0 controller itself cannot enter
an operative status, but has to
WAIT for the other controller
coming out from the fault status.

This warning (presents only in

At the next travel request with
DEAD MAN trucks with “Dead Man” switch)
98 dead man switch close the
ABSENT appears when the “Dead Man”
warning disappears.
switch is open.

A) If the fault is present at start

up, it is very likely that the hw
overcurrent protection circuit is
damaged, it is necessary to
VALVE COIL This alarm occurs when there is a
76 replace the controller.
SHORTED short circuit on an on/off valve coil.
B) If the fault is present when
the controller drives the
outputs, the problem is located
in the harness and in the coils.

Check if there is a short or a

low impedence between the
EV1/5 DRIVER Electrovalve EV1 or EV2 driver is negative of one of those coils
74
SHORTED shorted. and –BATT. Otherwise the
driver circuit is damaged and
the controller must be replaced.

35
 Check if there is a short or a
low impedance between the
negative of this coil and –BATT.
This warning occurs also if the
external load is not present and
the parameter EV2 in the “Set
EV2 DRIVER
74 Electrovalve EV2 driver is shorted. Options” menu is set
SHORTED
“PRESENT”, in this case the
warning disappears setting the
EV2 parameter “ABSENT”.
Otherwise the driver circuit is
damaged and the controller
must be replaced.

Check if there is a short or a

low impedance between the
negative of this coil and –BATT.
This warning occurs also if the
external load is not present and
the parameter EV3 in the “Set
EV3 DRIVER
74 Electrovalve EV3 driver is shorted. Options” menu is set
SHORTED
“PRESENT”, in this case the
warning disappears setting the
EV3 parameter “ABSENT”.
Otherwise the driver circuit is
damaged and the controller
must be replaced.

Check if there is a short or a

low impedance between the
negative of this coil and –BATT.
This warning occurs also if the
external load is not present and
the parameter EV4 in the “Set
EV4 DRIVER
74 Electrovalve EV4 driver is shorted. Options” menu is set
SHORTED
“PRESENT”, in this case the
warning disappears setting the
EV4 parameter “ABSENT”.
Otherwise the driver circuit is
damaged and the controller
must be replaced.

36
 The device or its driving circuit
The EVP valve driver is not able to
48 EVP DRIVER KO is damaged, replace the
drive the load (cannot close).
controller.

The device or its driving circuit

EVP2 DRIVER The EVP2 valve driver is not able
47 is damaged, replace the
KO to drive the load (cannot close).
controller.
In standby condition (pump motor
not driven), the feedback coming This type of fault is not related
56 PUMP I NO ZERO from the current sensor in the to external components;
pump chopper gives a value out of replace the controller.
a permitted range,
because the pump current is not
A) Check the motor connection,
that there is continuity. If the
motor connection is opened,
This test is carried out when the the current cannot flow, so the
pump motor is running, and it test fails and the error code is
52 PUMP I=0 EVER
verifies that the current feedback displayed.
sensor is not constantly stuck to 0. B) If everything is ok for what it
concerns the motor, the
problem could be in the current
sensor or in the related circuit.

Check the wiring of the Lift and

lower inputs (use the readings
in the TESTER to facilitate the
troubleshooting). Check the
This alarm occurs when both forks microswitches for failures.
49 LIFT + LOWER movement requests(Lift + Lower) A failure in the logic is possible
are active at the same time. too. So, when you have verified
the travel demand switches are
fine working and the wiring is
right, it is necessary to replace
the controller.

The device or its driving circuit

The EV1 valve driver is not able to
75 CONT. DRV. EV1 is damaged, replace the
drive the load (cannot close).
controller.

The device or its driving circuit

The EV2 valve driver is not able to
75 CONT. DRV. EV2 is damaged, replace the
drive the load (cannot close).
controller.

37
 The device or its driving circuit
The EV3 valve driver is not able to
75 CONT. DRV. EV3 is damaged, replace the
drive the load (cannot close).
controller.

The device or its driving circuit

The EV4 valve driver is not able to
75 CONT. DRV. EV4 is damaged, replace the
drive the load (cannot close).
controller.

The device or its driving circuit

The EV5 valve driver is not able to
75 CONT. DRV. EV5 is damaged, replace the
drive the load (cannot close).
controller.

PUMP VACC NOT The minimum of the lift It is suggested to repeat a

89
OK potentiometer is not correctly set. “PROGRAM VACC” procedure.

- Check the correct connection

of the motor temperature
A) The motor temperature sensor
sensor.
SENS. MOT. is not correctly connected to A22.
67 - If the current sensor is
TEMP. KO B) The motor temperature sensor
correctly connected, replace it.
is damaged.
- If the problem persist, it is due
to the controller.

EPS-AC0 CONTROLLER

Error Message
Possible cause Fault elimination
Error Error text
Main uC and Slave uC
communicate via a local
serial interface. This alarm
It is necessary to
occurs when the slave uC
6 SERIAL ERR #1 replace the controller.
does not receive the
communication from the
main uC through this serial
interface.

38
 It occurs if a test to write
and read one location in
EEPROM fails. The SW
expects to read the written
value. It occurs also when
It is necessary to
the hour counter gives
13 EEPROM KO replace the controller.
different values between the
three redundant locations in
which it is recorded. It
occurs also when the busy
bit of the EEPROM does not
rise within 12 msec.
This alarm occurs in the rest
state if the output of the
It is necessary to
16 LOGIC FAILURE #4 voltage amplifier of the
replace the controller.
phase Vw-Vv have a drift
larger than ±0.25 V.
This alarm occurs in the rest
state if the output of the
It is necessary to
17 LOGIC FAILURE #3 voltage amplifier of the
replace the controller.
phase Vu-Vw have a drift
larger than ±0.25 V.
This alarm occurs when the
real voltage between It is necessary to
18 LOGIC FAILURE #2 phases W and V of the replace the controller.
motor is different from the
desired.
This alarm occurs when the
real voltage between
It is necessary to
19 LOGIC FAILURE #1 phases W and U of the
replace the controller.
motor is different from the
desired.
This alarm occurs in the
initial rest state after key on
if the outputs of the motor It is necessary to
32 VMN NOT OK
voltage amplifiers are not in replace the controller.
the window from 2.2 to 2.8
Vdc.

39
 This alarm occurs only
when the setting CAN BUS
is PRESENT. Then the
Find, on the traction
eps-ac0 waits for a via CAN
controller, the reason for
information that the traction
48 MAIN CONT. OPEN keeping the main
controller has closed the
contactor open.
main contactor. If this
information lacks more than
about 1.5 secs, this alarm
occurs.
This alarm occurs two ways:
1) In the initial rest state
after key on, if the outputs of
the current amplifiers are
not comprised in the It is necessary to
53 STBY I HIGH window 2.2 to 2.8 Vdc. replace the controller.
2) After the initial diagnosis
this alarm occurs when the
outputs of the current
amplifiers at rest have a drift
larger than ±0.15 V.
This alarm occurs if the Improve the cooling of
temperature of the the controller; otherwise
61 HIGH TEMPERATURE controller base plate it is necessary to
overtakes 75 degrees. replace the controller.
This alarm occurs only
when DIAG MOTOR TEMP
is on and the thermal
sensor inside the motor
Check the thermal
measures a temperature
sensor in the motor is
higher than 150 degrees. It
right working. If it is,
65 MOTOR TEMPERAT. occurs also when trying to
improve the cooling of
acquire the motor
the motor.
resistance with a
temperature in the motor
higher than 150 degree
(still with DIAG MOTOR
TEMP to ON).

40
 This alarm occurs if the Check the motor is
circuit to limit via hardware suited to work with the
the current in the motor is eps-ac0 (not oversized).
70 HIGH CURRENT either always active at Otherwise it is
key-on or repeatedly active necessary to replace
when the motor is turning. the controller.
Check the power fuse is
OK. Check the battery
positive arrives to the
This alarm occurs when the
controller. Check the
current in the phase V of the
71 POWER FAILURE #3 continuity of the wire in
motor is zero and the motor
the phase V of the
is commanded for moving.
motor. Otherwise it is
necessary to replace
the controller.
Check the power fuse is
OK. Check the battery
This alarm occurs when the positive arrives to the
current in the phase U of the controller. Check the
72 POWER FAILURE #2 motor is zero and the motor continuity of the wire in
is commanded for moving. the phase U of the
motor. Otherwise it is
necessary to replace
the controller.
Check the power fuse is
OK. Check the battery
This alarm occurs when the
positive arrives to the
current in the phase W of
controller. Check the
the motor is zero and the
73 POWER FAILURE #1 continuity of the wire in
motor is commanded for
the phase W of the
moving.
motor. Otherwise it is
necessary to replace
the controller.
It occurs in applications with
toggle switches when the Swap in between the
applied frequency two encoder channels
83 BAD ENCODER SIGN
(FREQUENCY) and the (CNB#7 with CNB#8).
motor speed (ENC SPEED)
have opposite sign.

41
 This alarm occurs if the
command potentiometer
(CPOC1 on CNA#9 or
CPOC2 on CNA#8)
changes with a jerk larger Change the twin pot.
84 STEER SENSOR KO
than MAX SP SLOPE (see
12.4.6.3). This alarm is
used to catch a discontinuity
in the voltages of the
command potentiometer.
This is just a warning to
inform that the steering
controller is limiting the
85 STEER HAZARD angle in the steering ——
direction. No speed
reduction occurs on the
traction.
The main uC sends an
analog signal towards the
slave uC to reset the slave
uC on demand. When the
slave uC detects this analog It is necessary to
218 CLOCK PAL NOT OK signal external to a window replace the controller.
from 2.2 to 2.8 and not in
the range to generate the
reset on demand, the slave
uC raises this alarm.

42
 When the safety
contacts are open, the
voltage on CNA#4 is
expected to be close to
0 Vdc and this is
independent from
whether the safety
It occurs when the voltage
contacts are connected
on CNA#4 (NK1: Lower
to a plus battery or to a
Potential Terminal of the
minus battery . In the
Safety Contacts (see 7.6) is
99 INPUT ERROR #1 first case (safety
higher than 12 V before to
contacts connected to a
turn the safety contacts
plus battery), when the
closed.
safety contacts are
open, CNA#4 is
connected to a minus
battery through a load.
Only a harness mistake
may connect NK1 to a
higher than 12 V
voltage.
It occurs when the encoder
counting of the main uC is It is necessary to
212 MICRO SLAVE #8 not matched with the replace the controller.
encoder counting of the
slave uC.
This alarm occurs if the
frequency and the
amplitude of the voltages
from the stepper motor lines
are mismatched in between
It is necessary to
219 STEPPER MOTOR MISM In normal condition when
replace the controller.
the amplitude of the stepper
motor lines increases, the
frequency of the stepper
motor lines must increase
too.
Search for a mechanical
This alarm occurs if the
problem locking the
current in the steering motor
motor. To make easier
220 MOTOR LOCKED stays close to the maximum
the fault catching, set
current longer than 1 sec.
DEBUG OUTPUT to
level 11.

43
 It occurs in one of the
following conditions:
(Open loop application only)
If the slave uC detects the
stator voltage phasor
rotates in the opposite
direction respect to the sign It is necessary to
221 MICRO SLAVE #4 of the stepper motor speed, replace the controller.
this alarm occurs. (Closed
loop application only) If the
slave uC detects the stator
voltage phasor rotates in
the opposite direction
respect to the commanded
position, this alarm occurs.
In application with the
In application with a feedback potentiometer,
feedback potentiometer, this verify the feedback
alarm occurs if the feedback potentiometer is not
potentiometer (CPOT on mechanically loosened.
CNB#6) does not change Check there is not a
(or changes in the opposite mechanical block of the
direction) its value even if steered wheel. Be sure
commanded to change. the wiper has not
222 FB POT LOCKED
In application with toggle reached its own
switches with ENCODER electrical limit because
CONTROL to off, this alarm of too much angle of the
occurs if the feedback steered wheel. Besides,
encoder counting does not this alarm may occur at
change its value even if the installation when the
commanded to change. motor rotates in the
wrong direction turning
away from the wished
This alarm occurs if the
feedback potentiometer
(CPOT on
CNB#6) changes with a jerk
larger than 0.3 V in 16 Change the feedback
223 JERKING FB POT msec. This potentiometer.
alarm is used to catch a
discontinuity in the voltages
of the
feedback potentiometer.

44
 This alarm occurs when the
It is necessary to send
parameters to compensate
the controller to Zapi to
for the gain of the current
225 CURRENT GAIN perform the maximum
amplifiers (ADJUSTMENT
current regulation.
#03 and ADJUSTMENT
#04) have the default values
Every 16msec, inside the
code cycle, the main uC
rises and then lowers an
input for the slave uC
(SYNC). When the slave uC
detects no edge for more
than 100 msec on this input, It is necessary to
226 NO SYNC
this alarm occurs. This is replace the controller.
just a watch dog function:
when the main uC does not
execute the code cycle it
does not update the SYNC
signal and the slave uC cuts
off the steer and traction.
Main uC and Slave uC
communicate via a local
serial interface. This alarm
occurs when the main uC It is necessary to
227 SLAVE COM. ERROR
does not receive the replace the controller.
communication from the
slave uC through this serial
interface.
This warning occurs only if
CAN BUS is PRESENT. At
key-on the eps-ac0 asks to
the traction controller to
send a list of parameters
via CAN Bus. From the
request until the parameters
237 WAITING DATA ——
are correctly relieved, this
warning occurs. The steer is
not activated yet, and the
safety relays remain open
when this warning is
present.

45
 Check the
potentiometer
connected to CNB#6 is
right working. If toggle
switches are connected
to CNA#2 and CNA#3,
verify they are right
working and the setting
AUX FUNCTION 11 is
This alarm occurs for an
correct. Verify also the
error in the redundant test
228 POSITION ERROR sensor bearing in the
of the feedback sensors.
motor (encoder) has not
a slip (the sensor
bearing has two rings:
one is connected to the
rotor shaft; the other is
connected to the motor
frame. Check these two
rings are strictly
connected to their
structure without slip.
This is a real alarm that cut
off the traction. It occurs at
the initial alignment if the
straight-ahead condition is
not matched within 6sec.
238 EPS NOT ALIGNED ——
Throughout this 6 secs
delay, the steer is not
activated yet, the safety
relays are open and the
traction is stopped.

At key-on the eps-ac0

needs an assent from the
traction controller to close
the safety contacts and to
turn onto operational mode.
Until this assent is not
239 WAITING FOR TRAC ——
relieved, this warning
occurs. The steer is not
activated yet and the safety
relays remain open when
this warning is present.

46
 This condition is several
times due to either, a
mismatching between
the Encoder resolution
It occurs when ENCODER used in the SW and the
CONTROL is set ON and real encoder resolution,
the real frequency does not or a wrong connection
241 ENCODER ERROR
pursuit the commanded between the two
frequency encoder channels. In
this latest case
exchange in between
the two encoder
channels.
Check the continuity of
This alarm occurs when the
the stepper motor
mean voltage on the
connections. In
Quadrature line of the
particular the resistance
stepper motor (connection
between CNA#8 and
242 Q LINE SENSOR KO CNA#8) is not null: the
the minus battery (with
voltage on every stepper
the stepper motor at
motor line is a sine wave
rest) is expected being
with null mean voltage.
very low (close to 30
ohms).
Check the continuity of
This alarm occurs when the
the stepper motor
mean voltage on the Direct
connections. In
line of the stepper motor
particular the resistance
(connection CNA#9) is not
between CNA#9 and
243 D LINE SENSOR KO null: the voltage on every
the minus battery (with
stepper motor line is a sine
the stepper motor at
wave with null mean
rest) is expected being
voltage.
very low (close to 30
ohms).

This alarm occurs when the

acquiring the motor
resistance or when
adjusting the parameters to
245 DATA ACQUISITION compensate for the gain of Recycle the key.
the current amplifiers
(maximum current factory
adjusted).

47
 The parameters to
compensate for the gain of
the current amplifiers
(ADJUSTMENT #03 and
ADJUSTMENT #04) are
It is necessary to send
recorded in a not volatile
the controller to Zapi to
memory (eeprom) with a
244 GAIN EEPROM KO execute the maximum
redundant handling. In fact
current regulation.
every adjustment is
recorded in three eeprom
locations. If the values in
these three locations are
different in between this
alarm occurs.
In stepper motor
application, this alarm
occurs if the main uC is
detecting a direction of the
stepper motor not matched
with the one that the slave
uC is detecting.
In closed loop application,
this alarm occurs if the main
It is necessary to
246 MICRO SLAVE KO uC is detecting a direction
replace the controller.
of the steering error not
matched with the one that
the slave uC is detecting.
Furthermore, this alarm
occurs also if the main uC is
detecting no steering
limitation meanwhile the
slave uC is detecting e
steering limitation.
This alarm occurs only
when the setting CAN BUS
Check the CAN Bus
is PRESENT. Then the
communication system
eps-ac0 must receive the
and analyse the
event messages from the
247 CAN BUS KO frames from the traction
traction controller. If these
controller to the steer
messages lack more than
controllers.
about 1 sec, this alarm
occurs.

48
 This alarm occurs for a fault
on the command
potentiometer (CPOC1 on
CNA#9, CPOC2 on
CNA#8). When a single
Check the connections
command pot is chosen, the
of the potentiometer.
alarm occurs if its wiper
This alarm occurs when
248 S.P OUT OF RANGE (CPOC1) exits the range
one connection of the
from 0.8 Vdc to 4.2 Vdc.
command
When the twin pot is
potentiometer is broken.
chosen, the alarm occurs if
the sum of the two wiper
voltages (CPOC1+CPOC2)
exits the range from 4.5 Vdc
to 5.5 Vdc.
Check the connections
This alarm occurs for a fault
of the feedback
on the feedback
potentiometer. This
potentiometer (CPOT on
249 F.B OUT OF RANGE alarm occurs when one
CNB#6). This alarm occurs
connection of the
if CPOT exits the range
feedback potentiometer
from 0.3 Vdc to 4.7 Vdc.
is broken.

It occurs when the

information on the status
bus between the main uC It is necessary to
250 MICRO SLAVE and the slave uC is frozen replace the controller.
to the 0xFF value (the slave
uC does not update the
status bus configuration).

This alarm occurs if the

slave uC detects the safety
It is necessary to
251 KM OPEN contact, of the main uC,
replace the controller.
open when expected being
closed.
This alarm occurs if the
main uC detects the safety
It is necessary to
252 KS OPEN contact, of the slave uC,
replace the controller.
open when expected being
closed.

49
 This alarm occurs if the
connection CNA#5 (K1)
is around a voltage of
This alarm occurs at key on
12 Vdc when switching
if the slave uC detects the
on the key. In fact, when
safety
the safety contacts are
253 KM CLOSED contact, of the main uC,
open, K1 is expected
closed prior to be
being connected to a
commanded.
battery voltage (not 12
V). Search for a harness
problem or replace the
controller.
This alarm occurs if the
connection CNA#4
(NK1) is around a
voltage of 12 Vdc when
This alarm occurs if the
switching on the key. In
main uC detects the safety
fact, when the safety
contact, of the slave uC,
254 KS CLOSED contacts are open, NK1
closed prior to be
is expected being
commanded.
connected to a minus
battery voltage (not 12
V). Search for a harness
problem or replace the
controller.

50