Electrical Forklift Truck

(3-Wheel Counterbalanced Battery Forklift Truck)

SERVICE MANUAL

CPDS13/15/16/18/20J-C1
CPDS13/15/16/18/20J-C2
CPDS13/15/16/18/20J-D1

HANGCHA GROUP CO., LTD.

th
Dec. 2010 4 EDITION
 Foreword

Thanks for your purchasing our 3-Wheel Counterbalanced Battery Forklift Truck.
3 wheel counterbalanced battery forklift truck is our company’s new product. It has the
character of small turning radius, beautiful shape, small dimensions, low gravity. This series
forklift truck use front 2-motor drive, rear wheel turning, lifting and turning share one pump etc.
new technology.
This manual has two parts. First one is how to use, operation and maintenance 3 wheel
battery forklift truck. The second part simply introduces the structure and principle of the 3
wheel forklift truck and some of the trouble shooting. Please operator and whom in charge of the
truck must read the manual carefully before operate the truck.
We have the right to improve the truck, maybe there are some difference between your
product and the description in this manual.
If you have any questions please keep in touch with the sales department of HANGCHA
GROUP CO., LTD. or let the agents know.

3-Wheel counterbalanced battery forklift truck has passed the CE certification.

Model meaning
Tow by electronic Lift by electronic Rated starting weight (t) /
Model
control control Load Center（mm）
1.3/500,1.5/500,1.6/500,
CPDS13/15/16/18/20J-D1 ACS×2(INMOTION) EVC255
1.8/500,2/500

1.3/500,1.5/500,1.6/500,
CPDS13/15/16/18/20J-C1 1236×2（CURTIS） EVC255（CURTIS）
1.8/500,2/500

1.3/500,1.5/500,1.6/500,
CPDS13/15/16/18/20J-C2 1236×2（CURTIS） 1236（CURTIS）
1.8/500,2/500

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© Dec. 2010 4 edition HANGCHA GROUP CO., LTD.
 Content

1. Drive system ······································································································1

1.1 GP20 reduction gear box ··········································································1
2. Steering system ·································································································4
2.1Steering device ···························································································4
2.2 Steering axle ······························································································5
3. Brake system ·····································································································7
3.1 Master pump······························································································7
3.2 Hand brake device ····················································································8
4. Hydraulic system································································································9
5. Lifting system ···································································································11
5.1 Mast················································································································12
5.2 Lifting cylinder ··························································································13
5.3 Tilting cylinder ··························································································14
6. Electrical system ······························································································15
6.1 Summary ·································································································15
6.2 CPDS13/15/16/18/20J-D1 forklift····························································17
6.3 CPDS13/15/16/18/20J C1 forklift ····························································25
6.4 CPDS13/15/16/18/20J-C2 forklift····························································31
6.5 Maintenance of controller ········································································33
7. Maintenance record ·························································································34
1. Drive system
3 wheel counter balanced battery forklift truck adapt structure of front two motor driven, each separated
excited driven motor rated capacity is 8kW. Each motor’s rotating speed is controlled by the rear wheel
rotating angle. Each side motor connects to ZF made GP20 model reduction gear box, wet disk brake
system, and solid tire and rim such etc.
GP20 reduction gear box is two grades reduce speed gear, one grade straight gear and one grade planet
gear. So the gear box is very small.
Wet disk brake do not need for maintenance on schedule.
Trouble Probably cause Method of troubleshooting
The impact noise is too loud Gear clearance is too big. Adjust.
When traveling or changing Too much worn of gear. Replace.
direction.
Too much noise when traveling Oil level is low. Add oil.
Gear clearance is too big. Adjust.
Too much worn of gear. Replace.

1.1 GP20 reduction gear box

1.1.1 Data
Specification
Item Parameter
Service weight (without oil) kg 31
Oil volume l 0.35
Oil type ATF DEXRON II
Brake fluid
Foot brake

Oil pressure 60-80 bar

Normal pressure (continuous working) 80bar
Max. pressure 100bar
Normal fluid volume in brake booster 1.71cm3
Max worn fluid volume in brake booster 3.71 cm3
Hand brake pull force 100N
Hand brake

Clearance 6mm

Max worn limit clearance 13mm

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1.1.2 Structure of reduction gear box

2
There are 3 holes on the brake booster of reduction gear box.
1. Air bleed plug. After add brake fluid, please loose the air bleed plug to let the air out of brake oil tube,
and then tighten the plug.
2. The parking brake line connects to the head of booster. The maximum worn limit is 13mm, if
exceed this limit, please replace a new one.
3. The oil inlet of the braking pump. When oil leak happens, change the braking pump.

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2. Steering system
Steering system include rear steering axle and steering device.
2.1Steering device
It consists of steering wheel, upside steering column, downside steering column, bearings, steering gear,
priority valve, clamp bolt and hydraulic switch etc. You can adjust the steering angle forward and
backward by yourself. Refer to fig. 2-2.

Tilt forward 6 degrees

Tilt backward 6 degrees

Neutral position A-A rotation

Release position

B direction rotation
Lock position

C direction rotation

1. Steering wheel 3.Upside steering column 8.Gimbal

10.Down side steering axle 12. Bearing 13. Snap ring
14. Down side steering column 17. Steering gear 18. Priority valve
19. Clamp bolt 22. Clamp lever 26. Hydraulic switch

Fig. 2-2 Steering device

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2.2 Steering axle
The steering axle is import from Italy. Structure please refers to Fig. 2-3.
More details please refer to spare part lists.

Head body fix to chassis rear end, applied force from ground is accepted by support bearing 10 and 19.
Use nut 8 to adjust pre-tightening force of bearing 10 and 19; cylinder 15 and head body connect together, rack's (11) end
acts as piston, when the fluid from priority flow control flow to cylinder 15, hydraulic oil push rack 11 to move left or
right, gear axle and rack 11 are engaged, then gear axle make steering wheels turn left or right, the angle of turn both are
0
85 .
Caution when using:

1. Cylinder leaks oil, check and change seal ring 12 ,14 ,16, check guide sleeve at the same time ,and
make sure whether cylinder is damaged or not.
2. Check bearing 10, 19, and seal ring 9, 20 at regular intervals; if it is damaged, change bearing and
seal ring at once; change grease at regular intervals also.
3. Check bearing 26, 28 and seal ring 25; if it is damaged, change bearing and seal ring at once; change grease at
regular intervals at the same time.
4. Adjust pre-tightening force of steering hub bearing: remove counter weight, and cover etc, lift the back of head body
by jack, make wheel leave from ground. Screw down nut 3 to the location till it is not moved, then turn it 1/6~1/4
circle in the opposite direction.
5. Adjust pre-tightening force of support bearing (10, 19): remove counter weight, and cover etc, lift the back of head
body by jack, make wheel leave from ground. Screw down nut 8 to the location till it is not moved, then turn it
1/6~1/4 circle in the opposite direction.

1. Shaft 2.Support 3.Nut 4.Screw 5.Washer 6.Ring nut

7.Washer 8.Cover 9.Seal 10. Bearing 11.Rack 12.Seal
13.Guide 14.Seal 15.Liner 16.Seal 17.Head 18.Head body
19. Bearing 20.Seal 21.Shaft 22.Pin 23.Pin 24.Ring
25.Seal 26.Bearing 27.Hub 28. Bearing 29.Washer 30.Cotter pin
31.Nut 32.Cover 33.Plug
Fig. 2-3 Rear Steering Axle

5
 Condition Probable cause Corrective action
High effort for pump damaged or trouble change
steering of failure
priority valve damaged or blocked change or clean
to rotate steering
wheel tube or connect damaged or blocked change or clean
dividing valve pressure is too low Adjust pressure
air is in the oil circuit remove air
Difficult to steer steering reposition failure, positioning of spring piece
change spring piece
break or lack elasticity
innner leakage of steering cylinder is too large. check seal of piston
oil level is lower Add oil
steering gear axle and rack damaged Change
Abnormal noise wheel hub or supported bearing damaged Change
not enough lubricate add grease
suction pipe or oil filter blocked Clean or change
seal ring of steering cylinder or connect or pipeline
Change
oil leak damaged
parameter of controller is not correct Change seal ring
seal ring of wheel
hub or supported parameter of controller is not correct adjust
bearing damaged

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3. Brake system
Brake system is composed of hand brake control and foot brake control ;handle of brake control is composed of handle
and backstay cable; foot brake control is composed of brake pedal, brake master pump, pipeline and brake; brake is
wet disc brake, avoid maintenance.

3.1 Master pump

The master pump contains a valve seat, check valve, return spring, primary cup, piston and secondary cup,
which are kept in place with stop washer and stop wire. The exterior of the cylinder is protected from dust by means
of a rubber dust cover. The piston is actuated through the push rod by operation of the brake pedal. First, as the
brake pedal, the push rod pushes the piston forwards. The brake fluid in the cylinder flows back to the reserve tank
through the return port until the primary cup blocks up the return port. After the primary cup passes the return port,
the brake fluid in the cylinder is pressurized and opens the check valve, flowing through the brake lines to the wheel
cylinder. Thus, each wheel cylinder piston is forced outwards. This brings the brake shoes into contact with the
wheel drum and slows or stops the lift truck. Meanwhile, the cavity caused behind the piston is filled with brake
fluid led through the return port and inlet port to lubricate the piston. When the brake pedal is released, the piston is
forced back by the return spring. At the same time, the brake fluid in each wheel cylinder is pressurized by the force
of the brake shoe return spring, thus returning into the master through the check valve. With the piston in its original
position, the fluid in the cylinder flows into the reserve tank through the return port. The brake fluid in the brake
lines and wheel cylinders has a residual pressure proportioned to the set pressure of the check valve, which makes
each wheel cylinder piston cup securely seated to prevent oil leakage and eliminates of vapor lock developing when
the lift truck is sharply broken.

1. lock nut 2. Rod 3. Duct cover 4. Stop wire 5. Stop washer 6.secondary cup
7. Piston 8. Primary cup 9. Spring 10. Check valve 11. Valve seat 12. Cylinder body
Fig. 3-1 Master cylinder

7
3.2 Hand brake device
The hand brake device adopts a hand-pulling soft brake wire device. It makes use of auto-assist pressure
linings type brake together with foot brake. Only when parking truck, use the hand brake. If it occurs for foot brake
malfunction, use hand brake to stop the truck.

Trouble diagnostic

Condition Probable cause Corrective action

Oil leakage in brake lines. Correct and replenish.

Air in brake lines. Bleed air.
Insufficient brake Water or oil on linings. Clean or replace.
force Uneven wear or contact of brake linings. Grind or replace.
Improper functioning of master cylinder or Correct or replace.
wheel cylinder.
Clogged oil lines. Clean.
No free play of brake pedal. Adjust.
Improper shoe sliding. Adjust.
Improper operation of wheel cylinder. Adjust or replace.
Faulty piston cup. Replace.
Brake dragging
Weak or broken return springs. Replace.
Clogged master cylinder return port. Clean.
Clogged oil lines. Clean.
Wheel bearing out of adjusting. Adjust or replace.

8
4. Hydraulic system
The high pressure oil from main pump goes to control valve, then goes to lifting cylinder or tilting cylinder.
When the lifting and tilting spools are in neutral, the lifting pump will be off work. When pulling lifting spool, high
pressure oil goes to the bottom of lifting cylinder piston and then push piston rod under. When pushing lifting spool,
it is that bottom of lifting cylinder piston connects with low pressure line and then piston rod drops by deadweight
and weight of cargo. In this time, oil from lifting cylinder goes by unidirectional speed limiting valve so as to
control the falling speed, then the lifting pump out off work also. When operating tilting spool, high pressure oil
goes to one house of tilting cylinder and another connects with low pressure line so as to make mast tilt forward or
backward.

Main pump
Trouble Probable cause Corrective action
No oil from Low oil level in tank. Add oil to specified level.
oil pump Clogged suction pipe or strainer. Clean oil line and tank. If oil is dirty, change.
Worn bearing damaged backup ring
Replace faulty parts.
and O-ring.
Readjust to specified pressure using pressure
Low Maladjusted relief valve.
gauge.
discharge
Retighten suction side pipe.
pressure on oil
Add oil in oil tank.
pump.
Air in oil pump. Checks pump oil seal.
Do not operate pump until bubbles in tank
disappear.
Cavitation due to crushed suction
Adjust or replace crushed hose and clean strainer.
hose or clogged strainer.
Air being sucked from loose suction
Retighten each joint.
Noisy oil side joint.
pump ·
replace with new oil having proper viscosity for
Cavitation due to too high oil
temperature at which pump is to be operate.
viscosity.
·
to operate when oil temperature is normal.
Bubbles in hydraulic oil. Determine cause of bubbles and remedy.
Oil leaking
Faulty oil seal on pump, faulty O-ring
from oil Replace faulty parts.
or worn sliding surfaces on pump.
pump

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Control valve
Trouble Probable cause Corrective action
Loose of pressure-adjust screw. Readjusted and retighten.
Pressure of relief Distorted or damaged pressure-adjust
Replace.
valve is not steady spring.
or too low. Worn or blocked relief valve core. Replace or clean.
Pump abated. Examine and repair pump.
Fork tilt forward Replace valve core and tilt lock valve as
Worn or damaged tilt lock valve.
when control lever is an assembly.
used while engine is Broken tilting lock spring. Replace spring.
off. Damaged tilt valve plunger O-ring. Replace O-ring.
Mast is unstable when
Malfunctioning tilt relief valve. Replace tilt relief valve assembly.
tilting forward.
Valve body and spool valve is worn and Replace spool valve with specified
Lowering distance
clearance between them is too great. clearance.
of mast is big when
Spool valve is not in centre. Keep being in the centre.
spool valve is in the
Cylinder seal abated. Examine and repair cylinder.
centre.
Taper valve is worn or blocked by dirt. Replace or clean taper valve.
Damaged or distorted reposition-spring. Replace spring.
Spool valve is not Dirt exists between valve body and spool
Clean.
return neutral valve.
position. Blocked control device. Adjusted.
Not coaxial parts at reposition Reinstall，be coaxial
Damaged O-ring. Replace.
Faulty seal of joint. Check and retighten.
Leakage Loose seal plate. Clean seal plate and retighten blots.
Loosed lock-nut of relief valve and
Tighten.
connect-nut between plate and plate.
Control valve can
not move back and Back and forward adjust handle intervene adjust
forward

Main relief valve adjustment:

The pressure of main relief valve has been adjusted correctly before leaving the factory, usually not forbidden to
adjust by users. This is the way of adjustment with specified load 1600kg, as following steps:
（1） Lay 125% specified load on fork, 2000kg.
（2） Push the pedal down to end, then lift fork, if fork can lift 0-300mm, the pressure of main relief valve is
correct, or adjust according to step 3.
（3） If fork can not leave from ground, increase the pressure of main relief valve, remove front base plate at
first, then screw adjust-bolt in clockwise to increase the pressure of main relief valve. If fork height
exceeds 300mm, screw adjust-bolt in counterclockwise to decrease the pressure of main relief valve.
（4） Push the pedal down to end, the fork lift between 0-300mm. Or adjust according to step 3 till meet
requirement.

Warning: The load must lay steadily and firmly; do not adjust the pressure randomly after adjusting the
required pressure.

10
5. Lifting system
Condition Probable cause Corrective action
Fork arm carrier 1.Tilt cylinder and ring abraded excessively Replace piston ring tilt cylinder.
or mast tilt by 2. The hydraulic control valve spring is
Replace it.
itself. inoperative.
The fork arms 1. Caused by piston jamming or bent piston rod. Replace the faulty parts.
carrier moves up
and down 2. Too much dirt is accumulated in the cylinder. Strip it down and clean.
sluggishly.
Adjust clearance with thrust metal and
1. Carriage bracket assembly out of adjustment.
carriage side roller.
2. Insufficient clearance between inner and outer
Forks are lifted Adjust clearance with rollers.
masts or rollers and mast.
or lowered
3. Biting foreign materials between moving parts. Remove foreign materials.
unsmooth.
Apply grease on contact surfaces of
4. Insufficient lubrication.
sliding parts.（butter）
5. Bent carriage bracket assembly. Repair or replace.
Forks are lifted
1. Lift chains out of adjustable. Adjust lift chains.
unevenly
1. Grease stiffened or dirt accumulated on lift roller
Lift roller does Clean and lubricate lift rollers.
and mast sliding surfaces.
not rotate
2. Improperly adjusted lift roller. Adjust.
1. Insufficient lubrication. Lubricate.
2. Improperly adjusted lift roller, side roller and
Adjust.
back-up metal.
Excessive mast
By adjusting shims and rubber pad,
noise
3. Rubber pad on lower of outer mast is useless for piston rod is in touch with bottom of
container fork lift truck. cylinder body after inner mast is in
touch with rubber pad.
Excessive wear occurs between the oil pump body Replace the worn parts or the oil
and gears, causing too much clearance. pump.
2. The lifting jack piston Yx-ring has worn, resulting in
Replace Yx-ring.
excessive inner leaks.
3. Springs of the multiple control valve and its
Replace.
relief valve are inoperative oil leaks.
4. Excessive wear occurs of the hydraulic control
Replace.
valve, resulting in excessive oil leaks.
Insufficient lift 5. Oil leaks occur between the hydraulic control Dismantle for regrinding the joint
power or no lift valve sections. surfaces and reassemble the valve.
movement. Tighten the joint nuts and inspect the
6. Leakage occur in the hydraulic pipe.
seal for damage.
Change the wrong hydraulic oil or stop
operation for reducing the oil
7. The hydraulic oil temperature is too high. Oil
temperature. Find out the reasons for
viscosity is too low and the rate is insufficient.
high oil temperature and eliminate the
trouble.
8. The load carried is beyond the designed
Observe the lifting capacity limit.
capacity.

11
5.1 Mast
The basic type mast is 3 meters 2 stages mast. The lifting system is composed of inner and outer mast, fork
arm carrier, fork arm, load backrest, chain, roller, lifting jack, and tilt cylinder, etc. Oil line system, hydraulic
pressure system and it compose fork lift truck work equipment.

1. Outer mast 2.Inner mast 3.Lifting chain assy. 4.Left Lifting cylinder
5.Fork carriage 6. Fork assy. 7.Tilting cylinder 8.Right lifting cylinder

Fig. 5-1 Mast

Dimension and weight of basic type mast (lift height is 3m)

Type Dimension of mast Weight of mast(kg)

CPDS13J(D1) 、CPDS13J-C1

CPDS15J(D1) 、CPDS15J-C1

CPDS16J(D1)、 CPDS16J-C1 1895╳1050╳287 428

CPDS18J(D1)、CPDS18J-C1

CPDS20J(D1)、CPDS20J-C1

12
5.2 Lifting cylinder

1. Piston 2.AF dust proof 3. B3 dust proof 4.O ring 5.Guide

6. Cylinder body 7. Snap ring 8. Piston 9.Support ring 10.Protector
14. Nozzle assy.
11.B7 seal ring 12.Valve guide 13.Snap ring
(Left cylinder has no nozzle)
15. O ring 16. Pin

Fig. 5-2 Tilting cylinder

13
5.3 Tilting cylinder

1. Support 2.Bearing 3.Lubrication nipple 4.Washer

5.Nut 6.Bolt 7. Pistion rod 8. AM dust proof

9.Guide 10.Guide ring 11.B3 seal ring 12.Bush

13.Snap ring 14. O ring 15.Cylinder body 16.Piston

17.O ring 18.Guide ring 19.Nut 20. Pin

21.OK seal ring 22. O ring

Fig. 5-3 Tilting cylinder

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6. Electrical system
6.1 Summary
The ZAPIMOS chopper family represents ZAPI’s answer to the needs of the 21rst’ century’s. To ensure
that products remain on the market, without running the risk of becoming technically obsolescent, the
ZAPIMOS family offers the following features:
- Advanced technology.
- Economical costs.
- Maximum safety.
- Maximum flexibility.
- Open to future technical innovations.
- Optimum level of protection.
The design has been derived from:
- High Frequency Mos Technology.
- Real time control over the internal and external components that influence the behavior of the machine,
with self diagnosis of the checking circuits themselves.
- Stored Program Machine (SPC), where the hardware is completely separate from the functions to be
configured. The programmer is parametric and can easily be modified by the end user.
- Various chopper configurations can be selected by the user, without the need for hardware
modifications.
- Future technological updates are made easy for the user.
- The communication protocol will continue to evolve, thereby offering increased possibilities of
interaction and expansion. For this reason, the Zapimos family offers a standard dialogue mode with
external systems. This allows interfacing with commercially available systems, and its price will be
different with the different performance.
- electrical controller can meet the requirement of IP51, and offer good protection function, which can
protect from dust and liquid such as water, acid and so on coming inside. Its control logical can be easily
open and it is allowed to do simply change.

6.1.1 Potentiometer of steering angle sensor

Front double-wheel drive. A steering angle sensor helps to measure the steering angle to make the
controller differential the front two wheel.
Using “SET STEER MIN” and ” SET STEER MAX” functions it is possible to acquire
the voltage value corresponding to the two limits of the steering potentiometer’s stroke.

6.1.2 SAFETY & PROTECTION FEATURES

- Reverse Polarity of the battery
Electrical Circuit diagrams must be consulted in order to avoid damage to the power unit. A Line (Main
Contactor), managed by the logic unit, is necessary for protection against reverse battery polarity.
- Connection errors
All inputs are protected against connections errors. Contactor drivers are suitable for loads up to 2 Amps,
and are protected against overload.
- Thermal protection
If the controller temperature exceeds 85°C, the maximum current reduces in proportion to the thermal
increase. The temperature can never exceed 95°C.
- Low Battery charge
15
When the battery charge is low, the maximum current is reduced proportionally to the battery discharge.
- External Agents
The chopper is protected against dust and spray of liquid to a degree of protection meeting IP51.
- Protection against accidental Start Up
A precise sequence of operations is necessary before the machine will start.
Operation cannot commence if these operations are not carried out correctly.
Requests for drive must be made after closing the Key Switch.
- Protection against uncontrolled movements.
The Main Contactor will not close if:
·The Power Unit is not functioning
·The Logic Unit is not operating correctly
·The output voltage of the accelerator does not fall below the minimum voltage
value stored, with 1Volt added.
·Running micro-switch in closed position.

6.1.3 OPERATIONAL FEATURES

- Speed Control.
- Optimum sensitivity at low speeds.
- Speed Reductions in both directions. Levels can be set using Console.
- Regenerative Braking based on deceleration ramps.
- Three different modes of Braking: Release Braking, Inversion Braking, Speed Limit Braking.
- Speed Control during descent: the motor speed follows the accelerator. The chopper automatically
brakes if the motor speed overcomes the accelerator set point. This provides optimum performance on a
gradient.
- Starts on a Ramp without roll back, even without an electric brake.
- Programmable Anti Roll Back: When the Key Switch is closed, if the motor is
rotating, the chopper controls the speed and automatically brakes This keeps the motor at a very low
speed during descent on a gradient. This is a very useful safety feature and is not driver dependent.
- Electro-brake management (optional)
- Output for hydraulic steering with adjustable delay.
- Self Diagnosis with indication of fault shown via flashing Red Led. ( In addition to Console Display).
- Modification of the parameters via Digital Console. See the specific description.
- Internal Hour Meter that is displayed on the Console.
- Memory of the last 5 Alarms, with relative Hour meter count and chopper temperature all displayed on
the Console.
- Test Function within Console for checking main parameters.
See the specific Description.
- Internal Contactor Coil Suppression.
- High motor and battery efficiency due to High Frequency Switching.
- Presence of a second microprocessor for safety that monitors the CPU that controls the motor.

16
6.2 CPDS13/15/16/18/20J-D1 forklift
CPDS13/15/16/18/20J-D1 forklift contains ac motor, traction controller, traction controller matches ac motor, traction
controller uses two ACS electronic controllers from Inmotion company, lift controller uses Curtis EVC255 electronic
control.
6.2.1 AC Motor
This truck walk motor uses three-phase AC frequency conversion motor, high electric power transition, without
commutator and brush, avoid maintenance.

17
6.2.2 Electric system schematic of CPDS13/15/16/18/20JD1 forklift
CPDS13/15/16/18/20J D1 ELECTRICAL SYSTEM PRINCIPLE DIAGRAM
18
6.2.3 Diagnostics of traction system fault
diagnostic error by VMC20
code source condition time Traction Main explanation
controller contactor
Accel
switch activate accelerator switch
101 KEY→ON cut close
active at with starting
key-on
Dir.Switch
activate back/forward
102 active at cut
direction switch with starting
key-on
activate back/forward
Direction
103 direction switch at the same KEY=ON cut close
error
time
potentiometer voltage >95%
Tract pot
104 or potentiometer voltage KEY=ON close close
error
< 5% VX_out
Tract switch before activating accelerator
105 KEY=ON close close
error switch, voltage >30%
potentiometer voltage >95%
Steer pot
106 or potentiometer voltage KEY=ON close close
error
< 5% VX_out
Battery
107 under 48V:<28.2V/.8s KEY=ON cut cut
voltage
ACS under voltage< limit continuous
108 KEY=ON cut cut
voltage time more than 0.8s
Battery over
109 >65V/0.8s KEY=ON cut cut
voltage
ACS over voltage> limit continuous
110 KEY=ON cut cut
voltage time more than 0.8s
Can comm.
111 See 1.2.1 KEY=ON cut close
Error
warning battery <
Battery low 25%
114 KEY=ON - close
voltage Decrease drive speed
battery <15%
inner error in starting
115 Startup error KEY=ON cut close
process

19
Checked error by left towing controller（emergency）
code source Condition Time Tractor main explanation
controller contactor
short ACS or motor
251 Short circuit KEY=ON cut cut
terminal
ACS over ACS radiator
252 KEY=ON cut close
temperature temperature > 125 ℃
Motor over Motor temperature
253 KEY=ON cut close
temperature > 180 ℃
ACS current ACS current sensor
354 KEY→ON cut close
sensor error error

Cap.not Cap.not charging in 10s

255 KEY→ON cut close
charging after power up

ACS no ACS has no response in

256 KEY=ON cut close
response starting process
communication time
L.tract slave between ACS and
257 comm. tractor controller KEY=ON OFF close
timeout exceeds (diagnoses by
VMC20 )
ACS SDO error
ACS SDO
258 (incorrect software KEY=ON cut close no use
error
edition)
communication time
L.tract slave between ACS and
259 comm.timeo tractor controller KEY=ON cut close
ut exceeds (diagnoses by
VMC20 )
ACS low
260 ACS voltage <18V KEY=ON cut close no use
voltage trip
ACS high
ACS voltage > 68V
261 voltage KEY=ON cut close no use
(software)
trip (SW)
ACS high
ACS voltage >68V
262 voltage KEY=ON cut close no use
(hardware)
trip(HW)
364 Other error KEY=ON cut close

20
diagnosed error by left towing controller（warning）
code source condition time Tractor main explanation
controller contactor
minimum
ACS low temp ACS radiator
201 KEY=ON close close accelerator value
warning temperature < -20 ℃
loaded
minimum
ACS high ACS radiator
202 KEY=ON close close accelerator value
temp warning temperature> 85 ℃
loaded
minimum
Motor high motor temperature >
203 KEY=ON close close accelerator value
temp warning 145 ℃
loaded

ACS radiator
Heat sink temp
204 temperature sensor KEY=ON close close
sensor error
error

Motor low Motor temperature <

205 KEY=ON close close
temp warning -50 ℃
disconnect or short
Motor temp
206 motor temperature KEY=ON close close
sensor error
sensor
Speed disconnect or short
207 feedback speed feedback KEY=ON close close
sensor error sensor
ACS high minimum
208 voltage ACS voltage > 68V KEY=ON close close accelerator value
warning loaded
ACS low minimum
209 voltage ACS voltage < 23.4V KEY=ON close close accelerator value
warning loaded
ACS default default values loaded
210 KEY=ON close close
values loaded in ACS
Power reduce(by
211 Power reduce some warning KEY=ON close close
condition)
Checksum
212 Checksum error KEY=ON close close
error
Current sensor Current sensor default
216 KEY=ON close close
default error error

21
diagnosed error by right towing controller（emergency）
code source condition time tractor main explanation
controller contactor
Short ACS or motor
351 Short circuit KEY=ON cut cut
terminal
ACS over ACS radiator
352 KEY=ON cut close
temjperature temprature>125 ℃
Motor over Motor temprature >
353 KEY=ON cut close
temperature 180 ℃
ACS current ACS current sensor
354 KEY→ON cut close
sensor error error
Cap.not Cap.not charging in
355 KEY→ON cut close
charging 10s after power up

ACS no ACS has no response

356 KEY=ON cut close
response in starting process

communication time
between ACS and
R tract slave
357 tractor controller KEY=ON cut close
comm.timeout
exceeds (diagnoses
by VMC20 )
ACS SDO error
ACS SDO
358 (incorrect software KEY=ON cut close no use
error
edition)
communication time
between ACS and
R tract master
359 tractor controller KEY=ON cut close
comm.timeout
exceeds (diagnoses
by VMC20 )
ACS low
360 ACS voltage <18V KEY=ON cut close no use
voltage trip
ACS high
ACS voltage > 68V
361 voltage KEY=ON cut close no use
(softaware)
trip(SW)
ACS high
ACS voltage >68V
362 voltage KEY=ON cut close no use
(hardware)
trip(HW)

364 Other error KEY=ON cut close

22
diagnosed error by right towing controller（warning）
code source condition time Tractor Main explanation
controller controller
ACS low temp ACS radiator
301 KEY=ON close close
warning temprature< -20 ℃
ACS high ACS radiator
302 KEY=ON close close
temp warning temprature> 85 ℃
Motor high motor temprature >
303 KEY=ON close close
temp warning 145 ℃
Heat sink temp ACS heat sink temp
304 KEY=ON close close
sensor error sensor error
Motor low motor temperature
305 KEY=ON close close
temp warning < -50 ℃

disconnect or short
Motor temp
306 motor temperature KEY=ON close close
sensor error
sensor

Speed disconnect or short

307 feedback speed feedback KEY=ON close close
sensor error sensor
ACS high minimum
308 voltage ACS voltage > 68V KEY=ON close close accelerator value
warning loaded
ACS low minimum
309 voltage ACS voltage < 22.5V KEY=ON close close accelerator value
warning loaded
ACS default default values loaded
310 KEY=ON close close
values loaded in ACS
Power reduce(by
311 Power reduce some warning KEY=ON close close
condition)
Checksum
312 Checksum error KEY=ON close close
error
Current sensor Current sensor default
316 KEY=ON close close
default error error

23
6.2.4 The table of EVC255 lift(pump) controller fault

Condition
Condition light explanation May cause
code
LED OFF No power or defective controller
SOLID ON Controller error（MCUfault）

0,1 ■¤ Controller operational, no known faults

1. EEPROM data lose

2. EEPROM data check
error, use 311 programme
1,1 ¤¤ EEPROM fault
device and change any
parameter to banish this
fault.
1. MOSFET short
1,2 ¤¤¤ Hardware fault
2. motor cut

2,1 ¤¤¤ Deep under voltage battery voltage too low

Activate promoted and locked

2,2 ¤¤¤¤ Promote and lock
function of controller

Any of SS1-SS4 switch close

2,3 ¤¤¤¤¤ Sequence fault（Startup lockout）
before KSI or INTERLOCK

1. Main contactor cement

3,2 ¤¤¤¤¤ contactor cement 2. The set of “CONTACT
CNTRL” is incorrect.
1. Precharge circuit work
3,3 ¤¤¤¤¤¤ precharge fault irregularly
2. Motor short.

1. Main contactor circle

loosen,
3,4 ¤¤¤¤¤¤¤ unfixed or cut contactor（DNC）
2. Main contactor work
irregularly.

Battery voltage is lower than

4,1 ¤¤¤¤¤ under voltage protection
“LOVOLT CUTBACK” value

4,2 ¤¤¤¤¤¤ Over voltage protection Battery voltage is too high.

Temperature ptotection（over or under 1. Controller temperature is

4,3 ¤¤¤¤¤¤¤
temperature） too high or too low.
2. Temperature sensor work 24
irregularly.
6.3 CPDS13/15/16/18/20J C1 forklift
6.3.1 CPDS13-20JC1electronic control fault code chart
There are red and yellow led light on body case, different flicker means different fault. as followed
chart:
display condition meaning
controller has no power ,because of no battery or pipeline
two lights off
fault
yellow flicker controller work normally
red and yellow solid on software updating
red and yellow both flicker controller fault

Fault cod chart of left and right towing controller

Display fault code by hand
codes May cause
unit
1. Short connect terminal of U, V or W of motor outside.
1，2 Controller Overcurrent 2.Incorrect motor parameter by adjusting
3. Controller fault.

1.short between U, V, W phase and truck body.(stator short)

1，3 Current Sensor Fault
2. Controller fault.

1.The outside load of capacitance group(B+ terminal) prevent

1，4 Precharge Failed capacitance recharging
2. See 1311 battery check menu: capacitance voltage.
1. Controller work in extreme condition, lower than -40℃.
1，5 Controller Severe Undertemp
2. See 1311 controller menu: temperature.
1. Controller work in extreme condition, higher than +95℃.
2.Over loading;
1，6 Controller Severe Overtemp
3.Fix controller incorrectly;
4. See 1311 controller menu: temperature.
1.Adjust battery menu parameter incorrectly;
2.Over loading;
3. Internal impedance of battery is too high.
1，7 Severe Undervoltage
4.Disconnect battery when driving;
5. See 1311 battery check menu: capacitance voltage.
6. B+ fuse melt or main contactor unclosed.
1. Adjust battery menu parameter incorrectly;
2.The resistance is too high when battery produce rating rebirth
1，8 Severe Overvoltage current;
3.Disconnect battery when rebirth brake;
4. See 1311 battery check menu: capacitance voltage.

25
 Display fault code by hand
codes May cause
unit
1.Controller does not work at this temperature ,
lower than -25℃;
2，1 Controller Undertemp Cutback
2.Controller work in extreme condition;
3. See 1311 controller menu: temperature.
1.Controller does not work at this temperature ,
higher than 85℃。
2.Controller work in extreme condition;;
2，2 Controller Overtemp Cutback
3.Over loading;
4.Fix controller incorrectly;
5. See 311 controller menu: temperature.
1.Normal condition, fault means need recharging, the controller
performance is limited at this voltage,
2.Adjust battery menu parameter incorrectly;
3.Check whether is any other load run out of battery or not;
2，3 Undervoltage Cutback
4. Internal impedance of battery is too high.
5. Disconnect battery when driving.
6. See 1311 battery check menu: capacitance voltage.
7. B+ fuse melt or main contactor unclosed.
1. Operate normally. Fault shows rebirth current increase battery
voltage when rebirth brake. The controller performance is limited at this
voltage,
2，4 Overvoltage Cutback 2.Adjust battery menu parameter incorrectly;
3.Internal impedance of battery is too high.。
4.Disconnect battery when rebirth brake;。
5.See 1311 battery check menu: capacitance voltage.
1.Outside load resistance connected with +5v terminal(pin26) is too
2，5 +5V Supply Failure low;
2. se e 1311 input watch menu: current of 5Vand Ext.
1.Outside load resistance connected with digital output terminal
2，6 Digital Out 6 Overcurrent
6(pin19) is too low;

1.Outside load resistance connected with digital output terminal

2，7 Digital Out 7 Overcurrent
7(pin20) is too low;
1.Motor temperature ≥ seted cut off temperature , motor
temperature>145℃
2.Adjust temperature control parameter of motor incorrectly;
3. See 1311 motor check menu: temperature and motor input:Analog2;
2，8 Motor Temp Hot Cutback
4. If does not use electric heating adjuster, temperature compensate and
cut should be OFF.

1.Connect motor electric heating incorrectly;

2. If does not use electric heating adjuster, temperature compensate and
2，9 Motor Temp Sensor Fault
cut should be OFF.
3. See 1311 motor check menu: temperature and motor input:Analog2;
26
 Display fault code by hand
codes May cause
unit
1.Drive load open or short;
3，1 Coil 1 Driver Open/Short 2.Pin connector dirt;
3. Wiring harness damaged or connect wiring incorrectly.
1.Drive load open or short;
3，1 Main Open/Short 2.Pin connector dirt;
3. Wiring harness damaged or connect wiring incorrectly.
1.Drive load open or short;
3，2 Coil2 Driver Open/Short 2.Pin connector dirt;
3. Wiring harness damaged or connect wiring incorrectly.
1.Drive load open or short;
3，2 EM Brake Open/Short 2.Pin connector dirt;
3. Wiring harness damaged or connect wiring incorrectly.
1.Drive load open or short;
3，3 Coil3 Driver Open/Short 2.Pin connector dirt;
3. Wiring harness damaged or connect wiring incorrectly.
1.Drive load open or short;
3，4 Coil4 Driver Open/Short 2.Pin connector dirt;
3. Wiring harness damaged or connect wiring incorrectly.
1.Drive load open or short;
3，5 PD Open/Short 2.Pin connector dirt;
3. Wiring harness damaged or connect wiring incorrectly.
1.Motor coder fault;
3，6 Encoder Fault 2.Wiring harness damaged or connect wiring incorrectly;
3.See 1311 motor watch menu: motor RPM
1. The U、V、W wiring of motor open;
3，7 Motor Open
2. Wiring harness damaged or connect wiring incorrectly.
1.Main contactor pin cement;
2.The U phase of motor disconnect or open ;
3，8 Main Contactor Welded
3. There is current which an alternative voltage affords for capacitor
group (B+).
1.Main contactor unclosed;
2.Main contactor pin oxidation;
3，9 Main Contactor Did Not Close
3.Outside load at capacitor group(B+) prevent capacitor recharging;
4. B+fuse melt.

27
 Display fault code by hand
codes May cause
unit
1.The input voltage of accelerator is too high;
4，1 Throttle Wiper High
2. See 1311 input watch menu: accelerator voltage.
1.The input voltage of accelerator is too low;
4，2 Throttle Wiper Low
2. See 1311 input watch menu: accelerator voltage.
1.The input voltage of brake is too high;
4，3 Brake Wiper High
2. See 1311 input watch menu: brake voltage.
1.The input voltage of brake is too low;
4，4 Brake Wiper Low
2. See 1311 input watch menu: brake voltage.
1.The resistance of potentiometer connected with low terminal is too
4，5 Pot Low Overcurrent low;
2. See 1311 input check menu: low terminal.
Fail to write in EEPROM .EEPROM may be written by VCL, CAN
4，6 EEPROM Failure bus, adjusting parameter of 1311 or loading new software, above all
may cause fault.
1.The sequence of electric door ,interlock , direction and accelerator
input is incorrect;
4，7 HPD/Sequencing Fault 2.The wiring harness or transition switch of electric
door, interlock , direction and accelerator input damage.
3. See 1311 input watch menu.
1.Emergency reverse operating terminates, but
4，7 Emer Rev HPD accelerator, back and forward input , interlock switch do not revert to
empty shift.
1. Because some parameter setting of 1311 is changed, then this fault
appears, it can be eliminated by restarting electric door switch.
4，9 Parameter Change Fault
For example, if user change accelerator type, it may cause fault, it can
be eliminated by restarting electric door switch.

28
 Display fault code by hand
codes May cause
unit
1. VCL code run time error;
2. See 1311 controller watch menu: VCL error module and VCL error.
6，8 VCL Runtime Error
This fault may be compared to error code which is defined in run time
VCL module ID and system information file.
1.The current of outside load which 5V and 12V input produce is too
high or too low,
6，9 External Supply Out of Range 2.The outside maximum and minimum input of fault check menu
parameter is adjusted incorrect,
3. See 1311 input check menu: outside input current.
7，1 OS General 1. Inner controller fault.
1.The communicate receiving time of CAN PDO exceeds the overtime
7，2 PDO Timeout
cycle of PDO.
1.Motor stop;
2.Motor coder fault;
7，3 Stall Detect 3.Wiring harness damaged or connection incorrectly;
4.Coder power provide appears matter;
5.See 1311 motor watch menu: motor RPM。
8，7 Motor Characterization Fault 1. Motor performance description of motor description step is wrong.
1. Coder performance description of coder description step is wrong.
8，8 Encoder Characterization Fault 2.Motor coder pulse frequency is not a standard value（32，48，64，
80ppr）
8，9 Motor Type Fault 1. Motor type parameter exceeds range.
1.Truck remain run when sending out brake signal;
9，2 EM Brake Failed to Set
2. EM brake can not grip the rotary motor.
1. No matter coder fault（code 36） or stop check fault （code 73）
appear, as a result, limited operation control mode is activated.
Limited OperatingStrategy
9，3 2. Motor coder fault.
（LOS）
3.Wiring harness damaged or connection incorrect;
4. Truck stall.
1. emergency reverse is activated ,but emergency reverse has stopped
9，4 Emer Rev Timeout work, because emergency reverse time has exceeds required time.
2. Emergency reverse signal cement.

Lift (pump) controller, see fault code 6.2.4 "the fault code chart of EVC255 lift (pump) controller ".

29
6.3.2 The electric system schematic diagram of CPDS13-20JC1

30
6.4 CPDS13/15/16/18/20J-C2 forklift
6.4.1 CPDS13-20JC2Motor controller breakdown codes table
CPDS13-20JC2 traction motor 1236×2（CURTIS）is the same to CPDS13-20J-C1，motor break
down codes please refer to P76.

31
6.4.2 The electric system schematic diagram of CPDS13-20JC2

32
6.5 Maintenance of controller

Controller does not have spare parts, do not try to open, repair or change controller, if users do these, it will
damage controller, and guarantee repair is invalid; keep controller clean and dry.
Clean
Clean controller outside at regular intervals, it may avoid corrosion or other dirt, dust and electronic
control fault chemical caused.
Clean as the following steps:
1. Remove power supply plug;
2. Connect controller B+ and B- (for example contactor circle or horn) with load to recharge
capacitance in controller.
3. Clean dirt and corrosion which is at power supply and signal connection poles with wet cloth.
4. Airing controller before fixing power plug.

33
7. Maintenance record
DATE Maintain content Maintainer

34
 HANGCHA GROUP CO. , LTD.

■ Address for: OVERSEAS USERS

■ Manufacturing site: 88 Donghuan Road, LinAn Econimic Development zone,
Zhejiang, P.R.China ■ ZIP:311305
■ Registered Address：398 Shi Qiao Road, Hangzhou, P.R. China) ■ ZIP :310004
■ Fax: 0086-571-88926789 0086-571-88132890
■ Web: http://www.hcforklift.com
■ E-mail: sales@hcforklift.com