SM-A-1.0-X5.0-Electric Four-Wheel Forklift-202211-EN-CE

A Series
A series 1.0t-5.0t Lead acid Battery Counterbalanced Forklift Truck

A series1.0t-5.0t Lithium Battery Counterbalanced Forklift Truck
SERVICE MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.

SM21-A01(11/2022)
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 1.0t ~ 5.0 t 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. Four-wheel electric forklift trucks have been passed CE
certification.
A series four-wheel
Drive Motor Pump Motor Rated capacity(t) / Load center (mm)
model
1.0 / 500，1.5 / 500，1.75 / 500
CPD10~30-A Curtis1244 Curtis1253
2.0 / 500，2.5 / 500，3.0 / 500
CPD10~18-AC3 Curtis 1234 Curtis 1253 1.0 / 500，1.5 / 500，1.75 / 500
CPD35-AC3 Curtis 1238 Curtis 1253 3.5 / 500
CPD20~25-AC4 Curtis 1236 Curtis 1234 2.0 / 500，2.5 / 500

Inmotion Inmotion
CPD10~18-AD2 1.0 / 500，1.5 / 500，1.75 / 500
ACS48S-35P ACS48S-23P
Inmotion Inmotion
CPD20~25-AD2 2.0 / 500，2.5 / 500
ACS48M-35P ACS48M-23P
Inmotion Inmotion
CPD30~35-AD2 3.0 / 500，3.5 / 500
CPD25-ALC3 Curtis 1236 Curtis 1253 2.5 / 500
CPD25-ALC4 Curtis 1236 Curtis 1236 2.5 / 500

A series four-wheel
model
Inmotion Inmotion
CPD25-ALD2 2.5 / 500
CPD10~18-AC4-I Curtis 1234 Curtis 1234 1.0 / 500，1.5 / 500，1.8 / 500
CPD20~25-AC4-I Curtis 1236 Curtis 1234 2.0 / 500，2.5 / 500
CPD30-AC4-I Curtis 1236 Curtis 1236 3.0 / 500
CPD35-AC4-I Curtis 1238 Curtis 1236 3.5 / 500

ACE2 Z-S HP 48/350
CPD10~18-AZ3 1.0 / 500，1.5 / 500，1.75 / 500
36-48V/350A B C/CAN
ACE2 Z-S HP 48/500
CPD20~25-AZ3 2.0 / 500，2.5 / 500，
36-48V/450A B C/CAN
ACE2 80/350A Z-S HP 80/500
CPD25-ALZ3 2.5 / 500
GRANDE C/CAN
ACE2 80/350A Z-S HP 80/500
CPD30-AZ3 3.0 / 500
GRANDE C/CAN
AC-2 80/400A Z-S HP 80/500
CPD35-AZ3 3.5 / 500
PW FLASH C/CAN
ACE2 ACE2
CPD10~18-AZ4 1.0 / 500，1.5 / 500，1.75 / 500
36-48V/350A 36-48V/350A
ACE2 ACE2
CPD20~25-AZ4 2.0 / 500，2.5 / 500，
36-48V/450A 36-48V/350A
CPD25-ALZ4
Combi AC2 80 400+400 PW 2.5 / 500，3.0 / 500，3.5 / 500
CPD30~35-AZ4
ACE3
ACE3 PUMP
CPD40~50-AZ4 TRACTION 4.0 / 500，4.5 / 500，4.99 / 500
80V/550A
80V/550A
CPD40~50-AC4 1238E-6521 1236SE-6521 4.0 / 500，4.5 / 500，4.99 / 500
CPD40~50-AC4-I 1238E-6521 1236SE-6521 4.0 / 500，4.5 / 500，4.99 / 500

ACS80L-440C- ACS80L-440C-23
CPD40~50-AD2-I 4.0 / 500，4.5 / 500，4.99 / 500
35P P
ACS80L-440C- ACS80L-440C-23
CPD40~50-AD2 4.0 / 500，4.5 / 500，4.99 / 500
35P P
Inmotion Inmotion
CPD25-AD2-A 2.5 / 500
CPD25-AC4-A Curtis 1236 Curtis 1234 2.5 / 500
CPD10~18-AC4-E Curtis 1232SE Curtis 1232SE 1.0 / 500，1.5 / 500，1.8 / 500
CPD20~25-AC4-E Curtis 1234SE Curtis 1232SE 2.0 / 500，2.5 / 500
CPD20~25-AC4-EI Curtis 1234SE Curtis 1232SE 2.0 / 500，2.5 / 500
CPD10~18-AC4-EI Curtis 1234SE Curtis 1234SE 1.0/500, 1.5/500, 1.8/500
CPD25-ALC4-EI Curtis 1234SE Curtis 1234SE 2.5/500

A series four-wheel
model
CPD30~35-AC4-EI Curtis 1234SE Curtis 1234SE 3.0/500, 3.5/500
CPD10~18-AD2-I Inmotion Inmotion 1.0 / 500，1.5 / 500，1.8 / 500

ACS80S-35P ACS80S-23P
CPD20~25-AD2-I Inmotion Inmotion 2.0 / 500，2.5 / 500

ACS80M-35P ACS80S-23P
Inmotion Inmotion 3.0 / 500，3.5 / 500
CPD30~35-AD2-I
CPD25-ALC4-E
Curtis 1234SE Curtis 1234SE 2.5 / 500，3.0 / 500
CPD30-AC4-E
CPD35-AC4-E Curtis 1236SE Curtis 1234SE 3.5 / 500
1.0 / 500，1.5 / 500，1.8 / 500，
CPD10~25-AC3-E 1234SE-5421 1253-4804
2.0 / 500，2.5 / 500
CPD30-AC3-E 1234SE-6321 1253-8001 3.0 / 500
CPD35-AC3-E 1236SE-6521 1253-8001 3.5 / 500
ACE2 HP 48/500 B 1.0 / 500，1.5 / 500，1.8 / 500，

CPD10~30-AZ3-E
36-48V/450A C/CAN 2.0 / 500，2.5 / 500，3.0 / 500
ACE2 HP 80/500 C
CPD35-AZ3-E 3.5 / 500
80/400A PW C/CAN
ACE2 ACE2
CPD10~18-AZ4-E 1.0 / 500，1.5 / 500，1.8 / 500
36-48V/350A 36-48V/350A
ACE2 ACE2
CPD20~25-AZ4-E 2.0 / 500，2.5 / 500，
36-48V/450A 36-48V/350A
CPD25-ALZ4-E Combi AC2 80 Combi AC2 80
2.5 / 500，3.0 / 500，3.5 / 500
CPD30~35-AZ4-E 400+400 PW 400+400 PW
CPD10~18-AC4-NA 1234SE-5421 1234SE-5421 1.0 / 500，1.5 / 500，1.8 / 500
CPD20~25-AC4-NA 1236SE-5621 1234SE-5421 2.0 / 500，2.5 / 500

ACS48S-350C- HP 48/350 B
CPD10~18-AD1 1.0 / 500，1.5 / 500，1.8 / 500
35P C/CAN
ACS48S+-450 HP 48/500 B
CPD20~25-AD1 2.0 / 500，2.5 / 500，
C-35P C/CAN
CPD25-ALD1 ACS80M-330C-
HP80/500C/CAN 2.5 / 500，3.0 / 500，3.5 / 500
CPD30~35-AD1 35P
ACS48S+-450
CPD20~25-AD2-E ACS48S-23P 2.0 / 500，2.5 / 500
C-35P
CPD20-AXC3 Curtis 1234 Curtis 1253 2.0/500
CPD20-AXC4 Curtis 1234 Curtis 1234 12.0/500
CPD10~18-AC4-F 1232SE-5321 1232SE-5321 1.0 / 500，1.5 / 500，1.8 / 500
CPD20-AXC4-F 1232SE-5321 1232SE-5321 2.0 / 500
CPD20~25-AC4-F 1234SE-5421 1232SE-5321 2.0 / 500，2.5 / 500

A series four-wheel
model
CPD25-ALC4-F
1234SE-6321 1234SE-6321 2.5 / 500，3.0 / 500
CPD30-AC4-F
CPD35-AC4-F 1236SE-6521 1234SE-6321 3.5 / 500
CPD10~18-AC4-EF 1232SE-5321 1232SE-5321 1.0 / 500，1.5 / 500，1.8 / 500
CPD20~25-AC4-EF 1234SE-5421 1232SE-5321 2.0 / 500，2.5 / 500

CPD25-ALC4-EF
1234SE-6321 1234SE-6321 2.5 / 500，3.0 / 500
CPD30-AC4-EF
CPD35-AC4-EF 1236SE-6521 1234SE-6321 3.5 / 500
CPD10/15/18-AC6 F4-A FA-A
1.0 / 500，1.5 / 500，1.8 / 500,2.0/500
CPD20-AXC6 48-375-001 48-375-001
F4-A FA-A
CPD20/25-AC6 2.0 / 500，2.5 / 500
48-450-001 48-375-001
CPD30-AC6 F6-A F6-A
3.0 / 500,2.5/500
CPD25-ALC6 80-375-101 80-375-101
F6-A F6-A
CPD35-AC6 3.5 / 500
80-450-101 80-375-101
F10-A F6-A
CPD40/45/50-AC6 4.0 / 500，4.5 / 500，4.99 / 500
80-550-001 80-450-101
A series Drive Pump Rated capacity(t) / Load center

PC motor
four-wheel model Motor Motor (mm)
FJ-03-10 FJ-04-10 FJ-02-10-48V
CPD10~18-AF4 1.0 / 500，1.5 / 500，1.8 / 500
-48V/450A -48V/450A -1.5T-KDS-HC
FJ-03-10 FJ-04-10 FJ-02-10-48V
CPD20~30-AF4 2.0 / 500，2.5 / 500，3.0 / 500
-48V/450A -48V/450A -3T-KDS-HC
FJ-03-10 FJ-04-10 FJ-02-10-80V
CPD35-AF4 3.5 / 500
-80V/500A -80V/500A -3.5T-KDS-HC
© 11/2022 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 ....................................................................................... 28
Main pump .......................................................................................................... 29
Control valve ....................................................................................................... 30
5. LIFTING SYSTEM .............................................................................................. 32
Data .....................................................................................................................32
Fault .................................................................................................................... 33
Mast .................................................................................................................... 34
Lifting cylinder ..................................................................................................... 36
Tilting cylinder ..................................................................................................... 36
6. ELECTRICAL SYSTEM ........................................................................................ 37
Controller .............................................................................................................37
Electrical system principle diagram ..................................................................... 70
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
DC motor
Rated Rated Rated Rated Max. Excitations Insulation Cooling Protecting Ration Weight
Power Voltage Current Speed Speed Mode Grade Mode Grade
Model
kW V A r/m r/m min kg
Series
XQ-7A 7.0 45 180 1400 2400 F IC01 IP20 60 112
excitation
motor
Series
XQ-10.2 A 10.2 75 162.5 1500 2400 F IC01 IP20 60 120
excitation
Separated
XQD-8.6-3D-1 8.6 45 248 1600 3000 F IC01 IP20 5 47
excitation
Separated
XQD-10-3D-1 10.0 75 160 2000 3000 F IC01 IP20 15 90
excitation
The marker, sign and connecting type of exceed cable or terminal of motor
A1：Motor armature's head
A2：Motor armature's end

Series excitation motor
D1：Shunt excitation's head
D2：Shunt excitation's end
A1：Motor armature's head
A2：Motor armature's end

Separated excitation motor
F1：Separated Excitation excitation's head
F2：Separated Excitation excitation's end

Connection mode：
Series excitation motor
1
Separate excitation motor
Height above sea level No exceed 1200m
Environment temperature
400C/-25℃
Electromotor highest/lowest
applied range
Relative temperature Until on the surface of motor dew 100%
Cooling air Must not contain volatile gas
Three times of rated current ,admit time is one

Most work Tractor motor minute
current of the
motor One point eight times of rated current,admit time is
Lifting motor、steering motor
one minute
Admit temperature Rolling bearing （ Environment
95℃
temperature not exceed 40℃）
From brush box catadrome side to surface of the
2～4mm
commutation
Cooling insulation resistance （ When it approach work < 45V 0.5MΩ
temperature, please measure by 250Vmegohmmeter）。 45V～110V 1MΩ
Brush Metal plumbagin brush trade J201 chart No 5CZ、578
2
DC motor failure diagnosis
Failure phenomenon Possible cause

All of sheet copper
Brush’s pressure is wrong
nigrescence
Parts is short circuit
Parts of commutator according
Armature coil is short
to a certain order nigrescence
Parts of commutator is not fasten to armature coils open circuit
Parts of commutator are Commutator’s center line location change

nigrescent, but without definite
rule Commutator’ s surface is rough, out of round
Motor vibration
Clearance between brush and box is bigger.

Working surface distance between the box and commutator is
Brush wear and tear, change bigger
colors and break
Mice between parts of commutator extrude
Material of the brush is bad
Trademark of the brush is wrong
Motor overload
Commutator is unholy
Commutator is rough or out of round
Mica or parts of commutator extrude
Brush seat grinding is bad

Sparkle strong
The pressure of brush is not enough big
Trademark of the brush is wrong
The brush lock in the box
The brush frame is loose or vibrational
The polarity and tactic order of magnetic pole is wrong
The sparkle of brush is strong
The brush and wire heat The brush is not contacted with the cable
The cable is thinner
The brush have noise The surface of the commmutator is rough
3
DC motor of the use and maintain
The commutator has four check windows, with which you can observe and maintain the
commutator and brush. There are four average distributing magnetic poles in seat. The magnetic
pole coil is made of F state copper thread, dipping with F state insulating varnish. Parts of stator
and neutral position of brush have been adjusted; users mustn’t unpack and adjust randomly.
– Check armature for rotation and void frictionize.
– Check outgoing line of electric machine for connection.
– Brush should slide freely in the brush hold box.
– Check reverse chip for neatness, if need be，clear canaliculus between the reverse chip or the
commutator surface of powder, can used cleanly calico of soft and no thread downy , maybe
surface had oil ,calico can dip alcohol when wiping (stop process).
– Check all fasteners whether fastened.
– Brush’s shelf must reliable fastened, can’t become flexible. If need running or disassembly
brush’s shelf ， must make out marker ， can become flexible bolt. When the brush’s shelf
reposition, aim at marker line, screw down bolt, in order to keep brush in the former neutral
location.
– Winding isolating resistance should check of fix a date, when near work’s temperature, under
rule data, otherwise should put up dry.
– Fix a date open window shutter, check inside part whether transmutation and reverse partial
circs whether up to snuff.
– You should often clean bed load and other dirt on the motor’s shell, in order to giving out heat
quantity best.
– Every half year check motor one time as follow:
a. Inspect exterior and clean the dust for the motor；
b. Clean or replace bearing, during running it is permitted to giving off abnormal noise for
bearing；
c. Inspect the brush’s abrasion, if necessary replace it.
Burnishing for brush：
– When replaces the brush, using “00” thin emery
cloth to burnishing it. During burnishing you can
haul the emery cloth leftward or rightward.
– After burnish the brush and clean the
commutator with emery cloth, the motor should
lowered voltage and limiting speed to running
under load, in order to safety, till the brush’s
working face is shined.
4
AC motor
Rated Rated Rated Rated Max. Insulation Cooling Protecting Duty Weight
Power Voltage Current Speed Speed Grade Mode Grade
Model
kW V A r/m r/m kg
HPB8.6-4-C 8.6
HPB8.6-4 8.6 31 248 1600 3200 F IC00 IP44 S3-15% 65
HPB10-4HC 10 51 161.6 2000 / F IC01 IP44 S3-15% 80
HPQ8-4HC-A 8 33 182 3158 4500 IC411 IP20 82.5
HPQ11-4HC-A 11 33 241 2783 4500 IC411 IP20 94
HPQ15-4HC-A 15 55 198 2731 4500 IC411 IP20 102
XYQ-18-ZD 18 56 250 3100 H IP54 S2 60min 120
XYQ-16.6-ZD 16.6 56 250 3100 H IP54 S2 60min 145
HPB25.4-4 25.4 51 387 1620 3200 H IC00 IP20 5 min 115
CAUTION
 AC motor don’t have commutator and brush，not need maintain. You must check and
clear dust everyday.
5
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
6
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
7
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
N 10～29
torque at hub blot
Axial play of wheel bearing mm less than 0.08
Weight kg 125~130 195-198 202-208 350～380
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
Worn or damaged wheel hub bearing. Replace

Unstable driving
Loose driving axle and body connecting blots. Tighten
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.
8
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
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
9
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.
10
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
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.
CAUTION
 Be careful not to damage oil seal and outer race.
11
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:10～29N（refer to Fig.1-6）.
– Measure axial play of wheel hub to see if it is within specification. Axial play is less than
0.08mm （refer to Fig.1-7）.
Fig.1-6 Fig.1-7
12
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
13
Steering axle
General specifications
Axle body
Center support, swing type
type
Vertical play（mm） 0-1
Inner 1.0t~1.8t 79.5º
wheel 2.0t~3.5t 80º
Turning
angle 1.0t~1.8t 56º Adjusting shim for end
Outer shaft of axle thickness 0.5, 1.0, 1.6
wheel 2.0t~3.5t 55.7º （mm）
Tyre
0.8 MPa Part No. N163-220020-000
pressure
Kingpin wheel hub bearing
Kingpin axial play（mm） Less than 0.20 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（mm） Part No.
torque at hub blot 10-29.8N
Axial
0.10, 0.30, 0.70 N163-220012-000 Less than 0.10
play(mm)
Truck type 1.0t～1.8t CPD20-AXC4 2.0t-2.5 t 3.0t-3.5 t 4.0 t～5.0 t
Weight（kg） 66～68 66～68 96-99 98-100 135～150
Trouble diagnoses corrections
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
14
15
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.
16
– Adjust axial play to specification with shims. Axial plays less than 0.15mm.
– 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 0.10mm.
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
17
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
18
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
19
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
20
Replace brake shoe:
– Place the forklift truck on level concrete.
– Start the forklift and raise carriage about 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 2 to 3
km/h, set foot on brake pedal 2～3 times.
21
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.
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.
22
1.Mounting screw
2.Stator component
6 3.Braking friction plate

5
4.Axle sleeve
4
3
5.Friction disk
2
1
6. Dust cover
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
23
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).
5
– Put friction disk(5) on the motor end face.
– Cover the braking friction plate(3) above the shaft sleeve.

3
– Assemble stator component(2) and three mounting

screws(1). Note: remove three rubber pads from the stator
1
component.
2
– Screw down there mounting screws(1) with torque

wrench(14), and check braking air gap “Z” with feeler
gauge(15). 14
Z 15
– Put dust cover（6）.

– Connect brake wire. 6
24
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
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
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”
25
– 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.
1
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.
– General use environment temperature is -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.
26
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

Unstable operation in previous
Breaking-in for a while
use
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
27
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
28
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.
29
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
30
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 20Mpa. b.
taper thread at pressure mouth matches: Rc1/8R1/8; c. tightening torque is 20-22N•m.
(4) Start the engine, place the mast in vertical, and the fork is 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.
1.0t: 13MPa, 1.5t:15MPa, 1.8t:18.5MPa, 2.0t~3.5t:18.5MPa±0.25 MPa;
4.0t~5.0t:18.5MPa±0.5 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 20-22N•m. Drop the mast
to the ground and tilt backward to end.
(9) Retighten the tightening nut, and fix it on the front soleplate.
31
5. Lifting system
Data
Inspection and adjustment
Assly clearance Repair clearance
Place
(mm) (mm)
Mast to lift roller 0.1～0.8 0.2～1
Shims 0.5/1.0/2.0
Mast to back up metal 0.1～0.8 0.2～1
Shims 0.5/1.0/2.0
Inner mast to carriage side roller 0.1～0.6 0.2～1
Shims 0.5/1.0/2.0
Lift chain deflection 25～30 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） 22～29（M8），44-58（M10）
Lift cylinder fixing bolt（U type） 14～18（M8），29-39（M10）
32
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.
33
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
34
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
35
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
36
6. Electrical system
Controller
CURTIS 1244 Controller
Summarize
Curtis PMC 1244 MultiMode controllers are separately excited motor speed controllers designed
for use in a variety of material handling vehicles. These programmable controllers are simple to
install, efficient, and cost effective.
Typical applications include low lifts, stackers, fork lifts, reach trucks, personnel carriers,
counterbalance trucks, order pickers, boom trucks, and other industrial vehicles.
The 1244 MultiMode controller offers smooth, silent, cost effective control of motor speed and
torque. A four quadrant, full-bridge field
Winding control stage is combined with a two quadrants, half-bridge armature power stage to
provide solid state motor reversing and regenerative braking power without additional relays or
contactors. The 1244 controller can also be specified to be compatible with CAN Bus
communication systems.
These controllers are fully programmable by means of the optional handheld 1307 programmer.
Use of the programmer provides diagnostic and test capability as well as configuration flexibility.
Like all Curtis PMC motor controllers, the 1244 offers superior operator control of the vehicle’s
motor drive speed. Features include:
Full-bridge field and half-bridge armature power MOSFET design, providing: Infinitely variable
forward, reverse, drive, and brake control；Silent high frequency operation；High efficiency.
– Regenerative braking, providing longer operation on a single battery charge and reducing
motor brush wear and motor heating.
– Programmability through the 1307 handheld programmer
– Complete diagnostics through the 1307 programmer and the internal Status LED
– Two fault outputs provide diagnostics to remotely mounted displays
– Continuous armature current control, reducing arcing and brush wear
– Automatic braking when throttle is reduced from either direction; this provides a compression
braking feel and enhances safety by automatically initiating braking in an operator hands off
condition.
– Deceleration Rate, Load Compensation, and Restraint features prevent downhill runaway
conditions; speed is controlled to within approximately 20% of level surface value.
– MultiMode allows four user-selectable vehicle operating personalities
– Programmable to match individual separately excited motor characteristics
– Meets or exceeds EEC fault detect requirements
– Vehicle top speed is controlled and limited in each mode
Linear temperature and under voltage cutback on motor currents; no sudden loss of power
– under any thermal conditions
37
– High pedal disable (HPD) and static return to off (SRO) interlocks prevent vehicle runaway at
startup
– Creep speed adjustable from 0% to 25% in each mode
– Continuous diagnostics during operation, with microprocessor power-on self-test
– Internal and external watchdog circuits ensure proper software operation
– Programmable coil drivers provide adjustable contactor pull-in and holding voltages
– Hour-meter enable output is active whenever the controller is providing motor current
– Optional Electromagnetic Brake Driver provides automatic control of an electromagnetic
brake or other similar function.
38
CURTIS 1244 Controller Fault code
LED PROGRAMMER LCD
EXPLANATION POSSIBLE CAUSE
Code DISPLAY
HW FAIL SAFE1-2-3 Self-test or watchdog fault 1.Controller defective.
1,2 M-SHORTED Internal M- short to B- 1.Controller defective.
1.Motor field wiring loose.

FIELD OPEN Field winding fault
2.Motor field winding open.
ARM SENSOR Armature current sensor fault 1.Controller defective.
FLD SENSOR Field current sensor fault 1.Controller defective.

1,3
1.VSC input wire open.

THROTTLE FAULT1 Sliding signal overrange
2.VSC input wire shorted to B+ or B-.
1. Throttle pot defective。

2,1 THROTTLE FAULT2 VSC signal exceed range
2. Wrong throttle type selected.
1.KSI interlock and wrong orientation

SRO 2.SRO type wrong.
2.2 SRO failure
3.Interlock or direction switch open circuit
4.Sequencing delay too short.
1.Direction and accelerator sequence error.

HPD 2.HPD type wrong.
2,3 HPD failure
3.Accelerator potentiometer error correction.
4.Sequencing delay too short.
3,1 CONT DRVR OC Cont. driver output over current 1.Contactor coil shorted.
1. Main contactor stuck closed.

3,2 MAIN CONT WELDED Welded main contactor
2. Main contactor driver shorted.
1. Controller defective.
Internal voltage too low at
3,3 PRECHARGE FAULT 2. External short, or leakage path to B- on external
startup
B+ connection.
Missing contactor 1. Any contactor coil open or not connected.

3,4 MISSING CONTACTOR
Main contactor did not close 2.Main contactor missing or wire to coil open.
1. Battery voltage undervoltage cut off。

4,1 LOW BATTERY VOLTAGE Low battery voltage 2. Battery connector corrosion。
3. Battery or controller terminal loose
1. Battery voltage >overvoltage shutdown limit.

4,2 OVERVOLTAGE Overvoltage 2. Vehicle operating with charger attached.
3. Battery disconnected during regen braking.
1.Temperature >85℃ or < -25℃.
2. Excessive load on vehicle.
4,3 THERMAL CUTBACK Over-/under-temp. cutback
3. Improper mounting of controller.
4. Operation in extreme environments.
39
CURTIS 1253 Controller Fault code
LED Programmer
Explanation Possible cause
Code Lcd display
NO voltage or controller is not

OFF
working, error (such as MCII
ON defective)
Controller work normally, no

0,1 ■¤ error
1.EEPROM miss data

2.EEPROM data check error ， use
1,1 ¤¤ EEPROM defective
programmer 1311 to change any
parameter can delete the error.
1.MOSFET short down.

1,2 ¤ ¤¤ Hardware defective
2.Motor circuit is an open circuit.
2,1 ¤¤ ¤ Low voltage 1.Battery voltage is too low.
1.The function of lifting lock of the

2,2 ¤¤ ¤¤ Lifting lock.
controller is touch off.
1.Any switch of SS1-SS4 closes earlier

2,3 ¤¤ ¤¤¤ Order fault（Startup lockout）
than KSI or INTERLOCK.
1.Main contact bonded。

3,2 ¤¤¤ ¤¤ Contact err 2.The set of parameter “CONTACT
CNTRL” is wrong.
1.Pre-charge circuit work with err.

3,3 ¤¤¤ ¤¤¤ Pre-charge fault
2.Motor short down.
1.The connection of main contact coil

Contact has not been installed
3,4 ¤¤¤ ¤¤¤¤ or is not close.
loose.
2.Main contact works abnormally.
The voltage of battery is lower than the set

4,1 ¤¤¤¤ ¤ Low -voltage protect.
value of “LOVOLT CUTBACK”
4,2 ¤¤¤¤ ¤¤ Over-voltage protect. The battery voltage is too high.
1.The temperature of controller is too high

Temperature protect
4,3 ¤¤¤¤ ¤¤¤ （over-/under-temp）
or too low.
2.Temperature sensor works abnormal.
40
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 exceeds 85°C, the maximum current reduces
in proportion to the thermal increase. The temperature can never exceed 115°C; If the electric
machinery temperature exceeds 145°C, the maximum current reduces in proportion to the
thermal increase. The temperature can never exceed 165°C.
– 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;
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.
41
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.
42
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.
1. Leakage to vehicle frame from phase U, V, or W (short in motor stator).
1,3 Current Sensor Fault
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.
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.
1. Controller is performance-limited at this temperature.
Controller Undertemp
2,1 2. Controller is operating in an extreme environment.
Cutback
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.
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.
7. Blown B+ fuse or main contactor did not close.
43
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
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.
3,1 Main Open/Short 2. Dirty connector pins.
3,2 Coil2 Driver Open/Short 2. Dirty connector pins.
3,2 EM Brake Open/Short 2. Dirty connector pins.
3,3 Coil3 Driver Open/Short 2. Dirty connector pins.
Coil4 Driver
3,4 2. Dirty connector pins.
Open/Short
3,5 PD Open/Short 2. Dirty connector pins.
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
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.
44
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.
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.
45
Inmotion Controller
Summarize
International advanced closed-loop system and the advanced control technology are integrated in the
controller. Large screen clearly displays common messages as “power”, “speed”, “total running hours”,
“drive working time”, “lifting working time” and etc. Faults displayed by codes improve the efficiency of
maintenance. The peripheral components can also be detected by the meter, and the functions of the
handheld unit can be realized by the meter.
(1) Actuating motor
Actuating motor adopt three-phase alternating current frequency conversion electromotor ，
increase conversion efficiency，not have commentator brush in order not to maintenance.
(2) Lift motor
Lift motor adopt three-phase alternating electromotor ，increase conversion efficiency，not have
commentator brush in order not to maintenance.
(3) 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 exceeds 85°C, the maximum current reduces
in proportion to the thermal increase. The temperature can never exceed 115°C; If the electric
machinery temperature exceeds 145°C, the maximum current reduces in proportion to the
thermal increase. The temperature can never exceed 165°C.
– 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 cannot commence if these operations are not carried out
correctly. Requests for drive must be made after closing the Key Switch.
– When the electrical components are damaged, the electronic control self-protection can avoid
the enlarged loss
(4) 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.
46
– Three regenerative braking mode:
a. Acceleration pedal part release appear regenerative braking;
b. Direction reverse regenerative braking;
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.
47
warning and error handling for Inmotion
Serial error
Analysis description Solution
number code
1 10 Operation sequence fault Reset all the traction controller switch
2 13 HPG CONTROLLER EEPROM KO Reset key
Incorrect start Accelerator pedal Release pedal switch
3 20
switch active before key on
Incorrect start Forward switch or Turn off the direction switch
4 21
reverse switch active before key on
Forward switch and reverse switch Direction switch fault
5 22
active at the same time
Throttle fault or analog need to be
6 23 Throttle analog value out of range
calibrated
Throttle fault or analog need to be
7 24 Throttle analog fault
calibrated
HPG CONTROLLER BATTERY HPG CONTROLLER BATTERY VOLTAGE
8 30
VOLTAGE LOW LOW NEED CHARGE
Traction controller CAN Check CAN wire of controller and display
9 31
communication fault
10 32 BDI level is too low Need charge
11 33 DC MOTOR VOLTAGE HIGH RESET KEY
12 34 CPU fault Reset key
More than one pump functions are Reset all the pump speed mode switchs
13 35
active at the same time
Incorrect start Tilt switch active
14 36 Reset tilt switch
before key on
Incorrect start Side switch active
15 37 Reset side switch
before key on
Incorrect start Attachment switch
16 38 Reset attachment switch
active before key on
Incorrect start Lift switch active
17 39 Reset lift switch
before key on
18 40 Lift analog value out of range Lift analog fault or need to be calibrated
19 43 Steer analog value out of range Steer analog fault or need to be calibrated
1、Vehicle speed is too high alarm
20 44 Traction controller speed protection
2、Traction motor encoder fault
1、Traction controller encoder fault
21 45 Traction controller encoder fault
2、Traction motor speed sensor connection
48
Serial error
number code
wire is open
DC MOTOR OPERATING CURRENT IS 1、HPG CONRTOLLER SENSOR FAULT
22 49
ZERO 2、Pump motor Open
1、Check power wiring
23 51 Slave traction controller short
2、Controller enable before contactor pull
DC bus voltage of Slave traction Battery need charge
24 52
controller is low cut back
1、HPG CONRTOLLER OVER CURRENT
25 53 HPG CONRTOLLER OVER CURRENT
2、Pump motor fault
1、Vehicle overload or Mechanical clamping
26 54 Slave traction controller over current
2、Slave traction motor speed sensor fault
DC bus voltage of Slave traction DC bus voltage of Slave traction controller
27 55
controller is high cut back is high cut back
DC bus voltage of Slave traction DC bus voltage of Slave traction controller
28 56 controller is high cut back(Hardware is high cut back(Hardware monitoring)
monitoring)
Slave traction controller precharge Replace the pre charge resistance
29 57
failed
1、Slave traction motor temperature is high
Slave traction motor temperature is need cool
30 58
high cut back 2、Slave traction motor temperature sensor
fault
Slave traction controller temperature Slave traction controller temperature is
31 59
is high cut back high need cool
Slave traction controller temperature Slave traction controller temperature
32 60
sensor fault sensor fault
change the Slave traction motor encoder
33 61 Slave traction motor controller fault
AB
HPG CONTROLLER TEMPERATURE HPG CONTROLLER TEMPERATURE HIGH
34 62
HIGH NEED COOL
1、Slave traction motor temperature sensor
Slave traction motor tenperature is fault
35 63
sensor fault 2、Slave traction motor temperature sensor
connection wire is open
Open drain of Slave traction output Check the wire of open drain of Slave
36 64
open or short traction output open or short
37 65 Slave traction Internal power supply Slave traction motor temperature sensor or
49
Serial error
number code
error speed sensor connection wire is open
HPG CONTROLLER BATTERY LOW NEED
38 66 HPG CONTROLLER BATTERY LOW
CHARGE
Slave traction motor encoder fault
39 67 Slave traction motor encoder fault Slave traction motor speed sensor
40 74 HPG CONTROLLER DRIVER SHORTED HPG CONTROLLER DRIVER SHORTED
41 76 HPG CONTROLLER COIL SHORTED HPG CONTROLLER COIL SHORTED
HPG CONTROLLER VACC NOT OK

42 78 HPG CONTROLLER VACC NOT OK
HPG CONTROLLER INCORRECT HPG CONTROLLER INCORRECT START

43 79
START
Traction controller temperature is low
44 81 Traction controller temperature is low
alarm
Traction controller temperature is Traction controller temperature is high
45 82
high alarm
Traction controller temperature Traction controller temperature sensor
46 83
sensor fault fault
1、Traction motor temperature is low
47 84 Traction motor temperature is low 2、Traction motor temperature sensor is
fault
1、Traction motor temperature is high
48 85 Traction motor temperature is high 2、Traction motor temperature sensor is
fault
1、Traction motor temperature sensor is
Traction motor tenperature sensor fault
49 86
fault 2、Traction motor temperature sensor
1、Traction motor encoder fault
50 87 Traction motor encoder fault 2、Traction motor speed sensor connection
wire is open
DC bus voltage of traction controller 1、DC bus voltage high
51 88
is high 2、The ramp is too steep
DC bus voltage of traction controller
52 89 Need to charge or check power wiring
is low
The default value of the traction
53 90 Reset key
controller is updated
50
Serial error
number code
54 91 Traction drive limit Battery low vehicle speed limit
Open drain of traction output open or Check the wire of open drain of traction
55 97
short output open or short
Traction controller over current or
56 98 Check power wiring
short
1、Check power wiring
57 101 Traction controller short
2、Controller enable before contactor pull
Traction controller temperature is high
Traction controller temperature is
58 102 need cool
high cut back
1、Traction motor temperature is high need

Traction motor temperature is high
59 103 cool
cut back
2、Traction motor temperature sensor fault
1、Vehicle overload or Mechanical clamping
60 104 Traction controller over current
2、Traction motor speed sensor fault
61 105 Traction controller precharge failed Replace the pre charge resistance

62 110 Battery need charge
is low cut back
DC bus voltage of traction controller DC bus voltage of traction controller is high
63 111
is high cut back cut back
DC bus voltage of traction controller is high
64 112 is high cut back(Hardware
cut back(Hardware monitoring)
monitoring)
Traction controller Internal power Traction motor temperature sensor or
65 114
supply error speed sensor connection wire is open
66 121 Pump controller temperature is low Pump controller temperature is low alarm
67 122 Pump controller temperature is high Pump controller temperature is high alarm
Pump controller temperature sensor Pump controller temperature sensor fault
68 123
fault
1、Pump motor temperature is low
69 124 Pump motor temperature is low
2、Pump motor temperature sensor fault
1、Pump motor temperature is high
70 125 Pump motor temperature is high
51
Serial error
number code

71 126 Pump motor temperature sensor fault 2、Pump motor temperature sensor
1、Pump motor speed sensor fault

72 127 Pump controller encoder fault 2、Pump motor speed sensor connection
wire is open
DC bus voltage of pump controller is DC bus voltage of pump controller is high
73 128
high
DC bus voltage of pump controller is
74 129 Check power wiring
low
The default value of the pump
75 130 Reset key
76 132 Pump drive limit Battery voltage low need charge
Open drain of pump output open or Check the wire of open drain of pump
77 137
78 138 Pump controller over current or short Check power wiring

79 141 Pump controller short
Pump controller temperature is high
80 142 Pump controller temperature is high alarm
cut back
Pump motor temperature is high cut
81 143 Pump motor temperature is high alarm
back
Pump controller current calibration
82 144 Reset key
error
83 145 Pump controller precharge failed Replace the pre charge resistance
84 148 BMS fault, Parking BMS fault，Check the battery
85 149 BMS secondary fault
DC bus voltage of pump controller is DC bus voltage of pump controller is low
86 150
low cut back cut back
87 151
high cut back cut back
88 152
high cut back(Hardware monitoring) cut back(Hardware monitoring)
1、Reset key
89 153 Pump controller CPU fault 2、Pump motor temperature sensor or
speed sensor connection wire is open
90 154 Pump controller speed control fault 1、Pump speed is too high alarm
52
Serial error
number code
2、Pump motor encoder fault
BMS Temperature Warning，Reduce
91 156 BMS fault，Check the battery
Power
92 157 BMS Temperature Protection, Parking BMS fault，Check the battery
BMS Voltage Warning, Reduce
Power
94 159 BMS Voltage Protection，Parking BMS fault，Check the battery
CHECK DISPLAY AND CONTROLLER CAN
95 161 DISPLAY CAN FAULT
CONNECTION
96 163 BMS Current Warning，Reduce Power BMS fault，Check the battery
BMS Feedback Current Protection，
Parking
Seat switch off after a period of time,
98 165 Reset direction switch
the direction of the request to reset
99 168 BMS indicates Limit Current alarm BMS indicates Limit Current alarm
100 169 BMS indicates cutoff Current alarm BMS indicates cutoff Current alarm
DC bus voltage of Slave traction

controller is low
DC bus voltage of Slave traction 1、DC bus voltage high
102 171
controller is high 2、The ramp is too steep
The default value of the Slave traction
103 172 Reset key
1、Slave traction motor temperature is low
Slave traction motor temperature is
104 173 2、Slave traction motor temperature sensor
low
is fault
1、Slave traction motor temperature is high
Slave traction motor temperature is
105 174 2、Slave traction motor temperature sensor
high
is fault
Slave traction controller temperature Slave traction controller temperature is low
106 176
is low alarm
Slave traction controller temperature Slave traction controller temperature is
107 177
is high high alarm
Slave traction controller speed 1、Vehicle speed is too high alarm
108 178
protection 2、Slave traction motor encoder fault
109 180 BMS indicates brake Current alarm BMS indicates brake Current alarm
110 181 BMS CAN Error BMS CAN Error
53
Serial error
number code
111 182 BMS Fault Check BMS
Open drain of slave traction output Check the wire of open drain of slave
112 185
open or short traction output open or short
113 200 Proportional valve error Proportional valve error
114 201 Steer controller short Check power wiring
Steer controller temperature is high Steer controller temperature is high need
115 202
cut back cool
1、Steer motor temperature is high need
Steer motor temperature is high cut
116 203 cool
back
2、Steer motor temperature sensor fault
117 205 Steer controller precharge failed Replace the pre charge resistance
DC bus voltage of Steer controller is
118 206 Battery need charge
low cut back
DC bus voltage of Steer controller is DC bus voltage of Steer controller is high
119 207
high cut back cut back
1、Steer motor encoder fault
120 210 Steer motor encoder fault 2、Steer motor speed sensor connection
wire is open
1、Steer motor temperature sensor is fault
121 211 Steer motor tenperature sensor fault 2、Steer motor temperature sensor
Steer controller temperature sensor
122 212 Steer controller temperature sensor fault
fault
Steer controller Internal power supply Steer motor temperature sensor or speed
123 214
error sensor connection wire is open
Open drain of Steer output open or Check the wire of open drain of Steer
124 217
1、Steer motor temperature is low
125 218 Steer motor temperature is low
1、Steer motor temperature is high
126 219 Steer motor temperature is high
127 220 Steer controller temperature is low Steer controller temperature is low alarm
128 221 Steer controller temperature is high Steer controller temperature is high alarm
129 222 DC bus voltage high
high
low
54
Serial error
number code
Steer Controller Internal power Steer motor temperature sensor or speed
131 234
supply error sensor connection wire is open
CHECK CAN WIRE OPEN AND CAN SPEED
132 241 HPG CONTROLLER CAN BUS KO
RATE
HPG CONTROLLER BATTERY OVER HPG CONTROLLER BATTERY OVER
134 242
VOLTAGE VOLTAGE
133 243 HPG CONTROLLER KEY SHORTED HPG CONTROLLER KEY SHORTED
HPG CONTROLLER WATCHDOG
134 244 HPG CONTROLLER WATCHDOG ERROR
ERROR
135 245 Attachment switch status error Reset attachment switch status
HPG CONTROLLER WAITING FOR TURN OFF THE PUMP CONCTACTOR
136 246
MAIN CONTACTOR PARAMETER
55
ZAPI controller
Italian ZAPI controller is reliable and high efficient, with great speed control. On the instrument is
state of charge, speed, total run time. If malfunctioned, cause of failure can be quickly and
efficiently determined by fault code or fault module part number. Operator can choose four
operation mode for different working conditions by using the instrument buttons.
Walking controller delivers excellent speed control and reliable regenerative braking performance.
– The motor velocity is controlled by the accelerator. Regenerative braking system will be
activated if speed increases above the default;
– Braking system (electric braking on the slope) will be activated if parked on a slope for a
preset time;
– Regenerative braking system for speed reducing on a slope;
– Regenerative braking system for accelerator pedal release (slowing down);
– Regenerative braking ratio can be adjusted to proportionally by analog input;
– High sensitivity at low speed;
– Longer driving torque (with current control) when started or overloaded.
– Electric braking system will be activated by the inverter;
The oil pump controller is designed for electric forklifts to improve better controller control. It
consists of “lift”, “forward/backward”, “power-assisted steering”, “side shifting(forward)” control
levers. It guarantees the speed while it has the characteristics as stably, safety, precision, bottom
noise, no arc spark, no large current impact to the battery when started.
Cautions：
1. No reverse of the battery polarity of the controller assembly.
2. Battery nominal voltage shall be no more than controller assembly nominal voltage.
3. No inversely connected U, V, W phase wires.
4. No connection between the charging circuit and the controller when charging.
5. Take safety measures during assembly, test run and maintenance, especially when galloping,
high current arc and battery liquid splashing.
56
ZAPI Fault code
Microcontroller Vehicle
Restart the
fault list Error Description Function status after
program
code test
Main contactor is not
FLASH checksum closed, Key switch
MDI mode allarm Program detects the fault electromagnetic brake Start restart the
71 starts, traction/lifting system
stop
Main contactor
Analog disconnects,
Analog channel, no reading Traction/liftin
MDI mode allarm electromagnetic brake Start, run
update g request
96 starts, traction/lifting
stop
Difference between the key
closed,
switch voltage and battery Traction/liftin
Wrong set battery electromagnetic brake Start
nominal voltage is 20% larger g request
starts, traction/lifting
than the standard voltage.
stop
Cpacitor charge closed,
Power capacitor voltage does not Traction/liftin
MDI mode allarm electromagnetic brake Start
increase g request
stop
Coil shorted hw ko The main contactor or solenoid closed,
Traction/liftin
MDI mode allarm valve/short auxiliary coil is electromagnetic brake Start
g request
76 damaged starts, traction/lifting
stop
Main contactor
disconnects(command
Driver shorted Main contactor drive circuit
has sent), start Start, stand Traction/liftin
MDI mode allarm shorted, unable to open the
electromagnetic by, run g request
74 contactor
brake, traction/lifting
stop
Main contactor
disconnects(command
Solenoid valve/auxiliary drive
has sent), start Start, stand Traction/liftin
Aux driver shorted circuit shorted, unable to open
electromagnetic by, run g request
the contactor.
stop
Main contactor
Safety in disconnects, Key switch
Safety input disconnect （ do not Start, stand
MDI mode allarm electromagnetic brake restart the
connect-BATT） by, run
stop
Main contactor
Safety output drive circuit is disconnects,
Traction/liftin
Safety out electromagnetic brake Start
damaged （short or open）. g request
stop
Main contactor
disconnects, Key switch
Watchdog#1 Incorrect status of watchdog Start, stand
electromagnetic brake restart the
MDI mode allarm 8 circuit signal #1 by, run
starts, traction/lifting system
stop
closed, Key switch
Watchdog #2 Incorrect status of watchdog Start, stand
electromagnetic brake restart the
MDI mode allarm 8 circuit signal #2 by, run
starts, traction/lifting system
stop
Keyoff shorted closed, Key switch
Cut off the circuit low logic signal
MDI mode allarm electromagnetic brake Start restart the
at startup
stop
57
Restart the
program
code test
closed,
Logic failure#1 Detect too low or too high voltage Start, stand Traction/liftin
electromagnetic brake
MDI code alarm 54 signal by, run g request
stop
Main contactor is not Traction/liftin
Logic failure #3 closed, g request
High current protection circuit is
damaged
stop
Main contactor is not Traction/liftin
Power mos shorted closed, g request
MDI mode allarm MOS tube shorted electromagnetic brake Start
stop
closed,
Start, stand Traction/liftin
VMN high Overhigh motor output voltage electromagnetic brake
by g request
stop
Main contactor
VMN low disconnects,
Traction/liftin
MDI mode allarm Too low motor output voltage electromagnetic brake Start, run
g request
stop
In the standby condition (no
Stby I high closed,
motor supply current), current Traction/liftin
feedback value exceeds the g request
allowable range
stop
closed,
Wrong 0 voltage Feedback value of motor phase Traction/liftin
electromagnetic brake Start
MDI code allarm 53 voltage is out of range g request
stop
Contactor closed closed,
Traction/liftin
MDI mode allarm LC contactor blocked electromagnetic brake Start
g request
stop
Watchdog circuit emitted fault closed, Key switch
Hardware fault 20 signal cannot close MOS driver electromagnetic brake Start restart the
circuit. starts, traction/lifting system
stop
The main contactor or solenoid closed, Key switch
Hardware fault 21 valve/short auxiliary coil is electromagnetic brake Start restart the
damaged starts, traction/lifting system
stop
Watchdog circuit emitted fault closed, Key switch
Hardware fault A1 signal cannot close main electromagnetic brake Start restart the
contactor driver circuit. starts, traction/lifting system
stop
Main contactor After the
Coil shorted MC disconnects, main
Traction/liftin
MDI mode allarm Main contactor coil shorted electromagnetic brake contactor is
g request
76 starts, traction/lifting closed, start,
stop stand by, run
Coil shorted EF Solenoid valve/ auxiliary coil Main contactor After the
Traction/liftin
MDI mode allarm shorted disconnects, main
g request
68 electromagnetic brake contactor is
58
Restart the
program
code test
starts, traction/lifting closed, start,
stop stand by, run
Main contactor After the
Contactor open disconnects, main
Main contactor coil is activated Traction/liftin
MDI mode allarm electromagnetic brake contactor is
but not closed g request
77 starts, traction/lifting closed, start,
stop stand by, run
Main contactor
disconnects(command
Logic failure#2
Feedback circuit of motor phase has sent), start Stand by, Traction/liftin
MDI mode allarm
voltage is damaged(fail to close) electromagnetic run g request
55
stop
Main contactor
disconnects(command
Contactor driver
Main contactor drive circuit is has sent), start Stand by, Traction/liftin
MDI mode allarm
damaged(fail to close) electromagnetic run g request
75
stop
Main contactor
Solenoid valve/ auxiliary drive disconnects,
Stand by, Traction/liftin
Aux Driver Open circuit is damaged( fail to start the electromagnetic brake
run g request
solenoid valve) starts, traction/lifting
stop
Main contactor
disconnects,
Encoder Error Traction/liftin
Encode reading error electromagnetic brake Run
MDI code allarm 82 g request
stop
Main contactor
Program detected that the
Wrong Ram disconnects, Key switch
registration information of
Memory electromagnetic brake Continue restart the
memory can be erased and find
MDI code allarm 71 starts, traction/lifting system
the error value
stop
Accelerator / lifting potentiometer
Vacc not OK value is greater than the Traction/pump motor Start, stand Traction/liftin
MDI code allarm 78 minimum record value, while the stop by, run g request
direction / enable switch is off
Incorrect start Traction/pump motor Start, stand Traction/liftin
Incorrect start sequence
MDI code allarm 79 stop by, run g request
Accelerator input signal is beyond
the scope of the minimum
Vacc out of range acceleration signal value - the Traction/pump motor Start, stand Traction/liftin
MDI code alarm 85 maximum acceleration signal stop by, run g request
value, the range is set by the
parameter PROGRAMM VACC
Linear decrease of the
The controller temperature current value of
Temperature reaches 85 ℃ at maximum traction controller from Continue
MDI code allarm 62 current, and forms speed maximum(85℃) to 0A
reducing condition
（105 ℃）
Motor temperature sensor is
Maximum current
Motor temperature disconnected (if it is a digital
halved and speed Continue
MDI code alarm 65 sensor) or exceed 150 ℃
reduced
threshold (if analog sensors)
In the case where the request No function, only
without the hand brake, the brake display fault signal Traction/liftin
Brake run out Continue
potentiometer input signal is the through handheld g request
maximum value. programmer
Traction request signal and the
Stand by, Traction/liftin
Handbrake hand brake input signal are Traction motor stop
run g request
effective at the same time
59
Restart the
program
code test
The maximum current gain
Current Gain parameters is factory defaults, Controller worked but
Start, stand
MDI code allarm indicating the maximum current lower than maximum
by
92 adjustment program is not current
implemented
Sens mot temp KO Output signal of motor Maximum current
MDI code allarm temperature sensor is out of halved and speed Continue
65 range reduced
Thermic sens Ko Output signal of controller Maximum current
MDI code allarm temperature sensor is out of halved and speed Continue
61 range reduced
Slip profile
Wrong Slip profile parameter Traction/pump motor Traction/liftin
MDI code alarm Continue
setting stop g request
99
EEPROM KO Controller used
MDI code allarm Eeprom error parameter is the Continue
71 default one
Forward+Backward Walking command is effective in Start, stand Traction/liftin
Traction stop
MDI code alarm 80 forward and backward directions by, run g request
60
Chinese FJ controller
FJ controller, independently developed by FJ, owns good compatibility and the communication
control accuracy, and also the programmable functions to electronic control system parameters.
Compact instrument can display all the electronic control system analog and digital signals, clearly
show the "state of the charge", "speed", "total run time" currently running "energy mode" and other
common information. Fault code is adopted to improve maintenance efficiency. Instrument can
enter two modes: 1. Diagnostic mode, to check the truck system parameters and recent 10 fault
information. 2. Calibration mode (turn off this mode), not only to check various system parameters
and fault information, but also modify the system parameters. To avoid users mistakenly adjusting
the system parameters causing the truck unable to work properly, it is prohibited to activate the
function of instrument calibration system parameters through the PC software
Fault code and solution of Chinese FJ controller
Battery overvoltage protection
 Fault code:1
 Fault level:1
 Fault reason: The instant battery voltage exceeds 63V by the internal measurement for the control unit.
 Solutions：
1、 Check if the battery is well connected with the electronic control system
2、 Check if the battery voltage level is normal.
3、 Replace control unit.
Battery undervoltage protection

 Fault code:2
 Fault level:1
 Fault reason: The instant battery voltage is lower than 24V by the internal measurement for the control unit.
 Solutions:
1、 Check if the battery wiring is right, positive and negative electrode contact is severely rusted.
2、 Check the battery status: If the battery electrolyte is partially depleted, it may trigger the controller
undervoltage protection fault; or even work at a large current with little battery power (for example, oil
pump motor and drive motor are working with full load), undervoltage protection fault may also be
triggered.
Accelerator pedal has been depressed before start

 Fault code:3
 Fault level:1
 Fault reason: During system power-on self-test(main circuit breaker is not closed), the driver depresses the
accelerator pedal in advance.
 Solutions:
1、 Ifthe fault code is caused by the driver depresses the accelerator pedal in advance during system
power-on self-test (main circuit breaker is not closed), please release accelerator pedal and restart.
2、 Check calibration> acceleration pedal calibration setting value, see if the minimum and maximum
voltage value of accelerator pedal is accurate, or re-calibrate with PC monitoring software or instrument
for setting.
3、 Check if 42-pin connector of the main control and accelerator pedal terminals is properly connected, if
no problem, depress the accelerator pedal through the PC monitoring software, observe if the pedal
feedback voltage value is in the correct range.
K1-17(12V)
K1-30(grounded)
K1-18(pedal feedback signal input)
Flash fault alarm

 Fault code:5
 Fault level:1
 Fault reason: there is one or more control parameter value of vehicle performance or motor in the control unit
is beyond the allowable range or error is found when writing check(write and read inconsistency)
 Solutions:
1、 Flash reload default: Use FJ monitoring software, path: calibration> enable settings> "* restore system
default" setting, amend the parameter corresponding "new value" to "ON", power on again, the system
will automatically bring up the default parameters
2、 If the warning has not been relieved after plan 1 power on again, replace control unit
61
Pre-charging capacitor low pressure alarm
 Fault code:6
 Fault level:1
 Fault reason: The voltage level of pre-charging capacitor during motor running is lower than 70% of battery
voltage level over the same period.
 Solutions:
1、 After power on, it starts to work after contact is closed.
2、 Check if the main circuit breaker coil terminal and the main wiring harness terminal are connected
properly; the correct connection is as follows：
K1-29(positive)
K1-15(negative)
3、 Check if main circuit breaker is in good condition.
4、 Replace main circuit breaker.
Drive motor power module unsaturated or overcurrent

 Fault code:8
 Fault level:1
 Fault reason: Actual current of drive power module exceeds the limit value.
 Solutions：
1、 Check if the drive module and motor UVW three-phase cable connection is shorted (short circuit among
three-phase cable or certain-phase cable short with truck frame), check whether the motor coil burning
smells.
2、 Check if the pin 26 cable between control unit and the drive module is properly connected.
3、 Disconnect power module UVW cable connection, use multimeter high resistance to check if the
resistance value between +/-B terminal and UVW terminal is symmetrical, if one phase resistance differs
a lot from other phases, the power module has been burned and needs to replace.
Pre-charging capacitor charged too fast

 Fault code:9
 Fault level:1
 Fault reason: The pre-charging capacitor voltage increases too fast during system power on.
 Solutions：
2、 Replace the power modules one by one to exclude the drive and pump power modules.
Pump motor power module overheat alarm

 Fault code:10
 Fault level:6
 Fault reason: The pump motor power module temperature exceeds 90℃.
 Solutions：
1、 The fault may be caused by insufficient heat dissipation, check the heat dissipation between the power
module and aluminum plate, as well as between aluminum plate and truck frame, an appropriate
amount of thermal grease evenly between them is effective necessary to ensure cooling.
NOTE: Read the pump motor power modules temperature through FJ PC software or meter.
2、 If the above module cooling measures are good, you need to check if the pump motor works normally,
especially check if the lifting potentiometer and each switch control signal of the multiway valve lever
can reset normally; secondly, consider replacing the pump power module.
Pre-charging capacitor fails to effectively discharge when system startup

 Fault code:11
 Fault level:1
 Fault reason: Pre-charging capacitor reserved charge fails to discharge effectively during the system
power-on self-test.
 Solutions：
1、 Check if pump motor and pump power muddle UVW connecting cable is connected well, or 26 pin cable
of pump power module and control unit is normally connected.
2、 Replace pump motor power module.
62
Battery low voltage alarm
 Fault code:12
 Fault level:3
 Fault reason: Battery voltage is lower than discharge protection value（calibration>battery calibration> battery
discharge protection value）.
 Solutions：
1、 Charge the battery. Please note that if the battery voltage level is still below the "battery reset value"
(see calibration> battery calibration> battery reset value) after charging, then the fault code will not be
removed. It is necessary to ensure that the battery voltage is higher than "battery reset value" after
charging, the fault code will be removed, and the truck is allowed to work.
2、 Measure the battery voltage, replace the control unit if the measured value is in discrepancy with
“battery discharge protection value”.
Drive motor overheating alarm

 Fault code:13
 Fault level:5
 Fault reason: The measurement value of drive motor temperature is about to arrive the allowable maximum
temperature set by the user (calibration> drive motor> drive motor overheat protection point).
 Solutions：
1、 First check if the motor temperature sensor and main harness is correctly connected.
2、 The failure occurs if the motor is not hot：
1) Put a handheld multimeter in resistance measurement mode, measure the resistance value
between two lines of motor temperature sensor and compare with the truth table, if the measured
value is in discrepancy with the actual motor temperature, replace the temperature sensor.
2) Replace control unit.
3、 The failure occurs if the motor is very hot：
1) If the actual temperature is consistent with the one read from the meter or PC monitoring software,
check if the motor case is clean or the motor heat dissipation is normal.
2) Check if the drive motor works normally or if there is brake locking or other abnormal conditions.
Pump motor overheating alarm

 Fault code:14
 Fault level:6
 Fault reason: The measurement value of pump motor temperature is about to arrive the allowable maximum
temperature set by the user (calibration> pump motor>pump motor overheat protection point).
 Solutions：
1、 First check if the motor temperature sensor and main harness is correctly connected.
2、 The failure occurs if the motor is not hot：
1) Put a handheld multimeter in resistance measurement mode, measure the resistance value
between two lines of motor temperature sensor and compare with the truth table, if the measured
value is in discrepancy with the actual motor temperature, replace the temperature sensor.
2) Replace control unit.
3、 The failure occurs if the motor is very hot：
1) If the actual temperature is consistent with the one read from the meter or PC monitoring software,
check if the motor case is clean or the motor heat dissipation is normal.
2) Check if the motor works normally, especially check that the pump motor continuously work for a
long time due to the potentiometer or switch signal of the multiway valve lever cannot reset
normally, long time working of pump motor will cause overheat.
Drive motor current loss

 Fault code:15
 Fault level:1
 Fault reason: Drive motor phase current is not zero when system boots up.
 Solutions：
1、 Check if 26 pin cable between motor power module and control unit is correctly connected.
2、 Replace the power module.
Main circuit breaker coil overcurrent alarm

 Fault code:17
 Fault level:1
 Fault reason: Main circuit breaker current is too large.
 Solutions：
1. Check if there is external short of the main circuit breaker.
63
2. Replace main circuit breaker.
3. Replace control unit.
Drive motor power module overheating

 Fault code:20
 Fault level:5
 Fault reason: Drive motor power module temperature exceeds 90℃.
 Solutions：
1、 The fault may be caused by insufficient heat dissipation, check the heat dissipation between the power
module and aluminum plate, as well as between aluminum plate and truck frame, an appropriate
amount of thermal grease evenly between them is effective necessary to ensure cooling. NOTE: Read
the motor power modules temperature through FJ PC software or meter
2、 If the above module cooling measures are good, you need to check if the drive motor works normally,
abnormal work of the motor will lead to overheating of the power module; secondly, consider replacing
the power module.
Pump motor power module unsaturated or overcurrent

 Fault code:24
 Fault level:1
 Fault reason: Actual current of pump motor power modules exceeds the limit value.
 Solutions：
1、 Check if the pump module and motor UVW three-phase cable connection is shorted (short circuit among
three-phase cable or certain-phase cable short with truck frame), check whether the motor coil burning
smells.
2、 Check pin 26 connection cable between control unit and the pump module is properly connected.
3、 Disconnect power module UVW cable connection, use multimeter high resistance to check if the
resistance value between +/-B terminal and UVW terminal is symmetrical, if one phase resistance differs
a lot from other phases, the power module has been burned and needs to replace.
Pump motor current loss

 Fault code:36
 Fault level:1
 Fault reason: Pump motor phase current is not zero when system boots up.
 Solutions：
1、 Check if 26 pin cable between pump power module and control unit is correctly connected.
2、 Replace pump power module.
Control unit 5V voltage output fault

 Fault code:37
 Fault level:1
 Fault reason: Control unit K 1-16 connector (5V output) voltage is below 4.3V.
 Solutions：
1、 Check if 5V output is grounded, each motor encode wiring is correct.
2、 Exclude control unit 5V output used external components using one by one.
Control unit 12V voltage output fault

 Fault code:38
 Fault level:1
 Fault reason: Control unit K 1-17 connector (12V output) voltage is below 10.5V.
 Solutions：
1、 Check if 12V output is grounded, generally it is caused by the wrong wiring of the following devices：
 Accelerator pedal
 Elevation sensor
 Steering sensor
 Instrument
2、 Exclude control unit 12V output used external components one by one
Pump motor command bar activated when system startup
64
 Fault code:50
 Fault level:7
 Fault reason: The lifting potentiometer or tilting lever or other auxiliary function switch signal is activated when
the system boots up.
 Solutions：
1、 Reset all activated command（including lifting potentiometer and each switch signal）.
2、 Check if lifting potentiometer voltage is beyond the set value, use FJ PC software to
recalibrate(calibrate>improve the calibration)
Drive motor overheating shutdown

 Fault code:61
 Fault level:1
 Fault reason: The measurement value of drive motor temperature exceeds the allowable maximum
temperature set by the user (calibration> drive motor>drive motor overheat protection point).
 Solutions：
The same with fault 13.
Seat switch not closed when startup

 Fault code:63
 Fault level: Warning
 Fault reason: The seat switch is not closed during system power on; or after the main circuit breaker is closed,
seat switch off exceeds the time set by the parameter “seat switch delay”(menu calibration>time setting>seat
delay time)
 Solutions：
1、 Check if the seat switch is virtually connected or damaged.
Wrong starting condition

 Fault code:64
 Fault level: warning
 Fault reason: The forward/reverse switch is activated during the power on.
 Solutions：
1、 Check if the forward/reverse switch is activated when the truck is started.
2、 If the direction switch is not activated, check if the direction switch terminal and main harness terminal
are connected correctly. Carry out auxiliary check by FJ PC monitoring software.
3、 Replace direction switch.
Pump motor overheating shutdown

 Fault code:65
 Fault level:1
 Fault reason: The measurement value of pump motor temperature exceeds the allowable maximum
temperature set by the user (calibration> pump motor>pump motor overheat protection point).
 Solutions：
Drive motor power module overheating shutdown

 Fault code:66
 Fault level:1
 Fault reason: Drive motor power module temperature exceeds 95℃.
 Solutions：
Pump motor power module overheating shutdown

 Fault code:68
 Fault level:1
 Fault reason: Pump motor power module temperature exceeds 95℃.
 Solutions：
The same with 10.
Drive motor power module temperature sensor fault

 Fault code:71
65
 Fault level:5
 Fault reason: Feedback value of the drive motor power module temperature sensor exceeds the
measurement range.
 Solutions：
1、 Check if 26 pin cable between drive motor power module and control unit is correctly connected.
2、 Replace drive motor power module.
Pump motor power module temperature sensor fault

 Fault code:72
 Fault level:6
 Fault reason: Feedback value of the pump motor power module temperature sensor exceeds the
measurement range.
 Solutions：
1、 Check if 26 pin cable between the pump motor power module and control is correctly connected.
2、 Replace pump motor power module.
Pump motor encode fault

 Fault code:73
 Fault level:2
 Fault reason: Encode(A or B) channel signal suddenly lost during the pump motor running.
 Solutions：
1、 Check if the encode is correctly connected to：
 Motor itself
 Grounded：K1-30 connector
 +5V：K1-16 connector
 A channel：K1-35 connector
 B channel：K1-36 connector
2、 If it is correctly and well connected, replace the encoder.
Drive motor encode fault

 Fault code:74
 Fault level:2
 Fault reason: Encode(A or B) channel signal suddenly lost during the drive motor running
 Solutions：
1、 Check if the encode is correctly connected to：
 Motor itself
 Grounded：K1-30 connector
 +5V：K1-16 connector
 A channel：K1-32 connector
 B channel：K1-33 connector
2、 If it is correctly and well connected, replace the encoder..
Drive motor temperature sensor fault

 Fault code:77
 Fault level:8
 Fault reason: Drive motor temperature is higher than the pump motor, and the temperature difference
exceeds 70℃.
 Solutions：
1、 Check if the drive motor temperature sensor and main harness connection is normal.
2、 Replace the drive motor temperature sensor.
Pump motor temperature sensor fault

 Fault code:79
 Fault level:8
 Fault reason: Pump motor temperature is higher than the drive motor r, and the temperature difference
exceeds 70℃.
 Solutions:
66
1、 Check if the temperature sensor of pump motor and main harness connection is normal.
2、 Replace pump motor temperature detector.
Drive motor power module temperature sensor fault

 Fault code:80
 Fault level:8
 Fault reason: Drive motor power module temperature is higher than the pump motor power module, and the
temperature difference exceeds 70℃.
 Solutions:
1、 Check if 26 pin cable between the drive module and control unit is correctly connected.
2、 Replace drive power module.
Pump motor power module temperature sensor fault

 Fault code:82
 Fault level:8
 Fault reason: Pump motor power module temperature is higher than the drive motor power module, and the
temperature difference between the two motor power module exceeds 70℃.
 Solutions:
1、 Check if 26 pin cable between the pump module and control unit is correctly connected.
2、 Replace pump power module.
CRC Error
 Fault code:83
 Fault level:1
 Fault reason: Wrong software version
 Solutions:
1、 Use FJ PC monitoring software to restore factory default parameter(Calibrate>enable setting>restore
system default)
2、 If fault code still exists, replace control unit.
Driving startup sequence error

 Fault code:85
 Fault level:9
 Fault reason: Direction switch is not turned on before depressing the accelerator pedal while driving
 Solutions：
1、 Release the accelerator pedal, activate the direction switch and then depress the accelerator pedal.
Steering sensor fault

 Fault code:91
 Fault level:5
 Fault reason: The feedback voltage of steering sensor exceeds the calibration range.
 Solutions：
1、 Check if the following connection is correct:
 K1-17(12V)
 K1-30(grounded)
 K1-31(steering sensor feedback signal input )
2、 If the wiring is good, re-calibrate the steering sensor values clockwise, counterclockwise and median
value (calibration> smart steering).
3、 Replace the steering sensor, re-calibrate.
Pedal accelerator fault

 Fault code:92
 Fault level:2
 Fault reason: Accelerator pedal feedback voltage value > the sum of the minimum value and half of
difference between the set minimum and maximum values, but the accelerator pedal is not closed at this
time.
 Solutions:
1、 Check calibration> the setting accelerator pedal calibration value, see if the accelerator pedal minimum
and maximum voltage value is accurate, or re-calibrate, set with PC monitoring software.
2、 Check if 42 pin terminals of the main harness control unit and accelerator pedal terminals is properly
67
connected, if no problem, depress the accelerator pedal through the PC monitoring software, observe if
the pedal feedback voltage value is in the correct range:
 K1-17(12V)
 K1-30(grounded)
 K1-18(Pedal feedback signal input)
3、 Replace accelerator pedal
Lifting potentiometer fault

 Fault code:93
 Fault level:2
 Fault reason: Lifting potentiometer feedback voltage value > the sum of the minimum value and half of
difference between the set minimum and maximum values, and the lifting switch is not closed at this time.
 Solutions：
1、 Check if the lifting potentiometer voltage exceeds the set value, re-calibrate with FJ PC monitoring
software (calibration>improve the calibration)
2、 Replace lifting potentiometer
Pump motor temperature sensor short circuit fault

 Fault code:94
 Fault level:6
 Fault reason: The feedback resistance value of the pump motor temperature sensor exceeds the normal
range, tends to be zero.
 Solutions：
1、 Check if the pump motor temperature sensor and main harness connection is normal.
2、 Replace pump motor temperature sensor.
Drive motor temperature sensor short circuit fault

 Fault code:95
 Fault level:5
 Fault reason: The feedback resistance value of the drive motor temperature sensor exceeds the
normal range, tends to be zero.
 Solutions：
2、 Replace drive motor temperature sensor.
Pump motor temperature sensor open circuit fault

 Fault code:96
 Fault level:6
 Fault reason: The feedback resistance value of the pump motor temperature sensor exceeds the normal
range, tends to be infinite.
 Solutions：
1、 Check if the pump motor temperature sensor and main harness connection is normal.
2、 Replace pump motor temperature sensor.
Drive motor temperature sensor open circuit fault

 Fault code:97
 Fault level:5
 Fault reason: The feedback resistance value of the drive motor temperature sensor exceeds the normal
range, tends to be infinite.
 Solutions：
2、 Replace drive motor temperature sensor.
Capacitor precharging too slow

 Fault code:98
 Fault level:1
 Fault reason: The precharging capacitor voltage increases too slow during power-on self-test,
68
 Solutions：
1、 Check if the connecting cable between control unit and two power modules is correctly connected.
2、 Replace the power module one by one to exclude the drive and pump power modules
69
Electrical system principle diagram
CPD10/15/18/20/25/30/35-A
70
CPD10/15/18-AC3
71
CPD20/25-AC3
CPD25-ALC3 CPD20-AXC3
72
CPD30/35-AC3
73
CPD10/15/18/20/25/30/35-AC4 CPD10/15/18/20/25/35-AC4-F
CPD25-ALC4 CPD25-ALC4-F CPD25-AC4-A CPD20-AXC4 CPD20-AXC4-F
74
CPD10/15/18/20/25/30/35-AC4 （OPS option ）
75
DC转换器
IDD-43C 智能仪表
CPD10/15/18/20/25/30/35-AD2
CPD25-ALD2 CPD25-AD2-A
76
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
CPD10/15/18/20/25/30/35-AC4-I
CPD25-ALC4-I Electrical system principle diagram
77
CPD40/45/50-AC4-I
78
钥匙开关
KEY 1A1
前进
FWD 1A4
后退
BWD 1A5
SAFETY IN 1A11
座椅开关
SEAT 1A6
1A10
PPOT 1A2
CPOT 1A3
-BATT 1A9
ACE 2
TRACTION
48/80V
350/450A HB 1A13
NEB 1A18
SMART DISPLAY
PLC/PEB 1A17
NLC 1A16
CAN L 1A20
CAN H 1A21
HP-48/80V
PUMP
350/500A
CPD10/15/18/20/25/30-AZ3 CPD25-ALZ3
79
钥匙开关
KEY F1
前进
FWD E5
后退
BWD E6
座椅开关
SEAT F4
E14
PPOT E2
CPOT E1
AC 2 NPOT E3
TRACTION
80V/450A HB E7
PEB F3
NEB F9
NMC F8
PMC F2
SMART DISPLAY
CAN L C1
CAN H C3
CAN L OUT C2
CAN H OUT C4
HP-80V
PUMP
500A
CPD35-AZ3
80
钥匙开关
KEY 1A1
前进
FWD 1A4
后退
BWD 1A5
SAFETY IN 1A11
座椅开关
SEAT 1A6
1A10
PPOT 1A2
CPOT 1A3
-BATT 1A9
ACE 2
TRACTION
48V/450A
SMART DISPLAY
HB 1A13
NEB 1A18
PLC/PEB 1A17
NLC 1A16
CAN L 1A20
CAN H 1A21
SEAT 2A6
CAN L 2A20
CAN H 2A21
CAN T 2A12
KEY 2A1
2A4
ACE 2 2A5
PUMP 2A10
48V/450A
SAFETY IN 2A11
PPOT 2A2
CPOT 2A3
-BATT 2A9
NAUX 2A18
PLC/PEB 2A17
NLC 2A16
SAFETY OUT 2A19
CPD10/15/18/20/25-AZ4
81
CPD25-ALZ4 CPD30/35-AZ4
82
CPD30-AF4
83
钥匙开关
10A
KEY 1A1
前进
FWD 1A4
后退
BWD 1A5
1A10
PPOT 1A2
10A
CPOT 1A3
-BATT 1A9
ACE 3 座椅开关
STANDARD SEAT 1A6
TRACTION
80V/550A
SMART DISPLAY
NEB 1A18
PLC/PEB 1A17
NLC 1A16
CAN L 1A20
CAN H 1A21
SEAT 2A6
CAN L 2A20
CAN H 2A21
CAN T 2A12
KEY 2A1
2A4
2A5
ACE 3
2A11
STANDARD
PUMP
80V/550A
PPOT 2A2
CPOT 2A3
-BATT 2A9
NAUX 2A18
PLC/PEB 2A17
NLC 2A16
CPD40/45/50-AZ4
84
CPD40/45/50-AC4 Electrical system principle diagram
85
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
CPD10~35-AC4-E CPD25-ALC4-E CPD10~35-AC4-EF CPD25-ALC4-EF Electrical system principle diagram
86
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
CPD10/15/20/25/30/35-AC4-EI CPD25-ALC4-EI Electrical system principle diagram
87
钥匙开关
KEY 1A1
前进
FWD 1A4
后退
BWD 1A5
SAFETY IN 1A11
座椅开关
SEAT 1A6
1A10
PPOT 1A2
CPOT 1A3
-BATT 1A9
ACE 2
TRACTION
48/80V
350/450A
NEB 1A18
SMART DISPLAY
PLC/PEB 1A17
NLC 1A16
CAN L 1A20
CAN H 1A21
（OPT）
（OPT）
HP CAN-48/80V
PUMP
350/500A
CPD10/15/20/25/30-AZ3-E CPD25-ALZ3-E Electrical system principle diagram
88
钥匙开关
KEY 1F1
前进
FWD 1E5
后退
BWD 1E6
座椅开关
SEAT 1F4
1E8
PPOT 1E2
CPOT 1E1
NPOT 1E3
AC 2
TRACTION 1F5
80V/450A 1F11
PEB 1F3
NEB 1F9
NMC 1F8
PMC 1F2
SMART DISPLAY
CAN L 1C1
CAN H 1C3
CAN L OUT 1C2
CAN H OUT 1C4
HP CAN-80V
PUMP
500A
CPD35-AZ3-E Electrical system principle diagram
89
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
CPD10/15/20/25/30/35-AC3-E CPD25-ALC3-E Electrical system principle diagram
90
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
CPD10~25-AC4-NA Electrical system principle diagram
91
CPD10~15-AD2-I Electrical system principle diagram
92
93
94
DC转换器
ACS 80M
440C-35P
ACS 80M
440C-23P
CPD40/45/50-AD2-I Electrical system principle diagram
95
DC
ACS 80M
440C-35P
ACS 80M
440C-23P
IDD-43C
CPD40/45/50-AD2 Electrical system principle diagram
96
DC转换器
PUMP
CPD15/18/20/25/30/35-AD1 Electrical system principle diagram
97
3401T meter
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Acceleration enabling
Accelerated analog quantity
Pressure analog quantity
Overload alarm (optional)
CPDCPD10/15/18/20/25/30/35-AC6 CPD20-AXC6 CPD25-ALC6 Electrical system principle diagram
98
3401T meter
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Acceleration enabling
Accelerated analog quantity

+12V
Lifting analog quantity
Pressure analog quantity
Overload alarm (optional)
CPDCPD40/45/50-AC6 Electrical system principle diagram
99
Maintenance record
Date Maintain content Maintainer

Revision Table
Revision Version no. Date Note

00 SM21-A01 03/2022 Original
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

SM-A-1.0-X5.0-Electric Four-Wheel Forklift-202211-EN-CE

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SM-A-1.0-X5.0-Electric Four-Wheel Forklift-202211-EN-CE

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Available Formats

A Series

A series 1.0t-5.0t Lead acid Battery Counterbalanced Forklift Truck

HANGCHA GROUP CO., LTD.

CPD20~30-AC3 Curtis 1236 Curtis 1253 2.0 / 500，2.5 / 500，3.0 / 500

CPD35-AC3 Curtis 1238 Curtis 1253 3.5 / 500

CPD10~18-AC4 Curtis 1234 Curtis 1234 1.0 / 500，1.5 / 500，1.75 / 500

CPD20~25-AC4 Curtis 1236 Curtis 1234 2.0 / 500，2.5 / 500

CPD30-AC4 Curtis 1236 Curtis 1236 3.0 / 500

CPD35-AC4 Curtis 1238 Curtis 1236 3.5 / 500

CPD25-ALC4 Curtis 1236 Curtis 1236 2.5 / 500

CPD20~25-AC4-I Curtis 1236 Curtis 1234 2.0 / 500，2.5 / 500

CPD30-AC4-I Curtis 1236 Curtis 1236 3.0 / 500

CPD35-AC4-I Curtis 1238 Curtis 1236 3.5 / 500

CPD40~50-AC4-I 1238E-6521 1236SE-6521 4.0 / 500，4.5 / 500，4.99 / 500

CPD10~18-AC4-E Curtis 1232SE Curtis 1232SE 1.0 / 500，1.5 / 500，1.8 / 500

CPD20~25-AC4-E Curtis 1234SE Curtis 1232SE 2.0 / 500，2.5 / 500

CPD20~25-AC4-EI Curtis 1234SE Curtis 1232SE 2.0 / 500，2.5 / 500

CPD10~18-AC4-EI Curtis 1234SE Curtis 1234SE 1.0/500, 1.5/500, 1.8/500

CPD25-ALC4-EI Curtis 1234SE Curtis 1234SE 2.5/500

CPD10~18-AD2-I Inmotion Inmotion 1.0 / 500，1.5 / 500，1.8 / 500

CPD20~25-AD2-I Inmotion Inmotion 2.0 / 500，2.5 / 500

CPD35-AC3-E 1236SE-6521 1253-8001 3.5 / 500

ACE2 HP 48/500 B 1.0 / 500，1.5 / 500，1.8 / 500，

CPD10~18-AC4-NA 1234SE-5421 1234SE-5421 1.0 / 500，1.5 / 500，1.8 / 500

CPD20~25-AC4-NA 1236SE-5621 1234SE-5421 2.0 / 500，2.5 / 500

CPD20-AXC4 Curtis 1234 Curtis 1234 12.0/500

CPD10~18-AC4-F 1232SE-5321 1232SE-5321 1.0 / 500，1.5 / 500，1.8 / 500

CPD20-AXC4-F 1232SE-5321 1232SE-5321 2.0 / 500

CPD20~25-AC4-F 1234SE-5421 1232SE-5321 2.0 / 500，2.5 / 500

CPD10~18-AC4-EF 1232SE-5321 1232SE-5321 1.0 / 500，1.5 / 500，1.8 / 500

CPD20~25-AC4-EF 1234SE-5421 1232SE-5321 2.0 / 500，2.5 / 500

A series Drive Pump Rated capacity(t) / Load center

A1：Motor armature's head

A2：Motor armature's end

D2：Shunt excitation's end

A1：Motor armature's head

A2：Motor armature's end

F2：Separated Excitation excitation's end

Height above sea level No exceed 1200m

Cooling air Must not contain volatile gas

Three times of rated current ,admit time is one

Brush Metal plumbagin brush trade J201 chart No 5CZ、578

Failure phenomenon Possible cause

Parts of commutator are Commutator’s center line location change

Clearance between brush and box is bigger.

Material of the brush is bad

Trademark of the brush is wrong

Commutator is rough or out of round

Mica or parts of commutator extrude

Brush seat grinding is bad

Trademark of the brush is wrong

The brush lock in the box

The brush frame is loose or vibrational

The polarity and tactic order of magnetic pole is wrong

The sparkle of brush is strong

The cable is thinner

The brush have noise The surface of the commmutator is rough

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

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

HPQ8-4HC-A 8 33 182 3158 4500 IC411 IP20 82.5

HPQ11-4HC-A 11 33 241 2783 4500 IC411 IP20 94

HPQ15-4HC-A 15 55 198 2731 4500 IC411 IP20 102

XYQ-18-ZD 18 56 250 3100 H IP54 S2 60min 120

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