CPD20SR

3-Wheel Electric Forklift

Service Manual

1 2021.04.16
 1. Structure

Overhead guard

Handle

Steering wheel

Cover Arm rest

Back cushion

Baffle 2
Baffle 1

Battery compartment side door

Battery
Foot mat

Steering mechanism

Baffle 3

Roller

Pedal assembly

2
 Triplex mast

Front cover plate

Forged fork

3
 Oil pump motor

Upper foot lock

Oil tank/hydraulic system

Tilt oil tank

Drive wheel assembly

Mast half

1.1 Cover disassembly After disassembly

1.1.1 Baffle 1 disassembly

① Screw off 1#screw, 2 in total;

② Remove 2# baffle 1 ;

③ Refer to the figure at right for the status after disassembly

1.1.2 Baffle 2 disassembly

4
 After disassembly

1、2

① Screw off 1# screw, 4 in all; and remove 2# washer, 4 in all;

② Remove 3# baffle 2;

③ Refer to the figure at right for the status after disassembly. After disassembly
1.1.3 Cover disassembly

1 2

① Disassemble the 1# steering wheel (refer to 2.3) and 2# arm rest (refer to 2.4);

② Remove 3# cover;

③ Refer to the figure at right for the status after disassembly.

1.1.4 Left and right side doors disassembly After disassembly

① Disassemble 1# screw, 2 in all at both sides;

② Remove the 2# side door;

③ Refer to the figure at right for the status after disassembly.

1.1.5 Baffle 3 disassembly

5
 After disassembly

① After battery compartment side door disassembly (refer to 1.1.4), remove and pull out the battery
pack (refer to 2.5) .
② Screw off 1# screw, 4 in all;
③ Remove 2# baffle 3;
④ Refer to the figure at right for the status after disassembly.
After disassembly
1.1.6 Front cover disassembly

① Disassemble 1# screw, 2 in all at both sides;

② Remove the 2# front cover;

③ Refer to the figure at right for the status after disassembly.

After disassembly
1.1.7 Upper foot lock disassembly

① Screw off 1# screw, 2 in all at both side after disassembling the front cover (refer to 1.1.6)

② Remove the upper 2# foot lock;

③ Refer to the figure at right for the status after disassembly.

6
2 Mechanical structure maintenance
2.1 Steering wheel disassembly

9
8
7

5
3
1

6
4
① Suspend the steering wheel before disassembly, an turn the steering gear
2 assembly 90°;
② Disassemble 1# screw, 3 in total, and remove 2# dust cover;
③ Remove 3# cotter pin, Screw off 4# nut, and remove 5# washer, 2# dust cover in order;
④ Remove 7# tyre, 8# bearing and 9# skeleton oil seal.

2.2 Drive wheel disassembly

10

9
8

6 5 4

12
22
11

8
13 1
14 3

① Suspend the drive wheel before disassembly, screw out 1# fixing nut, 5 in total;
② Remove 2# tyre.

2.3 Steering wheel disassembly

7
 2 1
3

6 7

① Screw off 1# handle, and remove 2# rubber cover;

② Screw off 3# screw, and remove 4# steering wheel cover;
③ Screw off 5# screw , 3 in total and 6# washer, 3 in total;
④ Remove 7# steering wheel.

2.4 Arm rest disassembly

5
4
3

2 1

① Screw off 1# screw, 3 in total and remove 2# washers, 3 in total;

② Remove 3# arm rest;
③ Remove 4# nylon pad and 5# sliding pad, 3 pieces for each.

2.5 Battery pack disassembly

8
① Remove the battery compartment side door (refer to 1.1.4);
② Unplug the power connector;
③ Place the battery on the battery cart near the side door.

2.6 Electromagnetic brake and drive motor disassembly

6
5

2 4
3

① Disconnect all electric connections;

② Remove 1# circlip for shaft;
③ Screw off 2# bolt and 3# washer, 5 pieces for each;
④ Remove 4# electromagnetic brake to finish disassembling the electromagnetic brake;
⑤ Remove 5# screws and 6# washer, 3 pieces for each;
⑥ Remove 7# drive motor to complete disassembling the drive motor.

2.7 Hydraulic oil repair/maintenance

After years’ usage, hydraulic oil is contaminated, which needs to be replaced. Follow the instruction
to refill hydraulic oil and oil filters.
① Oil draining: Move the truck to a proper place, then screw off #6 oil draining bolt under the oil tank
and 7# bonded washer to drain the oil;
② Replace oil filters, including oil suction filter and oil returning filter: remove 4# screw and 5# part to
replace oil returning filter; remove 1# screw, and 2# oil tank cover plate to replace 3# oil suction filter.

9
2.8 Hydraulic oil filling

① Tilt the mast maximum ;

② Remove 2# cover;
③ Remove the oil filling lid to add proper amount of hydraulic oil to the oil gauge position(if the oil gauge
scale is blurred or there is no visible scale, please add oil to 80% of the tank volume.)
④ Screw on the oil filling lid, and put back the cover.

2.9 Hydraulic component replacement

4# gear pump, 1# priority valve, 5# electronic direction-switch valve and other related accessories
could be seen after removing the cover at back of the mast following the instruction mentioned above.
① Gear pump replacement: take out the gear pump by removing the inlet and outlet oil pipes, then their
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 joints and 2# bolt.
② Priority valve replacement：remove the oil pipe on1# priority valve, then remove 3# screw.
③ Electronic direction-switch valve replacement: remove the oil pipe on 5# electronic direction-switch
valve(mark every oil pipe interface carefully over disassembly to ensure accurate connecting
subsequence later.) Screw off the 4 mounting bolt at back of the electromagnetic valve to replace the
valve.

2.10 Steering gear and hydraulic motor replacement

① Follow the instruction above to remove related covers, then 3# bolt to take out the steering gear, and
remove the oil pipe on it.
② Remove the cover at both sides of the motor and the pipe oil on the motor, then screw off 1# bolt to
pull out the motor upright (pay attention to keep the motor upright for the sake of the rectangular
transmission key)

Recommended oil
Hydraulic system N 32 25L

Gear oil ATF gear oil 35L on the left and right

Grease 3# lithium grease Appropriate amount

Dripping point 170

2.11 Side shift cylinder maintenance

11
① Remove 1# bolt, 2# spring washer, 3# flat washer in order; hoist the mid mast with a crane to
separate the cylinder from 4# regulating screw until there is space to pull out the whole piston rod;
② Loosen 6# fastening screw, then loosen the cylinder hood with special moon shaped spanner;
③ Take out the piston rod to replace damaged parts;
④ Reverse the steps to assemble the cylinder .

2.12 Mid cylinder maintenance

① Loosen the oil pipe and chain bypass the mid mast by hoisting 1# sliding frame assembly;
② Remove 2# circlip for shaft, and remove the chain roller seat on 3# mid cylinder;
③ Remove the hood and its inner sleeve on 4# cylinder with special tools to replace the damaged parts;
④ Reverse the steps to assemble.

12
2.13 Tilting cylinder maintenance

① Hoist the outer mast vertically to prevent it from topping at a large extend after the mast is removed;
② Remove the L-pin shaft at location 1(removing left and right tilting cylinders simultaneously is
forbidden for the sake of safety. )
③ Remove 2# pulling ring by loosening the locking nut under it;
④ Remove 3# retaining ring, and move 4# hood left and right;
⑤ Expose 5# steel wire and pry it out wit a flat screwdriver;( Be careful that the steel wire retaining ring
is elastic )
⑥ Pull out the hood and piston rod to replace damaged parts;
⑦ Reverse the steps to assemble.

3. Electrical part
3.1 Electrical system diagram

13
NO. Parts No. Name NO. Parts No. Name
1 35108000271 Electric parts assembly 14 35701000008 Strobe light LTD152/12V
2 35503000026 Instrument 15 35806000026 Mast proximity switch
3 35506000011 Integrated handle 16 35706000006 LED headlight
35602000003 Key switch 35108000275 DC isolator/contactor
4 17
assembly
5 35614000001 Emergency switch 18 35204000016 AC motor(pump)
6 35208000002 USB port 19 35703000016 Horn 36V
7 35208000003 Lighter 20 35805000012 Mast potentiometer 45°
8 35805000004 Steering potentiometer 21 35505000010 Axial fan 12V
9 35806000025 Steering proximity switch 22 35204000090 AC motor
10 35608000005 Headlight switch 22.1 35204000091 AC motor

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11 35612000004 Micro switch 23 30506000057 Electric brake
12 35302000063 Lead-acid battery 24 35612000032 Pedal micro switch
12.1 35302000064 Lead-acid battery
13 35403000005 Connector 350A

3.2 Electrical schematic diagram

3.2.1 AC controller
1）Screw off 1# wiring screw, 5 in total to remove the harness connector;
2）Screw off 2# fixing screw, 4 in total to remove the controller.

3.2.1.1 Specification
1. Advanced design and functions
1. Functions, operation and system are all better than DC system.

15
 2. 0 to 300 Hz frequency range, low noise operation.
3. A battery voltage system of 24 to 80 volts, operating at 350 to 650 amperes in 2 minutes.
4. Powerful operating system ensures that truck control, motor control and client program run at
the same time.
5. Advanced pulse width modulation technology ensures that the battery is used efficiently, and
reduces the loss of motor energy consumption and torque conversion.
6. Curtis AC controller can be adapted to any type of AC motor.
7. On-board BDI and timer.
8. On site debugging and programming, with built-in flash memory, software can be downloaded at
any time.

2. Outstanding drive control

1. Vector control technology is applied, combined with Curtis algorithm, the controller can always
provide peak torque and the best efficiency.
2. Working area of torque and speed is wide, and the regeneration performance is perfect.
3. The speed and torque mode of internal closed loop control ensures the optimal performance
without any other devices.
4. Adjust the driving and braking performance to the best through programming parameter setting.
5. Torque control mode provides unique performance to ensure smooth transition and positive
response in any state.
6. Unique pump control mode, quick response to hydraulic changes.

1234E programmer error code display

LED error code display table
There is a red and a yellow LED indicators on the shell of the controller. Different blink modes
indicates different errors. Refer to the following table for more information.
Display Description
Both lights OFF Power off or a wiring error occurs
Yellow blink Controller works normally
Both lights always ON Software is under updating
Both lights blink Controller error

Error code and trouble shooting table

16
CODE PROGRAMMER LCD DISPLAy
EFFECT OF FAULT
12 controller overcurrent
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownTrottle;
FullBrake;
ShutdownPump.
13 current Sensor Fault
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownTrottle;
FullBrake;
ShutdownPump.
14 Precharge Failed
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownTrottle;
FullBrake;
ShutdownPump.
15 controller Severe undertemp
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownTrottle;
FullBrake;
ShutdownPump.
16 controller Severe overtemp
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownTrottle;
FullBrake;
ShutdownPump.
17 Severe undervoltage
Reduced drive torque.
POSSIBLE CAUSE
1. External short of phase U,V, or W
motor connections.
2. Motor parameters are mis-tuned.
3. Controller defective.
4. Speed encoder noise problems.
1. Leakage to truck frame from phase
U, V, or W (short in motor stator).
2. Controller defective.
1. See Monitor menu »Battery:
Capacitor Voltage.
2. External load on capacitor bank (B+
connection terminal) that prevents
the capacitor bank from charging.
1. See Monitor menu»Controller:
Temperature.
2. Controller is operating in an extreme
environment.
1. See Monitor menu »Controller:
Temperature.
2. Controller is operating in an extreme
environment.
3. Excessive load on truck.
4. Improper mounting of controller.
1. Battery Menu parameters are
misadjusted.
2. Non-controller system drain
battery.
3. Battery resistance too high.
4. Battery disconnected while driving.
5. See Monitor menu»Battery:
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SET/CLEAR CONDITIONS
Set: Phase current exceeded the current
measurement limit.
Clear: Cycle KSI.
Set: Controller current sensors have
invalid offset reading.
Clear: Cycle KSI.
Set: Precharge failed to charge the capacitor
bank to the KSI voltage.
Clear: Cycle Interlock input or use VCL
function Enable_Precharge().
Set: Heatsink temperature below -40°C.
Clear: Bring heatsink temperature
above -40°C, and cycle interlock or KSI.
Set: Heatsink temperature above +95°C.
Clear: Bring heatsink temperature
below +95°C, and cycle interlock or KSI.
Set: Capacitor bank voltage dropped
below the Severe Undervoltage limit
on (see page 58) with FET bridge enabled.
Clear: Bring capacitor voltage above
Severe Undervoltage limit.
 Capacitor Voltage.
6. Blown B+ fuse or main contactor
did not close.
18 Severe overvoltage 1. See Monitor menu»Battery: Set: Capacitor bank voltage exceeded
ShutdownMotor; Capacitor Voltage. the Severe Overvoltage limit (see page 58)
ShutdownMainContactor; 2. Battery menu parameters are with FET bridge enabled.
ShutdownEMBrake; misadjusted. Clear: Bring capacitor voltage below
ShutdownTrottle; 3. Battery resistance too high for given Severe Overvoltage limit, and then cycle KSI.
FullBrake; regen current.
ShutdownPump. 4. Battery disconnected while regen
braking.
22 controller overtemp cutback 1.See Monitor menu»Controller: Set: Heatsink temperature exceeded 85°C.
Reduced drive and brake Temperature. Clear: Bring heatsink temperature below
torque. 2.Controller is performance-limited at 85°C.
this temperature.
3. Controller is operating in an extreme
environment
4. Excessive load on truck.
5. Improper mounting of controller.
23 undervoltage cutback 1. Normal operation. Fault shows that Set: Capacitor bank voltage dropped below
Reduced drive torque. the batteries need recharging. the Undervoltage limit (see page 58) with the
Controller is performance limited at this FET bridge enabled.
voltage. Clear: Bring capacitor voltage above the
2. Battery parameters are misadjusted. Undervoltage limit.
3. Non-controller system drain on
battery
4. Battery resistance too high.
5. Battery disconnected while driving.
6. See Monitor menu»Battery: Capacitor
Voltage.
7. Blown B+ fuse or main contactor did
not close
24 overvoltage cutback 1. Normal operation. Fault shows that Set: Capacitor bank voltage exceeded the
Reduced brake torque. regen braking currents elevated the Overvoltage limit (see page 58) with the FET
Note: Tis fault is declared only battery voltage during regen braking. bridge enabled.
when the controller is running Controller is performance limited at this Clear: Bring capacitor voltage below the
in regen. voltage. Overvoltage limit.
2. Battery parameters are misadjusted.
3. Battery resistance too high for given
regen current.
4. Battery disconnected while regen
braking.
5. See Monitor menu »Battery:
Capacitor Voltage.

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25 +5V Supply Failure 1. External load impedance on the +5V
None, unless a fault action is supply (pin 26) is too low.
programmed in VCL. 2. See Monitor menu»outputs: 5 Volts
and Ext Supply Current.
26 digital out 6 open/Short 1. External load impedance on Digital
Digital Output 6 driver Output 6 driver (pin 19) is too low.
will not turn on.
27 digital out 7 open/Short 1. External load impedance on Digital
Digital Output 7 driver Output 7 driver (pin 20) is too low.
will not turn on.
28 Motor temp hot cutback 1. Motor temperature is at or above
Reduced drive torque. the programmed Temperature Hot
setting, and the current is being cut
back.
2. Motor Temperature Control Menu
parameters are mis-tuned.
3. See Monitor menu»Motor:
Temperature and » Inputs: Analog2.
4. If the application doesn’t use a motor
thermistor, Temp Compensation
and Temp Cutback should be
programmed Off.
29 Motor temp Sensor Fault 1. Motor thermistor is not connected
MaxSpeed reduced (LOS, properly.
Limited Operating Strategy), 2. If the application doesn’t use a motor
and motor temperature thermistor, Motor Temp Sensor Enable
cutback disabled should be programmed Off.
3. See Monitor menu »Motor:
Temperature and » Inputs: Analog2.
31 coil1 driver open/Short 1. Open or short on driver load.
ShutdownDriver1. 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
Main open/Short 1. Open or short on driver load.
ShutdownMotor; 2. Dirty connector pins.
ShutdownMainContactor; 3. Bad crimps or faulty wiring.
ShutdownEMBrake;
ShutdownTrottle;
FullBrake;
19
Set: +5V supply (pin 26) outside the
+5V±10% range.
Clear: Bring voltage within range.
Set: Digital Output 6 (pin 19) current
exceeded 15 mA.
Clear: Remedy the overcurrent cause
and use the VCL function Set_DigOut()
to turn the driver on again.
Set: Digital Output 7 (pin 20) current
exceeded 15 mA.
Clear: Remedy the overcurrent cause
and use the VCL function Set_DigOut()
to turn the driver on again.
Set: Motor temperature is at or above the
Temperature Hot parameter setting.
Clear: Bring the motor temperature within
range.
Set: Motor thermistor input (pin 8) is at the
voltage rail (0 or 10V).
Clear: Bring the motor thermistor input
voltage within range.
Set: Driver 1 (pin 6) is either open or shorted.
Tis fault can be set only when Main Enable =
Off
Clear: Correct open or short, and cycle driver.
Set: Main contactor driver (pin 6) is either
open or shorted. Tis fault can be set only
when Main Enable = On.
Clear: Correct open or short, and cycle driver
 ShutdownPump.
32 coil2 driver open/Short 1. Open or short on driver load. Set: Driver 2 (pin 5) is either open or shorted.
ShutdownDriver2. 2. Dirty connector pins. Tis fault can be set only when Main Enable =
3. Bad crimps or faulty wiring. 0
Clear: Correct open or short, and cycle driver.

EMBrake open/Short 1. Open or short on driver load. Set: Electromagnetic brake driver (pin 5) is
ShutdownEMBrake; 2. Dirty connector pins. either open or shorted. Tis fault can be set
ShutdownTrottle; 3. Bad crimps or faulty wiring. only when EM Brake Type >0.
FullBrake Clear: Correct open or short, and cycle driver.

33 Coil3 driver open/Short 1. Open or short on driver load. Set: Driver 3 (pin 4) is either open or shorted.
ShutdownDriver3. 2. Dirty connector pins. Clear: Correct open or short, and cycle driver.
3. Bad crimps or faulty wiring.

34 Coil4 driver open/Short 1. Open or short on driver load. Set: Driver 4 (pin 3) is either open or shorted.
ShutdownDriver4 2. Dirty connector pins. Clear: Correct open or short, and cycle driver.
3. Bad crimps or faulty wiring.

35 Pd open/Short 1. Open or short on driver load. Set: Proportional driver (pin 2) is either open
ShutdownPD. 2. Dirty connector pins. or shorted.
3. Bad crimps or faulty wiring. Clear: Correct open or short, and cycle driver.
36 Encoder Fault 1. Motor encoder failure. Set: Motor encoder phase failure detected.
ShutdownEMBrake; 2. Bad crimps or faulty wiring. Clear: Cycle KSI.
ShutdownTrottle. 3. See Monitor menu»Motor:
Motor RPM.
37 Motor open 1. Motor phase is open. Set: Motor phase U, V, or W detected open.
ShutdownMotor; 2. Bad crimps or faulty wiring. Clear: Cycle KSI.
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownTrottle;
FullBrake;
ShutdownPump.
38 Main contactor Welded 1. Main contactor tips are welded Set: Just prior to the main contactor closing,
ShutdownMotor; closed. the capacitor bank voltage (B+ connection
ShutdownMainContactor; 2. Motor phase U or V is disconnected or terminal) was loaded for a short time and the
ShutdownEMBrake; open. voltage did not discharge.
ShutdownTrottle; 3. An alternate voltage path (such as an Clear: Cycle KSI
FullBrake; external precharge resistor) is providing
ShutdownPump. a current to the capacitor bank (B+
connection terminal).
39 Main contactor did not close 1. Main contactor did not close. Set: With the main contactor commanded
ShutdownMotor; 2. Main contactor tips are oxidized, closed, the capacitor bank voltage (B+
ShutdownMainContactor; burned, or not making good contact. connection terminal) did not charge to B+.

20
 ShutdownEMBrake; 3. External load on capacitor bank (B+ Clear: Cycle KSI.
ShutdownTrottle; connection terminal) that prevents
FullBrake; capacitor bank from charging.
ShutdownPump. 4. Blown B+ fuse.
41 Throttle Wiper High 1. See Monitor menu »Inputs: Set: Trottle pot wiper (pin 16) voltage is
ShutdownTrottle. Trottle Pot. higher than the high fault threshold
2. Trottle pot wiper voltage too high. (can be changed with the VCL function
Setup_Pot_Faults()).
Clear: Bring throttle pot wiper voltage
below the fault threshold.
42 Throttle Wiper Low 1. See Monitor menu »Inputs: Set: Trottle pot wiper (pin 16) voltage is lower
ShutdownTrottle. Trottle Pot. than the low fault threshold
2. Trottle pot wiper voltage too low. (can be changed with the VCL function
Setup_Pot_Faults()).
Clear: Bring throttle pot wiper voltage
above the fault threshold.
43 Pot2 Wiper High 1. See Monitor menu»Inputs: Set: Pot2 wiper (pin 17) voltage
FullBrake. Pot2 Raw. is higher than the high fault threshold
2. Pot2 wiper voltage too high. (can be changed with the VCL function
Setup_Pot_Faults()).
Clear: Bring Pot2 wiper voltage below
the fault threshold.
44 Pot2 Wiper Low 1. See Monitor menu »Inputs: Set: Pot2 wiper (pin 17) voltage
FullBrake. Pot2 Raw. is lower than the low fault threshold
2. Pot2 wiper voltage too low. (can be changed with the VCL function
Setup_Pot_Faults()).
Clear: Bring Pot2 wiper voltage
above the fault threshold.
45 Pot low Overcurrent 1. See Monitor menu»Outputs: Set: Pot low (pin 18) current exceeds 10mA.
ShutdownTrottle; Pot Low. Clear: Clear pot low overcurrent condition and
FullBrake. 2. Combined pot resistance connected cycle KSI.
to pot low is too low.

46 EEPROM Failure 1. Failure to write to EEPROM memory. Set: Controller operating system tried to write
ShutdownMotor; Tis can be caused by EEPROM memory to EEPROM memory and failed.
ShutdownMainContactor; writes initiated by VCL, by the CAN bus, Clear: Download the correct software (OS)
ShutdownEMBrake; by adjusting parameters with the and matching parameter default settings into
ShutdownTrottle; programmer, or by loading new software the controller and cycle KSI.
ShutdownInterlock; into the controller.
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;

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 FullBrake;
ShutdownPump.
47 HPD/Sequencing Fault
ShutdownTrottle.
Emer Rev HPD
ShutdownTrottle;
ShutdownEMBrake.
49 Parameter Change Fault
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownTrottle;
FullBrake;
ShutdownPump.
51-67 OEM Faults
(See OEM documentation.)
68 Vcl Run Time Error
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownTrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake;
ShutdownPump.
69 External Supply Out of Range
None, unless a fault action
is programmed in VCL.
1. KSI, interlock, direction, and throttle
inputs applied in incorrect sequence.
2. Faulty wiring, crimps, or switches at
KSI, interlock, direction, or throttle
inputs.
3. See Monitor menu»Inputs.
1. Emergency Reverse operation has
concluded, but the throttle, forward and
reverse inputs, and interlock have not
been returned to neutral.
1. Tis is a safety fault caused by a
change in certain parameter settings so
that the truck will not operate until KSI
is cycled.
For example, if a user changes the
Trottle Type this fault will appear and
require cycling KSI before the truck can
operate.
1. Tese faults can be defined by the OEM
and are implemented in the
application-specific VCL code. See OEM
documentation.
1. VCL code encountered a runtime VCL
error.
2. See Monitor menu»Controller: VCL
Error Module and VCL Error.
Tis 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.
2. Fault Checking Menu parameters Ext
22
Set: HPD (High Pedal Disable) or sequencing
fault caused by incorrect sequence of KSI,
interlock, direction, and throttle inputs.
Clear: Reapply inputs in correct sequence.
Set: At the conclusion of Emergency Reverse,
the fault was set because various inputs were
not returned to neutral.
Clear: If EMR_Interlock = On, clear the
interlock, throttle, and direction inputs.
If EMR_Interlock = Off, clear the
throttle and direction inputs.
Set: Adjustment of a parameter setting that
requires cycling of KSI.
Clear: Cycle KSI.
Set: See OEM documentation.
Clear: See OEM documentation.
Set: Runtime VCL code error condition.
Clear: Edit VCL application software to fix this
error condition; flash the new compiled
software and matching parameter defaults;
cycle KSI.
Set: Te external supply current (combined
current used by the 5V supply [pin 26] and
12V supply [pin 25]) is either greater than the
upper current threshold or lower than the
 Supply Max and Ext Supply Min are lower current threshold. Te two thresholds are
mis-tuned. defined by the External Supply Max and
3. See Monitor menu »Outputs: External Supply Min parameter settings (page
Ext Supply Current. 53).
Clear: Bring the external supply current
within range.
71 OS General 1. Internal controller fault. Set: Internal controller fault detected.
ShutdownMotor; Clear: Cycle KSI.
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownTrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake;
ShutdownPump.
72 PDO Timeout 1. Time between CAN PDO messages Set: Time between CAN PDO messages
ShutdownTrottle; received exceeded the PDOTimeout received exceeded the PDO Timeout Period.
CAN NMT State set Period. Clear: Cycle KSI or receive CAN NMT
to Pre-operational. message.
73 Stall Detected 1. Stalled motor. Set: No motor encoder movement detected.
ShutdownEMBrake; 2. Motor encoder failure. Clear: Either cycle KSI, or detect valid motor
ShutdownTrottle; 3. Bad crimps or faulty wiring. encoder signals while operating in LOS mode
Control Mode changed to 4. Problems with power supply for the and return Trottle Command = 0 and Motor
LOS (Limited Operating motor encoder. RPM = 0.
Strategy). 5. See Monitor menu»Motor:
Motor RPM.
74 Fault on other traction Dual Drive fault: see Dual Drive manual.
controller
75 dual Severe Fault Dual Drive fault: see Dual Drive manual.
77 Supervisor Fault 1. Te Supervisor has detected a Set: Mismatched redundant readings;
ShutdownMotor; mismatch in redundant readings. damaged Supervisor; illegal switch inputs.
ShutdownMainContactor; 2. Internal damage to Supervisor Clear: Check for noise or voltage drift in
ShutdownEMBrake; microprocessor. all switch inputs; check connections;
ShutdownTrottle; 3. Switch inputs allowed to be within cycle KSI.
ShutdownInterlock; upper and lower thresholds for over
ShutdownDriver1; over 100 milliseconds.
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;

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 FullBrake;
ShutdownPump.
78 Supervisor incompatible
87 Motor Characterization Fault
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownTrottle;
FullBrake;
ShutdownPump.
88 Encoder Pulse error
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownTrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake;
ShutdownPump.
89 Motor Type Fault
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownTrottle;
FullBrake;
ShutdownPump.
91 Vcl/oS Mismatch
1. Te main OS is not compatible Set: Incompatible software.
with the Supervisor OS. Clear: Load properly matched OS code
or update the Supervisor code; cycle KSI.
1. Motor characterization failed during Set: Motor characterization failed during
characterization process. See Monitor the motor characterization process.
menu»Controller: Motor Clear: Correct fault; cycle KSI.
Characterization Error for cause:
0=none
1=encoder signal seen, but step size
not determined; set Encoder Step
Size manually
2=motor temp sensor fault
3=motor temp hot cutback fault
4= controller overtemp cutback fault
5=controller undertemp cutback fault
6=undervoltage cutback fault
7=severe overvoltage fault
8=encoder signal not seen, or one or
both channels missing
9=motor parameters out of character
ization range.
1. Encoder Steps parameter does not Set: Motor lost IFO control and accelerated
match the actual motor encoder. without throttle command.
Clear: Ensure the Encoder Steps parameter
matches the actual encoder; cycle KSI.
1. Te Motor_Type parameter value is out Set: Motor_Type parameter is set to an illegal
of range. value.
Clear: Set Motor_Type to correct value and
cycle KSI.
1. Te VCL software in the controller does Set: VCL and OS software do not match;
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 ShutdownMotor; not match the OS software in the when KSI cycles, a check is made to verify
ShutdownMainContactor; controller. that they match and a fault is issued when
ShutdownEMBrake; they do not.
ShutdownTrottle; Clear: Download the correct VCL and OS
ShutdownInterlock; software into the controller.
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake;
ShutdownPump.
92 EM Brake Failed to Set 1. Truck movement sensed after the EM Set: After the EM Brake was commanded to
ShutdownEMBrake; Brake has been commanded to set. set and time has elapsed to allow the brake to
ShutdownTrottle. 2. EM Brake will not hold the motor from fully engage, truck movement has been
Position Hold is engaged when rotating. sensed.
Interlock=On. Clear: Activate the throttle.
93 Encoder LOS (Limited 1. Limited Operating Strategy (LOS) Set: Encoder Fault (Code 36) or Stall
Operating Strategy) control mode has been activated, as a Detect Fault (Code 73) was activated, and
Enter LOS control mode result of either an Encoder Fault (Code Brake or Interlock has been applied to
36) or a Stall Detect Fault (Code 73). activate LOS control mode, allowing limited
2. Motor encoder failure. motor control.
3. Bad crimps or faulty wiring. Clear: Cycle KSI or, if LOS mode was
4. Truck is stalled. activated by the Stall Fault, clear by ensuring
encoder senses proper operation, Motor RPM
= 0, and Trottle Command = 0.
94 EMr Rev Timeout 1. Emergency Reverse was activated Set: Emergency Reverse was activated and
ShutdownEMBrake; and concluded because the EMR ran until the EMR Timeout timer expired.
ShutdownTrottle. Timeout timer has expired. Clear: Turn the emergency reverse input Off
2. Te emergency reverse input is stuck
On.
98 Illegal Model number 1. Model_Number variable contains Set: Illegal Model_Number variable; when
ShutdownMotor; illegal value. For 1234E/36E/38E KSI cycles, a check is made to confrm
ShutdownMainContactor; models, a value other than 1234, a legal Model_Number, and a fault is
ShutdownEMBrake; 1236, 1238, or 1298 is illegal. issued if one is not found.
ShutdownTrottle; For 1232E models, a value other Clear: Download appropriate software
FullBrake; than 1232 is illegal. for your controller model.
ShutdownPump. 2. Software and hardware do not match.
3. Controller defective.

99 Dualmotor Parameter Dual Drive fault: see Dual Drive manual.

Mismatch

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3.3.2 Charger

The charger consists of controller, power block and transformer. Intelligent closed-loop control, with
charging and fault state display, automatic detection of battery, dynamic tracking, closed-loop control,
make the battery always in the best critical state of electrochemical reaction.
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 3.2.1 Charger operation
1. Steps to charge
1） Connect to the power supply;
2） Connect to a matching battery.
After the charger detects that the accumulator is connected correctly, charging starts
and the program detects a delay of about 8-10 seconds. During this period, the indicator
lights and the digital tube blink one by one and light up one by one. If the accumulator is
connected correctly, the charger starts charging automatically, shows the charging
parameters, and indicates the charging status. Until the charger automatically judges that
the battery is full and the charger automatically stops charging, the charger periodically
maintains and charges the battery pulse as long as it is still connected to the charger until
the battery is disconnected from the charger and waits for the next charge to continue.

During the charging process, the charger automatically controls the charging
current according to the battery voltage value, and automatically tests the discharge
Capacity, determine the charging capacity； any manual operation is unnecessary!

2. Display data description

Display tube: it displays various charging parameters, including charging current, voltage, power
supply voltage, volume, charging time and error code.

At right of the display tube, there is a indicator to display corresponding unit.

“V” voltage,

“A” current,

“Hour” charging timer,

“A/Hour” charging volume,

“Error” charger error occurs

Error code and trouble shooting

1.1 What to do when the charger displays error code “-------”?
Battery is not connected or poor connection.
Battery is connected, but the charger fails to detect the battery voltage.

a. Battery is not connected properly

When the charger is not started for charging, measure the "+" and "-" output terminals of the
charger with the DC gear of the multimeter. If there is no voltage, it indicates that the fault is
that the output wire of the charger is open or the connector is in poor contact;

Or the charging plug is not plugged into the connecting socket of the battery at all, but into the
socket of the forklift motor.

b. Output fuse is burnt

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 Use a multimeter to measure the "upper end of output fuse" and "-" output end of charger. If
there is no voltage, it means that the output fuse is burnt out. If there is voltage, it means that
the output fuse is good.

Or, use a multimeter to measure whether the fuse is open.

c. Open circuit of voltage sampling connection line , It includes the main circuit output circuit,
voltage sampling connecting wire and PCBA connecting connector;

Check whether the voltage on the voltage sampling terminal (XP1 10, 12 pin) on the charger
control board is accurate;

The charger power supply and battery can be disconnected first , then open the white iron
dust cover of the top cover of the charger , Check the contact of XP1 connector on the
control board.

1.2 What to do when the charger displays error code “E--03”?

Cause：the positive and negative polarity of the battery are reversed.

For the user who directly connects the battery with the connecting wire, check whether the
positive and negative polarity of the connecting terminal between the battery and the
charger are correct.
1.3 What to do when the charger displays error code “E--04”?
Cause: charging current over-current.

When the charging control circuit detects 120% of the rated charging current, it will cut off the
main circuit and prompt E-04.

a. The rectifier module is damaged;

b. Poor contact of current sampling circuit or failure of current sampling operational amplifier
circuit on PCBA may cause abnormal digital value of current sampling.

c. If the charger can start charging normally, after starting the charger, press the information key
to check the charging current display; check whether the actual current is consistent with the
displayed current. If the values are inconsistent, check whether the sampling circuit has
abnormal contact.

d. If the charger can be restarted, but the overload protection is shut down immediately, the rectifier
module is damaged.
1.4 What to do when the charger displays error code “E--05”?
Cause： Battery specification is not matched.
When the charger starts to charge, the detected battery voltage is too low to reach the starting
voltage of the charger (less than 5 V / cell).

a. The battery voltage does not match the charger voltage specification;

Check whether the charger specification matches the battery voltage specification.
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 b. Poor contact of charger output connection line;

When there is no charging, press the information key to check the battery
voltage value displayed on the charger; measure the "+" and "-" output
voltage of the charger with the DC gear of the multimeter;

If the voltage displayed by the charger is the same as that measured by the multimeter, it
indicates that the fault may be the poor contact between the charger and the connecting
wire or connector of the battery. When there is charging current, the contact resistance
leads to the low voltage measured by the charger;

At this time, we need to check the output circuit wiring and each connector, and repair the
damaged output wire connector or terminal

c. Poor contact of control board voltage test connector.

If the two terminal voltage of the battery is greater than the display voltage of the charger,
the fault may be the abnormal contact of the charger detection circuit .Check whether the
input voltage of pin 10 and pin 12 on PCBA terminal XP1 is consistent with that of battery.
1.5 What to do when the charger displays error code “E--05”?
Cause：During charging, the output connection cable of the charger falls off, the accumulator is
disconnected from the charger, the charger detects an excessive voltage, and the cell
voltage of the accumulator exceeds 2.75V.
a. The battery plate is open and the connecting line between battery cells is open;
When there is no charging, press the information key to check the battery voltage, which
shows that the voltage is very high;

Use a multimeter to measure the voltage on the battery. If it is consistent with the
voltage displayed by the charger, it means that the battery is broken. Then measure the
single grid voltage of the battery one by one. If the voltage of a grid is obviously high,
it means that the single grid plate is broken or the connection of the single grid pile
head is open.

b. Poor contact of connecting wire or battery plug between battery and charger;

If the measured battery voltage is normal, it means that the connecting line between the
battery and the charger or the battery plug is in poor contact;

c. The rated voltage of the battery is too high and does not match the voltage specification of the
charger.

Check whether the charger matches the battery, and further check if it matches.

d. In the process of battery charging, the charger is still charging, and the socket connecting
the battery and charger is directly disconnected. At this time, there is a recoverable alarm.
After the charger detects that the battery has fallen off, it will confirm that the battery has
fallen off after a few seconds. The charger will automatically remove the alarm, return to the
standby state, and wait for the battery to be connected again.

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 1.6 What to do when the charger displays error code “E--07”?

Cause: low power supply voltage, power failure or input fuse damage.
Charger failure, charger no current output, rectifier module or control board damage.
a. Measure the three-phase voltage at the input end and output end of the charger input fuse in
turn with the AC Gear of the multimeter;
It is necessary to measure AB phase, BC phase and Ca phase respectively. If the voltage
between the two phases is the same or close, the mains voltage is about 380v-400v,
indicating that the three-phase voltage is normal;
In case of phase loss, some of the two phases are close to the mains voltage, while others are
abnormal.
b. If the three-phase voltage at the input side of the fuse lacks phase, it means that the power
supply lacks phase. The power supply of the distribution box should be checked. If the
three-phase voltage at the input end of the fuse is normal and the output end of the fuse has
phase loss, it means that a fuse is damaged.
c. If it is not open phase and there is no charging current output after the charger is started,
check whether the rectifier module of the main circuit is normal and whether the AC contactor
is closed normally.
e. If the above main circuit components function normally, it is necessary to check whether the
control circuit board output trigger pulse function is normal
Maybe the XP1 connector on the power board has poor contact: when the charger is powered
off and the battery is not connected, use the diode gear of the multimeter to measure whether
the "2", "6", "7" and "8" pins of XP1 are respectively connected with the "D18" negative pole,
"D22" negative pole, "D15" negative pole and "D20" positive pole on the PCBA. If one of them is
not connected, it means xP1There is a problem with the connector; if all the connectors are
connected, there is a problem with the control circuit board.
If there is something wrong with the xP1 connector, you can plug and unplug the xP1 connector
several times to make the connector contact reliable, and then power on and connect the
battery. If it can be charged normally, it means that it is really the problem of the connector.

1.7 What to do when the charger displays error code “E--09”?

Cause：the fan is damaged or the ambient temperature is too high, causing the temperature of
the module inside the fan to be too high

For the charger with cooling fan, when the charger starts charging, check whether the fan
rotates normally,

In addition, check whether the ventilation hole of the charger shell is blocked or there are
other obstructions blocking the cooling air outlet, resulting in the normal heat dissipation of
the charger.

3.3.3 Integrated handle

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 1） Screw off 4 screws with an inner hexagon spanner;
2） Pull out the connecting wiring to replace the handle.

3.3.4 Intelligent instrument

Press the square buckle to take out the instrument upright.

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4.4.1 Function description
1. Travel timer 2. Speed 3.BDI 4. Maintenance countdown（retain）5. Turning radius(EPS option)
6. Setting 7. Direction 8. Travel speed range 9. Speed mode 10. Controller error code

4.4.2 Instrument setting instruction

（1） Key: 5 function keys are at the panel to set parameters and switch error interfaces

(1) Speed mode: 3 modes are available, they are H/S/E mode, their corresponding speeds
are14.5km/h、10.5 km/h、8 km/h.
（2）Connecting port：External connector specification: TYCO P/N 770583-1PLUG; external pin
specification: TYCO P/N 770904-1

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(3)Read error description

3. Press Enter again to exit the error information interface.

（4）Language setting

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3.3.5 AC motor
Refer to 2.6 for more details.

34
 1. Motor 2. Encoder

3.3.6 Bolt fuse

Loosen 1# nut, 2 in all to remove and replace 2# bolt fus.

3.3.7 Contactor
1）Screw off 1# nut, 2 in total to remove the power line;
2）Screw off 2# nut, 2 in total to remove the contactor,

3.3.8 Horn

Screw off 1# screw with a M8 Inner hexagon spanner to take out the insert spring and replace the
horn.
3.3.9 Electromagnetic brake

Refer to 2.6 for details.

3.3.10 Steering potentiometer

35
 1） Screw off 1# fixing screw used to fix the steering potentiometer;
2） Remove the connecting wiring to replace the steering potentiometer.
3.3.11Lead-acid battery
Take out the connector to replace the whole battery.
3.3.12 Key switch
Screw off the fixing nut, unplug the connector to replace the key switch.
3.3.13 Pedal micro switch
Screw off 1# screw, 2 in total first, then unplug the insert spring to replace the micro switch.

3.3.14 Emergency stop switch

Screw off the fixing nut and Y piece and emergency stop switch.
3.3.15 Mast proximity switch
]Screw off the fixing nut and pull out the connector to replace the proximity switch.
3.3.15 DC / DC converter

1） Screw off the screw used to fix DC and DC convertor;

2） Remove the connecting wire to replace the DC convertor.

36