A Series

A series 2000lb~10000lb(1.0t ～5.0t )Lead acid Battery Counterbalanced

Forklift Truck

CPD10/15/18/20/25/30/35-AC4-E CPD25-ALC4-E
CPD40/45/50-AC4

SERVICE MANUAL

Original Instruction

HANGCHA GROUP CO., LTD.

08 / 2019
 FOREWORD
Thanks for your purchasing our electric four-wheel forklift truck.
A series electric four-wheel forklift truck is our company’s new product. It has the character of
small turning radius, beautiful shape, small dimensions, low gravity.
This service manual is about the structure,working principles and maintenance etc. To ensure
safety and exert the truck’s potential, all the personnel that in charge of maintenance and
management must read this manual thoroughly before starting work with the forklift.
This manual is about 2000lb~10000lb(1.0t ～ 5.0t )A series of four support battery counterbalance
forklift truck structure, working principle and maintenance etc. In order to ensure safety and give
full play to you buy the forklift truck performance, relevant operating personnel, equipment
management and maintenance personnel, should carefully read this manual.
Forbid repairing the truck if you haven’t been trained.
Our product design will update and perform better, so the content in this manual may be not the
same as the forklift you owned.
If you have any questions please keep touches with HANGCHA GROUP CO., LTD. sales
department or let the agents know.
A series four-wheel Rated capacity(t) / Rated capacity(lb) /
Drive Motor Pump Motor
model Load center (mm) Load center (in)
4.0 / 500，4.5 / 500， 8000/19.7,9000/19.7
CPD40~50-AC4 1238E-6521 1236SE-6521
4.99 / 500 10000/19.7
1.0 / 500，1.5 / 500， 2000/19.7,3000/19.7
CPD10~18-AC4-E Curtis 1232SE Curtis 1232SE
1.8 / 500 3600/19.7
CPD20~25-AC4-E Curtis 1234SE Curtis 1232SE 2.0 / 500，2.5 / 500 4000/19.7,5000/19.7
CPD25-ALC4-E
Curtis 1234SE Curtis 1234SE 2.5 / 500，3.0 / 500 5000/19.7,6000/19.7
CPD30-AC4-E
CPD35-AC4-E Curtis 1236SE Curtis 1234SE 3.5 / 500 7000/19.7

© 08/2019 HANGCHA GROUP CO., LTD.

 CONTENT
FOREWORD
1. DRIVING SYSTEM.................................................................................................................1
Motor.......................................................................................................................................... 1
Gear box....................................................................................................................................6
Driving axle...............................................................................................................................8
2. STEERING SYSTEM...........................................................................................................13
Steering device......................................................................................................................13
Steering axle.......................................................................................................................... 14
3. BRAKE SYSTEM................................................................................................................. 18
Brake schematic diagram...................................................................................................18
Master cylinder...................................................................................................................... 18
Foot brake.............................................................................................................................. 20
Hand brake device............................................................................................................... 22
Electromagnetic brake.........................................................................................................22
4. HYDRAULIC SYSTEM....................................................................................................... 29
Main pump..............................................................................................................................30
Control valve.......................................................................................................................... 31
5. LIFTING SYSTEM................................................................................................................33
Data..........................................................................................................................................33
Fault......................................................................................................................................... 34
Mast......................................................................................................................................... 35
Lifting cylinder........................................................................................................................37
Tilting cylinder........................................................................................................................37
6. ELECTRICAL SYSTEM.........................................................................................................38
Controller................................................................................................................................ 38
Electrical system principle diagram..................................................................................66
1. Driving system
Drive system is composed most components such as electrical engineering, gear box, driving axle
detent tyre and wheel rim.
Gear box is two grades reduce speed gear, one grade straight gear and one grade planet gear. So
the gear box is very small.
Detent is a hoof detent, if you need know the particular content, you can see relevant portion of
the trig system.

Motor

AC motor
Rated Rated Rated Rated Max.
Insulation Cooling Protecting Weight Weight
Model Power Voltage Current Speed Speed Duty
Grade Mode Grade kg lb
kW V A r/m r/m

HPB8.6-4-HC 8.6

HPB8.6-4 8.6 31 248 1600 3200 F IC00 IP44 S3-15% 65 143.3

HPB10-4HC 10 51 161.6 2000 / F IC01 IP44 S3-15% 80 176.4

XYQ-15-ZD 15 51 260 1200 / H IC00 IP54 S2-60min 130 286.6

XYQ-11-ZD 11 31 245 1400 / H IC00 IP54 S2-60min 85 187.4

XYQ-8-ZD 8 31 170 1400 / H IC00 IP54 S2-60min 110 242.5

XYQ-16.6-ZD 16.6 56 250 3100 / H IP54 S2 60min 145 319.7

HPB25.4-4 25.4 51 387 1620 3200 H IC00 IP20 5 min 115 253.5

CAUTION
 AC motor don’t have commutator and brush，not need maintain. You must check and
clear dust everyday.

1
Gear box
Gear box is two grades reduce speed gear, one grade straight gear and one grade planet gear. So
the gear box is very small.

1. Transmissiongearboxhouse 2. Bearing block 3. Locking piece 4.Bolt

5. Differential housing,R.H. 6. Differential housing,L.H. 7. Bolt 8. Pin
9.Gear shaft 10.Gear shaft 11.Washer 12. Half shaft gear
13.Planetary gear 14.Thrust washer 15.Big ring gear 16.Bearing
17.Double gear shaft 18.Bearing 19.Bearing 20.Bush
21.Adjustable pad 22.O-Ring 23.Bearing block 24.Washer
25.Bolt 26.Locknut 27.O-Ring 28.End cap
29.Bolt 30.Bearing 31.Double gear 32.O-Ring
33.Shaft 34.Bearing 35.Pinion 36.Pin
37.Tank cap 38.Washer 39.Bolt 40.Bolt
41. Locating plate 42. Bolt

2
 Method of
Trouble Probably cause
troubleshooting

Gear clearance is too big. Adjust

When traveling or change direction
Too much worn of gear. Replace

Oil level is low. Add oil

Too much noise when traveling Gear clearance is too big. Adjust

Too much worn of gear. Replace

3
 Driving axle
Data

Model 1.0t-1.8 t 2.0t-2.5 t 3.0t-3.5 t 4.0t-5.0t

Full floating, axle and truck body direct install, front
Driving axle type
wheel driving
Tire pressure MPa 0.79 0.9
Wheel hub rotation starting torque
N 10～29
at hub blot
Axial play of wheel bearing mm less than 0.08

Weight kg 125~130 195-198 202-208 350～380

Model 2000lb~3600lb 4000lb~5000l 6000lb~7000lb 8000lb~10000lb

Driving axle type Full floating, axle and truck body direct install, front wheel driving

Tire pressure psi 114.6 130.5

Wheel hub rotation starting
N 10～29
torque at hub blot
Axial play of wheel bearing in less than 0.003

Weight lb 275.6～286.7 429.9～436.5 445.3～458.6 771.6～837.8

Trouble diagnoses and corrections

Condition Probable cause Corrective action

Loose driving axle and body connecting blots. Tighten

Loose wheel nut Tighten

Worn or damaged wheel hub bearing. Replace

Abnormal noises
Wheel hub bearing not properly adjusted. Adjust

Worn axle shaft spliner. Replace

Insufficient lubrication Lubricate

Loose wheel nut. Tighten

Deformed wheel. Replace

Unstable driving
Worn or damaged wheel hub bearing. Replace

Loose driving axle and body connecting blots. Tighten

4
 Wheel hub bearing not properly adjusted. Adjust

Improper tire pressure. Adjust

Worn or damaged axle shaft oil seal. Replace

Oil leakage Final drive improperly installed. Replace gasket

Loose drain plug. Tighten.

1. Rim 2. Brake drum 3. wheel hub 4.Wheel nut 5. Wheel hub bolt
6. Bolt 7.Brake assy 8. Wash 9.Bolt 10. Half-axle nut
11. Half axle 12.Bolt 13. Oil seal 14. Taper roller bearing 15. Adjusting nut
16. Lock nut 17.Pin 18. Paper shim 19. Oil seal 20.Axle case
21. Supporter
Fig.3-1 Driving axle

5
Tighten torque: N.m

1.5t~1.8t 2.0t~3.5t 4.0t~5.0t

Axle shaft bolt○
A 65 N.m～78 N.m Non 110 N.m～130 N.m
Trig soleplate bolt○
B 110N.m ~130N.m 170N.m～190N.m 305 N.m ~335 N.m
nut connecting brake drum and
160N.m ~190N.m Non 324 N.m -373 N.m
hub○ C
Bolt and nut connecting support
260N.m ~347N.m 324N.m～373N.m 441 N.m～539 N.m
plate and truck body○
D
Tyre nut○
E 157N.m ~176N.m 363～490 N·m 363 N.m ~490 N.m
Tighten torque: ft·lbs
3000lb~3600lb 4000lb~7000lb 8000lb~10000lb
Axle shaft bolt○
A 47.9～57.5 Non 81.1～95.9
Trig soleplate bolt○
B 81.1～95.9 125.4～140.1 225.0～247.1
nut connecting brake drum and
118.0~140.1 Non 239.0～275.1
hub○ C
Bolt and nut connecting support
191.8 ~255.9 239.0～275.1 325.3～397.6
plate and truck body○
D
Tyre nut○
E 115.8~129.8 267.7～361.4 267.7～361.4

6
Driving axle assemble removal and installation

WARNING
 Be careful when removal and installation driving axle as it is heavy.
– Raise front end of forklift truck and support frame with wooden blocks.
– Remove mast assembles.
– Slightly raise axle with a hoist and place wooden blacks under differential gear carrier and
transmission case.
– After placing a pan under axle case, loose oil plug, drain oil from axle case.
– Disconnect brake nuts from left and right cylinders.(see fig.1-1）.

CAUTION
 Plug brake tube openings to prevent oil from flowing out.
– Disconnect brake cable at hand brake lever.
– Remove front wheels.
– Remove axle shaft.
– Support driving axle with wire ropes and lifting device.
– Remove bolts securing axle mounting bracket to frame.（see fig.1-2）.
– Remove nuts securing axle case to differential gear carrier.（see fig.1-3）.
– Remove driving axle assemble.

Fig.1-1 Fig.1-2 Fig.1-3

– Remove brake drum，remove wheel hub.
– Remove axle mounting bracket and brake component from axle tube.
– Remove oil seal from axle tube.
– To install driving axle assemble in the reverse order of removal. Observe the following:
a. When installing axle mounting bracket and brake component, apply a coat of calcium
grease to axle tube.
b. Apply 1/3～2/3 of volume of calcium grease to wheel hub，then install them on axle tube.
c. Install oil seal with its part number facing to the inside of forklift truck.
d. attach seal tape （PVC, white）to drain plug then installed after cleaned it.
e. Replenish axle case with gear oil. Tighten vent plug after clearing.

7
 1.0t～1.8t 4.5 L
Gear oil GL-5 85W/90
（Cold storage forklift selection： 2.0t～3.5t 6.0 L
GL-5 80W/90）
4.0t～5.0t 8.0 L

2000lb~3600lb 1.2gal
Gear oil GL-5 85W/90
（Cold storage forklift selection： 4000lb~7000lb 1.6gal
GL-5 80W/90）
8000lb~10000lb 2.1gal

CAUTION
 Vent plug should clear instantly to prevent pressure inside of wheel hub from rising.

Axle shaft and wheel hub

Remove
– Raise the front end of forklift truck and support frame with wooden blocks.
– Remove front wheel and axle shaft.
– Remove lock nuts, lock washers, snap ring, felt ring, adjusting nut. Use special tools.
– Remove brake drum（refer to Fig.1-4）；
– If brake drum is difficult to remove:
a. Remove adjusting hole plug. Then with flat-blade screwdriver extend adjusting hole, turn
adjusting ratchet wheel by 10 notches. To contract brake shoe lining(refer to Fig.1-5).
b. evenly tapping on brake drum with brass bar or wooden mallet.

Fig.1-4 Fig.1-5
– Remove wheel hub, be careful not to drop bearing inner race.
– Remove oil seal and inner bearing as an assembly by evenly tapping on periphery of seal with
a wooden mallet and brass bar.
– Remove bearing outer race from wheel hub by evenly tapping on its periphery with a wooden
mallet.

8
 CAUTION
 Be careful not to damage oil seal and outer race.

Inspection

Stepped wear or cracks on axle shaft splines Replace

Seized, scratched, noisy or rusted bearing or improper rotation of rollers Replace

Cracked or damage wheel hub Replace

Damaged oil seal felt ring. Replace

Installation

Install reverse order of removal.

Bearing adjusting
– Lubricate on taper roller bearing.
– Tighten roller bearing lock nut in wheel hub until wheel hub can no longer be rotated with one
hand.
– From that position, turn back lock nut approx. 600.
– Turn back wheel hub two or three rotations so that bearing settles down.
– Again tighten lock nut until it can no longer be rotated with one hand; then turn back
approx.600.
– Install snap ring and settles down felt ring, install lock washer so as to set its hole in the pin of
snap ring. Screw lock nut.
– Turn wheel hub back and forth two or three rotations to see if rotation starting torque is within
specifications. Rotation starting force:10N～29N（refer to Fig.1-6）.
– Measure axial play of wheel hub to see if it is within specification. Axial play is less than
0.003in(0.08mm) （refer to Fig.1-7）.

Fig.1-6 Fig.1-7

9
2. Steering system
Steering system include rear steering axle and steering device.

Steering 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. 2-1.

1. Steering wheel 14. Down side steering column

3. Upside steering column 17. Steering gear
8. Gimbal 18. Priority valve
10. Down side steering axle 19. Clamp bolt
12. Bearing 22. Clamp lever
13. Snap ring 26. Hydraulic switch
Fig. 2-1 Steering device

10
Steering axle
General specifications
Axle body
Center support, swing type
type
2000lb~3600lb Vertical play in（mm） 0~0.039 (0～1)
Inner (1.0t～1.8t) 79.5º
wheel 4000lb~7000lb
2.0t～3.5t 80º
Turning
2000lb~3600lb
angle (1.0t～1.8t) 56º Adjusting shim for end
Outer 0.020(0.5),0.039(
shaft of axle thickness
wheel 4000lb~7000lb 1.0),0.063( 1.6)
2.0t～3.5t 55.7º in（mm）

Tyre
0.8 MPa Part No. N163-220020-000
pressure
Kingpin wheel hub bearing

Kingpin axial play ≤0.008in（0.20 mm） Tighten steering spindle nut

until drive wheel hub no longer
Pre-tighte rotates with one hand. Then
Kingpin adjusting washer loose 1/8～1/6 rotations.
n
Or wheel hub rotation starting
Thickness in（mm） Part No.
torque at hub blot 10N-29.8N
0.004(0.10),0.012(0.30), Axial
0.028(0.70) N163-220012-000 ≤0.004in(0.10 mm)
play(mm)

Truck type 1.0t～1.8t 2.0t-2.5 t 3.0t-3.5 t 4.0 t～5.0 t

Weight（kg） 66～68 96-99 98-100 135～150

Truck type 2000lb～3600lb 4000lb～5000lb 6000lb～7000lb 8000lb～10000lb

Weight（kg） 145.5～149.9 211.6～218.3 216.1～220.5 297.6～330.7

Trouble diagnoses corrections

Condition Probable cause Corrective action

Loose wheel nut Tighten

Wheel bearing out of adjustment. Adjust

Unstable
driving
Improperly adjusted shims. Adjust

Faulty steering system. Refer to turning system section

Insufficient lubrication. Apply lithium grease

Loose bolts and nut. Tighten

Noises
Improperly adjusting shim for axle end Shaft. Adjust

Damaged joint bearing at two ends of rod. Replace

11
12
 Remove
Wheel hub
– Jack up and support forklift truck body with wooden blocks.
– Remove tire.
– Remove hubcap.
– Remove steering spindle nut.
– Pull off hub assembles.
– Remove bearing inner race.

CAUTION
 Not to drop bearing inner race.
 Be careful not to damage oil seal.

Kingpin and steering spindle

– Remove rod.
– Loose lock bolts.（See fig.2-2）；
– Remove grease nipples on kingpin.
– Remove kingpin.

CAUTION
 Hold kingpin to prevent it from dropping. (See fig.2-3).
– Take off spindle, thrust bearing and shim.

Fig. 2-2 Fig. 2-3

INSPECTION：
– Replace spindle if cracked.
– Replace bearing if its rollers or roller surfaces are rusted or nicked.
– Replace steel sleeve if it distortion, out of round, cracked.
– Replace thrust bearing and dust cap if them damaged.

Installation
To install, reverse the order of removal. Careful observes the following.
– Always insert kingpin from lower side.
– Install thrust bearing, set the tighten-ring below the support and loosen-ring. Pack all grease
between dust proof inside, loosen-ring, and tighten-ring.

13
– Adjust axial play to specification with shims. Axial plays less than 0.008in（0.20mm）.
– The character of seal tape faces outside. Apple grease to roller of roller bearing, also apply
grease between lip and groove of seal tape.
– Pack all grease nipple with a sufficient.
Wheel bearing adjustment
– Slowly rotate hub. Tighten steering spindle nut until it can no longer be rotated with one hand.
– From that position, turn back steering spindle nut 1/6～1/4 rotation. Measure hub bolt force is
10～30N.
– Make sure that hub rotates smoothly and that its axial play is within specification. Axial play is
less than 0.004in（0.10mm）.

Steering cylinder

1 2 3 4 5 6 7 8

1. Piston rod 2. LBH wiper 3. O-Ring 4. ISI seal ring

5. O-Ring 6. Guide sleeve 7. Glay ring 8. Crock
图 2-4 Steering cylinder

14
3. Brake system
Brake schematic diagram

drum brake schematic diagram

storage battery

traction motor
brake switch

electromagnetic brake
electromagnetic brake schematic diagram

Master cylinder
The master cylinder 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

15
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

图 3-1 Master cylinder

16
Foot brake
Brake
The configuration of the right detent can refer to fig 3-2.

1. Brake mount bracket 2. Wheel cylinder body 3. Cylinder return spring

4. Rubber cap 5. Piston 6. Cylinder dust cover
7. Push rod 8. Air bleeder cap 9. Air bleeder screw
10. Brake shoe assy (front) 11. Brake shoe assy (rear) 12. Guider
13. Adjuster cable 14. Adjusting bolt 15. Pawl
16. Spring 17. Brake shoe return spring 18. Return spring
19. Parking brake rod 20. Strut level 21. Spring
22. Bolt 23. Washer 24. Snap ring
25. Guider 26. Spring support rod 27. Spring bracket
28. Spring 29. Plug 30. Oil connector
31. Bush 32. Brake steel cable
Fig.3-2 forklift truck right brake assy

17
Replace brake shoe:
– Place the forklift truck on level concrete.
– Start the forklift and raise carriage about 3.9in（100mm）.
– Place chocks behind rear wheels to prevent movement of forklift truck.
– Loosen wheel nuts two or three turns each.
– Tilt mast fully backward, and place a wooden block under each side of outer mast.

WARNING
 Do not allow wooden blocks to touch front tires.
– Tilt mast forward until front tires are raised from surface.
– Support forklift truck by putting additional wooden blocks under each side of front-end frame.
– Stop the forklift.
– Remove wheel tire nuts and brake drum.
– Replace brake shoes with new ones.
– Install brake drum.
– Adjust shoe to drum clearance:
a. Remove adjusting hole plug on the bottom of the brake assemble.
b. Insert a flat-blade screwdriver to adjusting hole, turn adjusting ratchet wheel downward to
expand the brake shoes until wheel hub can not be turned by hand.
c. Move the ratchet wheel 2 ～ 3 notches to allow the wheel hub to be turned freely, slight
friction is allowed between the brake and shoe lining.
d. Replace the plug.
e. Install wheels.
f. Properly adjusting pedal stroke.
g. Remove blocks.
h. make sure no person or obstacle is around forklift, then operate forklift in reverse at
1.2mile/h~1.9mile/h（2km/h～3 km/h）, set foot on brake pedal 2～3 times.

18
Hand brake device
The hand brake is used for hand cable brake forklift truck. The hand brake device adopts a

hand-pulling soft brake wire cable 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.

Condition Probable cause Corrective action

Oil leakage in brake lines. Correct and replenish

Air in brake lines. Bleed air

Insufficient
brake force Improper functioning of master cylinder or wheel
Correct or replace
cylinder.
Clogged oil lines. Clean

No free play of brake pedal. Adjust

Faulty piston cup. Replace

Brake
Weak or broken return springs. Replace
dragging
Clogged master cylinder returns port. Clean

Clogged oil lines. Clean

Parking brake switch

The parking brake switch is used on 17 (E models) forklifts. Parking brake
switch A jog mode of energization that acts on the electromagnetic brake with the
seat switch through the harness.

Electromagnetic brake
The electromagnetic brake is used for electromagnetic forklift truck. The adopted brake of this

truck is spring weighted electromagnetic brake. This brake is one-chip brake, owns two friction

surfaces. It can generate strong braking torque in the power-off position by pressure spring,

electromagnetic effect realizes the release of brake.

19
 1.Mounting screw

2.Stator component

3.Braking friction plate

6

5 4.Axle sleeve
4
5.Friction disk
3

2 6. Dust cover
1

Working principle

Shaft(9) connects spline housing(4)through flat key; spline housing(4) connects friction disk

assembly(3) through spline. When the stator (11) is off power, spring (10) generated force works

on the armature(8), friction disk assembly(3) that drives the shaft(9) to rotate, grips between

armature(8) and friction disk(5), thus generates braking torque. For this moment, there will be a

gap “Z” between armature(8) and brake friction plate(3). When need to release the brake,

stator(11) connects the DC, then the generated magnetic field draws the armature(8) move to the

stator(11), spring(10) is compressed when armature(8) moves, at this time, friction disk

assembly(3) is loosened, brake is released.

1. Mounting screw
6
3. Braking friction plate

4. Axle sleeve
1 5. Friction disk
7
6. Dust cover
5
7. Hollow screw
3

8 8. Armature

9 9. Motor shaft
4
10.Pressure spring
10
11 11.Stator

Z. Air gap
Z

20
Install the brake

– Put the flat key(12) in the key groove of motor shaft(9), press 13
4 12
the shaft sleeve(4) on the shaft(9), and fix with inner snap
9
spring(13).

– Put friction disk(5) on the motor end face.

– Cover the braking friction plate(3) above the shaft sleeve.

– Assemble stator component(2) and three mounting

screws(1). Note: remove three rubber pads from the stator

component. 14

Z 15

6
– Screw down there mounting screws(1) with torque

wrench(14), and check braking air gap “Z” with feeler

gauge(15).

21
– Put dust cover（6）.

– Connect brake wire.

Warning

 No wire surface damage to avoid circuit damage.

 Do not process product locating surface or hole voluntarily so as not to affect magnet loop.

 Do not force too much when pressing fitting on the motor shaft, do not damage the friction

surface, remove burrs on the mounting hole and surface, install shaft sleeve on the shaft,

and fix it with axial snap spring.

 Measure the brake connected DC voltage, and compare the voltage with the one stipulated

on the nameplate. 10% deviation is allowable.

 During installation and use of the brake, keep away from oil dirt.

U=x V DC±10%

OIL

Adjust brake air gap

Rated air gap ”Z” will be larger for wear. Make sure the brake get enough brake torque, readjust

air gap before the air gap reaches the largest air gap value. Air gap can be adjusted repeatedly,

when the thickness of friction braking plate reaches the allowable minimum thickness (refer to

specification table), replace the friction disk plate.

When the air gap exceeds maximum air gas value, the brake may be unable to release, friction

22
braking plate burn out, braking force or retentivity decreases, noises increase, or even cause

severe accident. So check and re-adjust the air gap periodically, and cut off the truck general

power.
Specifications
Rated Rated Rated air Max. air Min. rotor Tightening torque of
torque power gap gap thickness mounting screw
11.8ft·lbs 0.008in 0.020in 0.319in 7.0 ft·lbs
（16 N.m） 30 W
（0.2 mm） （0.5 mm） (8.1mm) （9.5 N.m）
When the brake is off power, adjust three hollow screws(7), adjust the air gap between armature

and friction brake plate to rated value “Z” with the help of feeler gauge, and ensure that air gap of

each direction is the same. Procedures are as follows”

– Screw off three mounting screws(1).

– Rotate three hollow screws(7) clockwise a little with spanner.

– Screw down three mounting screws(1).

– Use feeler gauge to check if air gap ”Z” meets requirement. Readjust until ”Z” reaches the

rated range.

7
Z
-
+

In general working condition, the first air gap adjustment should proceed after brake working for

1500 ～ 2000hours, frequency of air gap adjustment is 6 months a time. In severe working

condition, like frequently brake, repeatedly sudden brake, the first adjustment can be shortened

and adjust the interval.

Maintenance

– If work in high temperature environment for long time, please prevent rust, it may influence

use if there is rust on the suction surface.

– Do not touch the friction surface with hand, no oil stain, otherwise it cannot reach the

maximum torque.

23
– General use environment temperature is 14℉~104℉（-10℃～+40℃）.

– Please check periodically, and the check item : if the switch motion is normal; if there is noise;

if there is abnormal heating; if any impurity, oil stain mixed into friction part or rotating part; if

clearance of friction part is proper, exciting voltage normal.

24
Common fault and troubleshooting

Fault Probable cause Corrective action

Power is obstructed Connect

Too low exciting voltage Check voltage and adjust.

Brake does not work Improper air gap Adjust air gap

Stator coil breaks Replace stator

Oil dirt mixed in Clean oil dirt

Install the switch to the DC circuit
Switch installed to AC circuit
after rectifying
Long brake time Improper air gap Adjust air gap

Oil dirt mixed in Clean oil dirt

Unstable operation in previous
Breaking-in for a while
use
Oil dirt mixed in Clean oil dirt
Slipping
Reduce load or replace large
Large load
specification
Adjust load peak or large the
Large load change
specification
Too high exciting voltage Check voltage and adjust.
Clutch or motor interfere to the Check control circuit, eliminate
brake interference
High temperature High environment temperature Set ventilation

High operating frequency Adjust to proper frequency

Over large load Reduce load

Product service environment
Silence design
needs silence
Impurity mixed in. Clear away the impurity
Large noise
Bad mounting Replace mounting surface or shaft
Large rotational inertia or Reduce rotational inertia or
dynamic unbalance value dynamic unbalance value

25
4. Hydraulic system
The high pressure oil from main pump goes to control valve and divide it to two parts by dividing
valve inside control valve: one of them goes to lifting cylinder or tilting cylinder, another part goes
to steering gear with invariable flow to control steering cylinder. When lifting and tilting spool is in
neutral, high pressure oil return oil tank directly from pass way. When pulling lifting spool, high
pressure oil goes by throttle valve and then push piston rod under lifting cylinder piston. 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. When operating tilting
spool, high pressure oil goes to front house of tilting cylinder and another connects with low
pressure line so as to make mast tilt forward or backward.

Fig.4-1 Hydraulic System Diagram

26
Main pump

Trouble Probable cause Corrective action

Low oil level in tank. Add oil to specified level.

No oil from oil
pump Clean oil line and tank. If oil is dirty,
Clogged suction pipe or strainer.
change.
Worn bearing damaged backup ring
Replace faulty parts.
and O-ring.
Readjust to specified pressure using
Maladjusted relief valve.
pressure gauge.

Low discharge Retighten suction side pipe.

pressure on oil
pump. Add oil in oil tank.
Air in oil pump.
Check pump oil seal.

Do not operate pump until bubbles in

tank disappear.
Cavitation due to crushed suction Adjust or replace crushed hose and
hose or clogged strainer. clean strainer.
Air being sucked from loose suction
Retighten each joint.
side joint.
Replace with new oil having proper
Noisy oil
viscosity for temperature at which pump
pump Cavitation due to too high oil is to be operate.
viscosity.
To operate when oil temperature is
normal.
Determine cause of bubbles and
Bubbles in hydraulic oil.
remedy.
Oil leaking Faulty oil seal on pump, faulty O-ring
Replace faulty parts.
from oil pump or worn sliding surfaces on pump.

27
Control valve

Trouble Probable cause Corrective action

Loose of pressure-adjust screw. Readjusted and retighten.

Distorted or damaged pressure-adjust

Pressure of relief spring. Replace.
valve is not steady
or too low. Worn or blocked relief valve core. Replace or clean.

Pump abated. Examine and repair pump.

Replace valve core and tilt lock

Worn or damaged tilt lock valve.
Fork tilt forward valve as an assembly.
when control lever
Broken tilting lock spring. Replace spring.
is used while
engine is off.
Damaged tilt valve plunger O-ring. Replace O-ring.
Mast is unstable
when tilting Malfunctioning tilt relief valve. Replace tilt relief valve assembly.
forward.
Valve body and spool valve is worn and Replace spool valve with specified
clearance between them is too great. clearance.
Lowering distance Spool valve is not in centre. Keep being in the centre.
of mast is big when
spool valve is in
the centre. Cylinder seal abated. Examine and repair cylinder.

Taper valve is worn or blocked by dirt. Replace or clean taper valve.

Damaged or distorted reposition-spring. Replace spring.

Dirt exist between valve body and spool

Spool valve is not valve. Clean.
return neutral
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
Clean seal plate and retighten
Loose seal plate.
blots.
Loosed lock-nut of relief valve and
Tighten.
connect-nut between plate and plate.
Multi-way valve
Multi-way valve moves back and forth to
cannot move back Adjustment
adjust handle interference
and forth

28
Adjusting the pressure of the main relieve valve
The main relieve valve has been adjusted before leaving the factory, , it is not allowed to adjust at
will in general condition. Adjusting way is as follows:
(1) Park the truck on solid and smooth road, place in neutral, pull up the hand brake handle, tilt the
mast backwards to the end, and drop the fork to the ground. The engine stops.
(2) Open front soleplate, release the pressure mouth bolt of oil inlet pipeline in the multi-way valve,
and put in clean place. If hydraulic oil outflows, please protect the environment.
-

(3) Connect the pressure gauge. Notice: a. Specification of gauge should be larger than 2901psi
（20MPa ） . b. taper thread at pressure mouth matches: Rc1/8R1/8; c. tightening torque is 14.8
ft·lbs ~16.2ft·lbs（20 N·m -22N·m）.
(4) Start the engine, place the mast in vertical, and the fork is 11.58in（300mm） from the ground.
(5) Read out the indication in the pressure gauge, and judge is the main safety valve of multi-way
valve is in normal scope.
2000lb：1885psi（1.0t：13MPa），3000lb：2175psi（1.5t：15MPa），3600psi：2683psi（1.8t：
18.5MPa），4000lb~7000lb：2683psi±36psi（2.0t~3.5t：18.5MPa±0.25 MPa）
(6) If the pressure is not in the normal scope, please release the main safety valve lock nut, and
adjust adjusting bolt.
If the indication is smaller than the normal scope, inner hexagon spanner the adjusting bolt in
clockwise (+) to increase main safety valve pressure.
If the indication is larger than normal scope, inner hexagon spanner the adjusting bolt in
counterclockwise (-) to decrease main safety valve pressure.
(7) Stable the pressure in normal scope for 30’s.
(8) Release pressure gauge, install the bolt, and the tightening torque is 14.8 ft·lbs ~16.2ft·lbs（20
N·m -22N·m）. Drop the mast to the ground and tilt backward to end.
(9) Retighten the tightening nut, and fix it on the front soleplate.

29
5. Lifting system
Data
Inspection and adjustment
Place Assly clearance Repair clearance
0.004in~0.031in 0.008in~0.04in
Mast to lift roller
（0.1 mm～0.8 mm） （0.2mm～1.0mm）

Shims 0.020in/0.039in/0.079in（0.5 mm / 1.0 mm / 2.0 mm）

0.004in~0.024in 0.008in~0.04in
Mast to back up metal
（0.1 mm～0.8 mm） （0.2mm～1.0mm）

Shims 0.020in/0.039in/0.079in（0.5 mm / 1.0 mm / 2.0 mm）

0.004in~0.031in 0.008in~0.04in
Inner mast to carriage side roller
（0.1 mm～0.6 mm） （0.2mm～1.0mm）

Shims 0.020in/0.039in/0.060in（0.5 mm / 1.0 mm / 1.5 mm）

Lift chain deflection 0.98in~1.18in（25 mm～30 mm）

Tightening torque

Place N·m

Lift chain lock nut 127~157（M16);176~216(M18) ; 245~314(M20)

Mast support cap blot 89～118（M14），176-216（M18）

Tilt cylinder lock nut 89-118（M14）

Lift cylinder bolt(head) 76-107（M12）

Lift cylinder bolt（toe） ，44-58（M10）

22～29（M8）

Lift cylinder fixing bolt（U type） ，29-39（M10）

14～18（M8）

Place ft·lbs

Lift chain lock nut 93.7～115.8（M16），129.8～159.3(M18)，180.7～231.6（M20）

Mast support cap blot 65.6～87.0（M14），129.8～159.3（M18）

Tilt cylinder lock nut 65.6～87.0（M8）

Lift cylinder bolt(head) 56.1～78.9（M12）

Lift cylinder bolt（toe） ，32.5～42.8（M10）

16.2～21.4（M8）

Lift cylinder fixing bolt（U type） ，21.4～28.8（M10）

10.3～13.3（M8）

30
Fault
Fault Probable cause Corrective action

Tilt cylinder and ring abraded excessively Replace piston ring tilt cylinder.
Fork arm carrier or
mast tilt by itself. The hydraulic control valve spring is
Replace it.
inoperative.

The fork arms Caused by piston jamming or bent piston rod. Replace the faulty parts.
carrier moves up
and down
sluggishly. Too much dirt is accumulated in the cylinder. Strip it down and clean.

Adjust clearance with thrust metal and

Carriage bracket assembly out of adjustment.
carriage side roller.
Insufficient clearance between inner and outer
Adjust clearance with rollers.
masts or rollers and mast.
Forks are lifted or
lowered Biting foreign materials between moving part. Remove foreign materials.
unsmoothly.
Apply grease on contact surfaces of
Insufficient lubrication.
sliding parts.（butter）

Bent carriage bracket assembly. Repair or replace.

Forks are lifted

Lift chains out of adjustable. Adjust lift chains.
unevenly
Grease stiffened or dirt accumulated on lift
Clean and lubricate lift rollers.
Lift roller does not roller and mast sliding surfaces.
rotate
Improperly adjusted lift roller. Adjust.

Insufficient lubrication. Lubricate.

Improperly adjusted lift roller, side roller and

Excessive mast Adjust.
back-up metal.
noise
By adjusting shims and rubber pad,
Rubber pad on lower of outer mast is useless piston rod is in touch with bottom of
for container fork lift truck. cylinder body after inner mast is in
touch with rubber pad.
Excessive wear occurs between the oil pump Replace the worn parts or the oil
body and gears, causing too much clearance. pump.
The lifting jack piston Yx-ring has worn, resulting in
Replace Yx-ring.
excessive inner leaks.
Springs of the multiple control valve and its
Replace.
relief valve are inoperative oil leaks.
Excessive wear occurs of the hydraulic
Replace
control valve ,resulting in excessive oil leaks.
Insufficient lift
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
Leakage occurs in the hydraulic pipe.
seal for damage.
Change the wrong hydraulic oil or stop
operation for reducing the oil
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.
The load carried is beyond the designed
Observe the lifting capacity limit.
capacity.

31
Mast
Basic mast is 3m high, composed of inner and outer mast, fork arm carrier, fork arm, chain and
idler wheel, etc.

1.Outer mast 2.Inner mast 3.Back rest 4. Fork arm carrier

5.Fork 6.Chain 7.Left lifting cylinder 8.Right lifting cylinder
9.Tilting cylinder 10.Idler wheel
Fig5-1 Double lift mast with wide view

1. Outer mast 2. Inner mast 3. Chain 4. Free lifting cylinder

5. Fork arm carrier 6. Fork 7. Left lifting cylinder 8. Right lifting cylinder
9. Fork arms 10.Tilt cylinder
Fig5-2 Double full free lift mast

32
1. Outer mast 2.Inner mast 3. Chain 4. Free lifting cylinder
5. Fork arm carrier 6.Fork 7. Sideway cylinder 8. Left rise cylinder
9. Right rise cylinder 10. Fork arms 11.Tilt cylinder
Fig 5-3 Container truck mast

1. Outer mast 2. Inner mast 3. Chain 4. Free lifting cylinder

5. Fork arm carrier 6. Fork 7. Sideway cylinder 8. Left rise cylinder
9. Right rise cylinder 10. Fork arms 11.Tilt cylinder
Fig 5-4 Triple full free lift mast

33
Lifting cylinder
Plunger feeder lifting cylinder has dash control, configuration see fig 5-5

1.LBH dust proof 2. ISI ring 3. Plug screw 4. O Ring

5.Piston 6.Bolt 7.Guide 8.bush
9. Cylinder body 10.Piston 11. Snap ring 12. Piston
13. Support ring 14. Back up rings 15. OSI ring 16. Valve guide
17.Snap ring 18. Steel axletree 19.Blowout patch 20.Adjusting washer
Fig 5-5 Lifting cylinder
Tilting cylinder

1. Retaining ring 2. Knuckle bearing 3. Support 4. Lubrication nipple 5. Nut

6. Bolt 7. Dust proof 8. Cylinder 9. Guide 10.U ring
11.O-Ring 12.Piston rod 13. O-Ring 14.Thimble 15.U ring
16.Piston 17.Cylinder body 18. Washer 19.Nut 20.Pin
21.bolt 22.Nylon tray 23. Snap ring 24.Snap ring 25.Adjusting washer
Fig 5-6 Tilting cylinder

34
6. Electrical system
Controller
CURTIS 1234/1236/1238 Controller
Summarize
CURTIS company procreates controller ，adopt international advanced closed loop system and
advanced control technique 。 Designing large screen instrument ， can clear display “electric
quantity” 、 “speed” 、“total time of run ” and so on information 。 Designation adopt code plus
character manner，increase maintain efficiency。Four work models can be set through meter so as
to suitable for different condition.
（1）SAFETY & PROTECTION FEATURES
– Reverse Polarity of the battery
– Connection errors
– All inputs are protected against connections errors.
– Current overload protection
– it have detecting element，control peak current.
– Thermal protection: If the controller temperature exceeds185℉（85℃）, the maximum current
reduces in proportion to the thermal increase. The temperature can never exceed 203℉
（95℃）; If the electric machinery temperature exceeds 293℉（145℃）, the maximum current
reduces in proportion to the thermal increase. The temperature can never exceed 320℉
（160℃）.
– Low Battery charge: When the battery charge is low, the maximum current is reduced
proportionally to the battery discharge.
– External Agents: Electric control is hermetical .The chopper is protected against dust and
spray of liquid to economy.
– Protection against accidental Start Up: A precise sequence of operations is necessary before
the machine will start. Operation can not commence if these operations are not carried out
correctly. Requests for drive must be made after closing the Key Switch.
（2）OPERATIONAL FEATURES
– Feedback control system make the vehicle speed follow accelerator ，whether low speed or
not high speed easy control .
– Two archives speed and acceleration design ，can apply to most situation.
– Regeneration technology make change direction of fork even smooth。
– Three regenerative braking mode ：
a. Acceleration pedal part release appear regenerative braking;
b. Direction reverse regenerative braking;

35
 c. Ramp downslide appear regenerative braking，except increase security drive，reclaim part
of electric energy，prolong work time of every time .
– Control speed during downgrade： speed lie on accelerator 。if speed exceed set point，
controller may automatic braking，this give optimal ramp.
Notice:
– Maintain electric control ， must first cut off electrical source ， then hold 10-100ohmic
resistance join controller anode and cathode，release residual voltage in the capacitor, or else
you may meet tip-and-run danger.
– Magnetic and radiation have some effect to inverter，long time effect may mangle controller,
So need apart form magnetic and radiation.

36
Failure code
There are two LEDs including a yellow LED and a red LED. The two LEDs have four different
display modes, indicating the type of information they are providing.

DISPLAY STATUS
Controller is not powered on, has a dead
Neither LED illuminated
battery, or is severely damaged.
Yellow LED flashing Controller is operating normally.

Yellow and red LEDs both on solid Controller is in Flash program mode.

Red LED and yellow LED flashing alternately Controller has detected a fault.

PROGRAMMER LCD
CODE POSSIBLE CAUSE
DISPLAY
1. External short of phase U, V, or W motor connections.
1,2 Controller Overcurrent 2. Motor parameters are mis-tuned.
3. Controller defective.
1. Leakage to vehicle frame from phase U, V, or W (short in motor stator).
1,3 Current Sensor Fault
2. Controller defective.
1. External load on capacitor bank (B+ connection stud) that prevents the
1,4 Precharge Failed capacitor bank from charging.
2. See 1311 menu Monitor » Battery: Capacitor Voltage.
Controller Severe 1. Controller is operating in an extreme environment.
1,5
Undertemp 2. See 1311 menu Monitor » Controller: Temperature.
1. Controller is operating in an extreme environment.
Controller Severe 2. Excessive load on vehicle.
1,6 Overtemp 3. Improper mounting of controller.
4. See 1311 menu Monitor » Controller: Temperature.
1. Battery Menu parameters are misadjusted.
2. Non-controller system drain on battery.
3. Battery resistance too high.
1,7 Severe Undervoltage
4. Battery disconnected while driving.
5. See 1311 menu Monitor » Battery: Capacitor Voltage.
6. Blown B+ fuse or main contactor did not close.
1. Battery Menu parameters are misadjusted.
2. Battery resistance too high for given regen current.
1,8 Severe Overvoltage
3. Battery disconnected while regen braking.
4. See 1311 menu Monitor » Battery: Capacitor Voltage.
1. Controller is performance-limited at this temperature.
Controller Undertemp
2,1 2. Controller is operating in an extreme environment.
Cutback
3. See 1311 menu Monitor » Controller: Temperature.
1. Controller is performance-limited at this temperature.
2. Controller is operating in an extreme environment.
Controller Overtemp
2,2 3. Excessive load on vehicle.
Cutback
4. Improper mounting of controller.
5. See 1311 menu Monitor » Controller: Temperature.
1. Normal operation. Fault shows that the batteries need recharging.
Controller is performance limited at this voltage.
2. Battery parameters are misadjusted.
3. Non-controller system drain on battery
2,3 Undervoltage Cutback
4. Battery resistance too high.
5. Battery disconnected while driving.
6. See 1311 menu Monitor » Battery: Capacitor Voltage.
7. Blown B+ fuse or main contactor did not close.

37
 PROGRAMMER LCD
CODE POSSIBLE CAUSE
DISPLAY
1. Normal operation. Fault shows that regen braking currents elevated the
battery voltage during regen braking Controller is performance limited at
this voltage.
2,4 Overvoltage Cutback 2. Battery parameters are misadjusted.
3. Battery resistance too high for given regen current.
4. Battery disconnected while regen braking
5. See 1311 menu Monitor » Battery: Capacitor Voltage.
1. External load impedance on the +5V supply (pin 26) is too low.
2,5 +5V Supply Failure
2. See 1311 menu Monitor » outputs: 5 Volts and Ext Supply Current.
2,6 Digital Out 6 Overcurrent 1. External load impedance on Digital Output 6 driver (pin 19) is too low.
2,7 Digital Out 7 Overcurrent 1. External load impedance on Digital Output 7 driver (pin 20) is too low.
1. Motor temperature is at or above the programmed Temperature Hot
setting, and the requested current is being cut back.
2. Motor Temperature Control Menu parameters are mis-tuned.
Motor Temp Hot
2,8 3. See 1311 menus Monitor » Motor: Temperature and Monitor » Inputs:
Cutback
Analog2.
4. If the application doesn’t use a motor thermistor, Temp Compensation
and Temp Cutback should be programmed Off.
1. Motor thermistor is not connected properly.
2. If the application doesn’t use a motor thermistor, Temp Compensation
2,9 Motor Temp Sensor Fault and Temp Cutback should be programmed Off.
3. See 1311 menus Monitor » Motor: Temperature and Monitor » Inputs:
Analog2.
1. Open or short on driver load.
3,1 Coil 1 Driver Open/Short 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
1. Open or short on driver load.
3,1 Main Open/Short 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
1. Open or short on driver load.
3,2 Coil2 Driver Open/Short 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
1. Open or short on driver load.
3,2 EM Brake Open/Short 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
1. Open or short on driver load.
3,3 Coil3 Driver Open/Short 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
1. Open or short on driver load.
Coil4 Driver
3,4 2. Dirty connector pins.
Open/Short
3. Bad crimps or faulty wiring.
1. Open or short on driver load.
3,5 PD Open/Short 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
1. Motor encoder failure.
3,6 Encoder Fault 2. Bad crimps or faulty wiring.
3. See 1311 menu Monitor » Motor: Motor RPM.
1. Motor phase is open.
3,7 Motor Open
2. Bad crimps or faulty wiring.
1. Main contactor tips are welded closed.
2. Motor phase U is disconnected or open.
3,8 Main Contactor Welded
3. An alternate voltage path (such as an external precharge resistor) is
providing a current to the capacitor bank (B+ connection stud).
1. Main contactor did not close.
2. Main contactor tips are oxidized, burned, or not making good contact.
Main Contactor Did Not
3,9 3. External load on capacitor bank (B+ connection stud) that prevents
Close
capacitor bank from charging.
4. Blown B+ fuse.
1. Throttle pot wiper voltage too high.
4,1 Throttle Wiper High
2. See 1311 menu Monitor » Inputs: Throttle Pot.

38
 PROGRAMMER LCD
CODE POSSIBLE CAUSE
DISPLAY
1. Throttle pot wiper voltage too low.
4,2 Throttle Wiper Low
2. See 1311 menu Monitor » Inputs: Throttle Pot.
1. Brake pot wiper voltage too high.
4,3 Brake Wiper High
2. See 1311 menu Monitor » Inputs: Brake Pot.
1. Brake pot wiper voltage too low.
4,4 Brake Wiper Low
2. See 1311 menu Monitor » Inputs: Brake Pot.
1. Combined pot resistance connected to pot low is too low.
4,5 Pot Low Overcurrent
2. See 1311 menu Monitor » Outputs: Pot Low.
1. Failure to write to EEPROM memory. This can be caused by EEPROM
4,6 EEPROM Failure memory writes initiated by VCL, by the CAN bus, by adjusting
parameters with the 1311, or by loading new software into the controller.
1. KSI, interlock, direction, and throttle inputs applied in incorrect sequence.
2. Faulty wiring, crimps, or switches at KSI, interlock, direction, or throttle
4,7 HPD/Sequencing Fault
inputs.
3. See 1311 menu Monitor » Inputs.
1.Emergency Reverse operation has concluded, but the throttle, forward
4,7 Emer Rev HPD
and reverse inputs, and interlock have not been returned to neutral.
1.This is a safety fault caused by a change in certain 1311 parameter
settings so that the vehicle will not operate until KSI is cycled. For
4,9 Parameter Change Fault
example, if a user changes the Throttle Type this fault will appear and
require cycling KSI before the vehicle can operate.
1. VCL code encountered a runtime VCL error.
2. See 1311 menu Monitor » Controller: VCL Error Module and VCL Error.
6,8 VCL Runtime Error
This error can then be compared to the runtime VCL module ID and error
code definitions found in the specific OS system information file.
1. External load on the 5V and 12V supplies draws either too much or too
little current.
External Supply Out of
6,9 2. Fault Checking Menu parameters Ext Supply Max and Ext Supply Min
Range
are mis-tuned.
3. See 1311 menu Monitor » Outputs: Ext Supply Current.
7,1 OS General 1. Internal controller fault.
1. Time between CAN PDO messages received exceeded the PDO
7,2 PDO Timeout
Timeout Period.
1. Stalled motor.
2. Motor encoder failure.
7,3 Stall Detect 3. Bad crimps or faulty wiring.
4. Problems with power supply for the motor encoder.
5. See 1311 menu Monitor » Motor: Motor RPM.
Motor Characterization 1. Motor characterization failed during the motor characterization process.
8,7
Fault
1. Encoder characterization failed during the motor characterization
Encoder Characterization
8,8 process.
Fault
2. Motor encoder pulse rate is not a standard value (32, 48, 64, 80 ppr).
8,9 Motor Type Fault 1. The Motor type parameter value is out of range.
1. Vehicle movement sensed after the EM Brake has been commanded to
9,2 EM Brake Failed to Set set.
2. EM Brake will not hold the motor from rotating.
1. Limited Operating Strategy (LOS) control mode has been activated, as a
result of either an Encoder Fault (Code 36) or a Stall Detect Fault (Code
Limited Operating 73).
9,3
Strategy（LOS） 2. Motor encoder failure.
3. Bad crimps or faulty wiring.
4. Vehicle is stalled.
1. Emergency Reverse was activated and concluded because the EMR
9,4 Emer Rev Timeout Timeout timer has expired.
2. The emergency reverse input is stuck On.

39
Electrical system principle diagram

CPD40/45/50-AC4 Electrical system principle diagram

40
 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16

CPD10~35-AC4-E Electrical system principle diagram

41
 Maintenance record

Date Maintain content Maintainer

HANGCHA GROUP CO. , LTD.

■ Address For: OVERSEAS USERS

■ Address: 666 Xiangfu Road, Hangzhou, Zhejiang, China
■ Fax: 0086-571-88926789 0086-571-88132890 ■ ZIP:311305
■ Web: http://www.hcforklift.com ■ E-mail: sales@hcforklift.com