A Series

ELECTRIC STACKER CQDB12/16/20-AC1S

CQDB12/16/20-AZ3S
CQDB12/16/20-AC1S-I
CQDB12/16/20-AZ3S-I
CQDB12/16/20-AC2S
CQDB12/16/20-AC2S-I

OPERATION AND MAINTENANCE MANUAL

Original Instruction

HANGCHA GROUP CO., LTD.

1/2023
 FOREWORD
Thank you very much for purchasing the A series high range stand-on electric stacker with mast
move of Hangcha Group.
The truck combines benefits of regular stacker and counterbalanced stacker. It can be used for
non-standard pallets, enclosed pallets, and enclose shelves. The mast can be retracted into truck
body, which reduces passage width required for operation significantly, and the stacker is an ideal
vehicle for operation in narrow passage. Cutting-edge AC control technology applied for the truck
offers excellent performance, comfortable operation, safety and reliability, and low maintenance
cost.
Part Ⅰ of this manual is about the brief introduction and correct operation of the A series high
range stand-on electric stacker with mast move, which will tell you how to operate safely and
maintain preventively; part Ⅱ will tell you the structure, working principle and maintenance of the
A series high range stand-on electric stacker with mast move. In order to guarantee safety and
utilize the truck performance to the best, relevant operator and maintainer must read this manual.
Because of the update and improvements of our products, there may be some differences
between this operation manual contents and your electric stacker.
If you have any questions, please contact HANGCHA GROUP CO., LTD. sales company or the
agent.

© 1/2023 HANGCHA GROUP CO., LTD

 Contents
Part Ⅰ: Operation and maintenance .............................................................................................1
1 Correct Use and Application ..................................................................................................... 1
1.1 General ...................................................................................................................................... 1
1.2 Correct application .....................................................................................................................1
1.3 Approved application conditions ............................................................................................... 2
1.4 Cautions for the use of cold storage truck ................................................................................ 3
1.5 Cautions for the use of lithium battery truck ............................................................................. 4
1.6 Proprietor responsibilities ..........................................................................................................5
1.7 Attachment installation or modification to the truck .................................................................. 5
2 Truck introduction ......................................................................................................................6
2.1 Truck models meaning .............................................................................................................. 6
2.2 Main parts and Functional Description ..................................................................................... 7
2.2.1 Main part introduction ............................................................................................................... 7
2.2.2 Functional Description .............................................................................................................. 8
2.3 Displays and Controls ............................................................................................................. 10
2.3.1 Display .....................................................................................................................................12
2.3.2 Open or down the safety side arms ........................................................................................15
2.4 Standard technical specifications ............................................................................................16
2.5 Product plates and warning labels location ............................................................................ 20
3 Safety Rules ............................................................................................................................22
4 Transport ................................................................................................................................. 25
4.1 Lifting the truck by crane ......................................................................................................... 25
4.2 Securing the truck for transport ...............................................................................................26
4.3 Transport ..................................................................................................................................27
5 Battery ..................................................................................................................................... 28
5.1.1 Attention for using battery .................................................................................................... 28
5.1.2 Safety precautions for using lithium battery ........................................................................... 29
5.2 Dimension / Weight ................................................................................................................. 32
5.3 Charging the battery ................................................................................................................33
5.4 Changing the battery ............................................................................................................... 40
6 New truck breaking-in ............................................................................................................. 41
7 Operation ................................................................................................................................ 42
7.1 Check before operation ........................................................................................................... 42
7.2 Starting up ............................................................................................................................... 44
7.3 Travel ....................................................................................................................................... 45
7.4 Braking .....................................................................................................................................46
7.5 Steering ....................................................................................................................................46
7.6 Parking .....................................................................................................................................46
7.7 Loading .................................................................................................................................... 46
7.8 Unloading .................................................................................................................................48
7.9 Parking the truck as required .................................................................................................. 48
8 Deposit the truck ..................................................................................................................... 49
8.1 Deposit the truck for long time ................................................................................................ 49
8.2 Start running after deposit for a long time .............................................................................. 49
9 Maintenance ............................................................................................................................50
9.1 Maintenance general ...............................................................................................................50
9.2 Periodic maintenance schedule .............................................................................................. 51
9.3 Truck used oil and lubrication ..................................................................................................54
9.4 Replace the key safe parts periodically .................................................................................. 56
9.5 Screw down the wheel retaining nut ....................................................................................... 56
9.6 Removing the rear panel assy ................................................................................................ 57
9.7 Removing the safety guard ..................................................................................................... 58
9.8 Install the load bracket ............................................................................................................ 59
9.9 Adjust the forks ........................................................................................................................ 60
Part Ⅱ: Structure, Principle and Maintenance .......................................................................... 61
1 Drive system ........................................................................................................................... 61
1.1 Reduction gearbox .................................................................................................................. 62
1.1.1 Working principle .....................................................................................................................62
1.1.2 Dismount and assemble order ................................................................................................63
1.1.3 Notice to installment and use ..................................................................................................63
1.1.4 Fault and troubleshooting ....................................................................................................... 63
1.2 Motor ........................................................................................................................................64
1.3 Electromagnetic brake .............................................................................................................71
1.3.1 Working principle .....................................................................................................................72
1.3.2 Brake installment .....................................................................................................................73
1.3.3 Brake air gap adjustment ........................................................................................................75
1.3.4 Maintenance ............................................................................................................................76
1.3.5 Common fault and troubleshooting .........................................................................................77
1.4 Schematic diagram of braking ................................................................................................... 78
2 Hydraulic system .....................................................................................................................79
2.1 Hydraulic system working principle .........................................................................................79
2.2 Hydraulic unit ...........................................................................................................................80
2.3 Hydraulic system fault diagnosis and correction .................................................................... 81
3 Electric system ........................................................................................................................82
3.1 Principles of electrical system .................................................................................................82
3.2 Fault code table ....................................................................................................................... 88
Attachment：Table for bolt’s tightening torque ..............................................................................139
Relevant safety directive or standard (CE or optional) ................................................................. 140
 Part Ⅰ: Operation and maintenance
1 Correct Use and Application
1.1 General
The industrial truck described in the present operating instructions is designed for lifting, lowering
and transporting load units.
It must be used, operated and serviced in accordance with the present instructions. Any other type
of use is beyond the scope of application and can result in damage to personnel, the industrial
truck or property.

1.2 Correct application

－
Lifting and lowering of loads.
－
Transporting the lowered loads.
－
Do not carry or lift passengers.
－
Do not overload.
－
Do not push or pull load units.
－
Do not work together on the same goods by multiple pallet trucks.

1
1.3 Approved application conditions
－
Used in specified area as factory, tourist attraction and recreation place.
－
Operation only on secure, level surfaces with sufficient capacity.
－
Operation only on routes that are visible and approved by the proprietor.
－
Use in specified rated load.
－
Average environment temperature under continuous operating condition +25℃.
－
The highest environment temperature in the short term (≤1h) +40℃.
－
The lowest environment temperature under normal indoor conditions when operation +5℃.
－
The lowest environment temperature under normal outdoor conditions when operation
-20℃.
－
Altitude: ≤2000m.
－
Negotiating inclines up to a maximum of 10 %.
－
It is prohibited to travel crosswise or obliquely. When going uphill with loads, keep the loads in
front; when going downhill, keep people in front.
WARNING
It’s prohibited to use the truck in the area of the explosion.
Special equipment and authorisation are required if the truck is to be used in extreme conditions (e.g. co

Cold-storage truck should meet the followings when working:

According to different grade of cold-storage truck, operate in cold storage based on standard
continuous working time. The recommended working times of our trucks are as follows:
－
Do not work continuously over 2 hours in the cold storage above -18℃;
－
Do not work continuously over 15 minutes/hour in the -18℃～-30℃cold storage.
Working condition for lithium battery:
－
Best operating temperature range: 15℃～35℃；
－ Charging temperature range: 0℃～40℃，No charging below 0℃.

－ Discharging temperature range: -20℃～55℃, discharge capacity at low temperature(-20℃～

0℃) is lower compared with normal temperature condition; battery can be used at 40℃～
55℃ temperature, but too high ambient temperature of battery may accelerate the aging of
inner battery material and shorten the battery service life;
Ambient humidity: HR≤85%, battery should be used under dry condition.
2
1.4 Cautions for the use of cold storage truck
－ Use special oil for cold storage, maintain and replace
－ All cold storage trucks cannot be shut down or parked in cold storage, or it may
damage of hydraulic system and electric
－ Before entering the cold storage, do necessary hydraulic and traction motion to
cold-storage truck, and then enter the cold storage after temperature
－ If there is condensate water on the truck surface after the truck left the cold storage, only
the surface is dry or the condensate water is complete dry can the truck enters the
storage
－ Shorten the maintenance period of the lubricating point to avoid its premature
－ Battery cannot be empty for a long time after discharging, charge in time to keep
electrolyte proportion and avoid electrolyte
－ Different truck models with operations can improve each truck functions in the cold
－ If the truck malfunctioned in the cold storage, remove it from the cold storage immediately
repair in buffer zone or maintenance area.

3
1.5 Cautions for the use of lithium battery truck
－
Never charge below 0℃;
－
If the lithium battery needs to interrupt or suspend charging, do not hot plug, avoid current arc
to damage charging base;
－
Charge the lithium battery immediately after per discharge to avoid battery loss;
－
Never place the battery near high temperature heat source, such as fire and heater etc.;
－
Do not use the battery in a location where static electricity and magnetic field is great,
otherwise, the safety devices may be damaged, causing hidden trouble of safety. Avoid
－
using the battery under high temperature for a long time, otherwise, it may cause
overheat of the battery or function invalid or service life being shortened;
－
Do not operate the electric truck with lithium battery at the temperature above 55℃ or below
-20℃;
－
Do not dismantle the battery box under any circumstance;
－
Never drop or knock the battery box etc.;
－
Short circuit of the battery is prohibited, never put any other object or tool to avoid battery
short circuit;
－
Never wash battery box directly, prevent water getting into the battery and ensure the safety;
－
It's forbidden to mix batteries of different brands, volumes and types;
－
Battery should be kept in a cool and dry place and avoid direct sunlight;
－
Do not change the battery setting parameter at will without the permission of the
manufacturer;
－
If the lithium battery is not used for a long time, it is necessary to charge and discharge the
battery once a month.

4
1.6 Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” is defined as any natural or
legal person who either uses the industrial truck himself, or on whose behalf it is used. In special
cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with
existing contractual agreements between the owner and user of the industrial truck, is charged
with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose for which it is
intended and that there is no danger to life and limb of the user and third parties. Furthermore,
accident prevention regulations, safety regulations and operating, servicing and repair guidelines
must be followed. The proprietor must ensure that all users have read and understood these
operating instructions.
Failure to comply with the operating instructions shall invalidate the warranty. The same applies if
improper work is carried out on the truck by the customer or third parties without the permission of
the manufacturer.

1.7 Attachment installation or modification to the truck

Without authorization by the manufacturer, it is not allowed to modify the truck privately.
The mounting or installation of any attachments which will interfere with, or supplement, the
functions of the truck is permitted only after written approval by the manufacturer has been
obtained. If necessary, the approval of local authorities has to be obtained.
Without the prior written approval of the original manufacturer, its authorized representative or its
successor, any change to the truck that may influence its performance, such as rated capacity,
stability or security, is not allowed. Changes include brake, steering, vision or dismountable
attachment. When the manufacturer or its successor approve to changes of the vehicle, it also
needs to make corresponding modification to vehicle nameplate, decals, logo and brochures. In
the event the truck manufacturer is no longer in business and there is no successor in the
interest to the business, the user may arrange for a modification or alteration to a powered
industrial truck manufacturer and the user shall:
a ) Arrange for the modification or alteration to be designed, tested and implemented by an
engineer(s) expert in industrial trucks and their safety;
b ) Maintain a permanent record of the design, test(s) and implementation of the modification or
alteration;
c ) Approve and make appropriate changes to the capacity plate(s),decals, tags and instruction
handbook;
d ) Affix a permanent and readily visible label to the truck stating the manner in which the truck has
been modified or altered together with the date of the modification or alteration, and the name and
address of the organization that made the modification or alteration.

5
 Model Meaning 2 Truck
CQDB Electric electric stacker introduction
12,16,20 Rated capacity ×100kg 2.1 Truck models
A Series meaning
C1,Z3,C2 Controller type The rated capacity depends on
the model. Users can get
S Folding platform
relevant information as rated
I lithium battery
load from the product model.

The rated capacity does not generally match the permissible capacity. The capacity can be found
on the load chart attached to the rack.

6
2.2 Main parts and Functional Description
2.2.1 Main part introduction

12
17
11

16
3

15

14
6
13

10
7
8 9
Item Component Item Component

1 Tiller 10 Battery

2 Meter 11 Battery panel

3 Lock switch 12 Lift cylinders

4 Safety side arms 13 Reach cylinder

5 Rear panel assy 14 Load wheels

6 Folding operator platform 15 Load backrest

7 Drive wheel 16 Forks

8 Emergency Disconnect switch 17 Mast

9 Key switch

7
2.2.2 Functional Description
Safety Mechanisms
－
Pressing the Emergency Disconnect switch rapidly cuts out all electrical functions in
hazardous situations.
－
Traveling speed will be automatically reduced after fork lifting 500mm.
－
Automatic speed reduction for cornering. Curve Control limits the speed and acceleration
when cornering. This reduces the risk of oscillations or tipovers.
－
Release braking, reverse braking, and three types of emergency braking can ensure safety of
traveling.
－
Anti-sliding function on slope can ensure safety of operation.
－
The belly button on top of operating handle can avoid the driber from injury effectively in case
of emergency during backward driving of the pallet truck.
－
The soft landing system reduces declining speed automatically when height from ground to
fork is less than 100mm, which provides effective protection for goods.
Frame system
－
Chassis welded by high-performance steel plate guarantees enough load capacity, with
longer service life.
－
Chassis adopts 3-wheel structure, including one drive wheel and two load wheels, thus
guarantee the good stability and safe travelling.
－
The truck has a folding operator platform and safety side arms.
Drive system
－
Adopted suspension design guarantees well wheel and ground contact, light turn and
convenient operation.
－
The high efficiency traction motor realizes high driving speed and strong climbing
performance.
Steering system

–
The driver steers with a tiller.
–
ESP(electric steering power) system offer easier and more flexible operation.
–
The control handle of latest development is simple but beautiful, and all operations can be
done easily with on hand.
–
The steering motion is transmitted directly from the steering controller via a steer motor
directly to the ring gear of the pivoted drive system.
Hydraulic system
－
Lifting and lowering are activated via the lift and lower buttons.
－
Modularization hydraulic power unit owns low noise, low vibration, stable and reliable lifting
and lowering.
－
When lifting is activated, the pump unit starts to operate, supplying hydraulic oil from the oil
8
 reservoir to the lift cylinder.
Electric system
－
24 volt system.
－
The latest AC control system realizes accurate and stable control, and higher efficiency. The
－
CANBUS structure makes communication of the entire machine faster and more reliable.
－
Multi-function instrument owns electric quantity display, time and fault diagnosis function.
－
Own electric lift limited and controller intelligent limited function.
－
All plug connectors are imported and waterproof, and all cables have reliable protection,
which increases reliability of electrical system significantly.

9
2.3 Displays and Controls

22
24 23
26
25

20 20
21

8 9
19

10
Ite Control/ Symb Functio

2 Displa Display battery charging status, running hours and

fault information.

3 Lock Unfolding or folding up the safety side arms, then

release the locked state of the safety side arms.
Emergency Disconnects the battery supply. All electric functions
8 Disconnect are cut out and the industrial truck decelerates.
Activates the industrial truck by switching on the
control voltage.
9 Key switch and
Removing the key prevents the truck from being
switched on by unauthorized personnel.
Press this button and indicator light (25) is on, it
means the truck changes to low speed travel mode.
When in low speed mode, the truck will travel in low
1 Slow travel
speed. travelling speed; Press this button and
indicator light (25) is off, it means the truck changes
to normal travelling mode.

2 Travel Controls the direction of travel as well as the

travel speed.
Safety function
When applied the truck travels for approx. 3 seconds
2 Collision safety in the forks direction. The parking brake then applies.
The truck remains switched off until the travel switch
is set to neutral.

2 Horn When pressing the horn button, it will give out

sound warning signal.

2 Fork lift/lower Control forks lift /

Mast reach forward

2 / Control mast reach forward /

Mast forward /
2 reverse Control mast forward / reverse

Sideshifter left /
2 right Control sideshifter left / right

11
2.3.1 Display LED Hour meter indicator light (Green) The
CQDB12/16-AC1S green LED indicator light being normal on
means that the timer is working, and the
minimum timing unit is 0.1hour.
LCD will display truck accumulated working
hours for each start, and this time is the basis
of periodical maintenance to the truck.
CQDB12/16-AZ3S

LCD

The LCD type is an 8-alphameric character,

dot matrix LCD, and can display truck fault
code, battery residual capacity and ALARM LED LCD DISPLAY

accumulated working hours. LED function

The MDI-CAN has only a LED. This LED
LCD displays battery residual capacity when
is red and lights and blinks when an alarm is
truck is in normal operation.
present.
LED Fault indicator light (Red)
When there is a fault, the red LED light is on Display function

and the LCD will display the fault code. Fault

code displays alternately every two seconds
when there is more than one fault. Relevant
fault code and diagnosis information, please
refer to the Fault Code Table in this manual. Three symbols inform the operator as
follows:
LED Low battery capacity indicator light
Turtle Symbol:
(Yellow)
When the residual battery capacity is lower
than 20%, the yellow LED indicator light
flashes, issued an “energy depletion” warning,
It is normally off; when it appears (fixed) it
meanwhile the LCD displays “20%” for one shows activation of the “soft” mode of the truck,
second, and then change to “Low BDI”. When in which maximum speed and acceleration are
yellow LED indicator light is flashing, the lifting reduced;
function is locked automatically, and the Monkey Wrench Symbol:
travelling speed is reduced. Charge the truck
immediately.

12
 appears. The string shown on
the display is XXAYY, where
XX and AYY represent respectively the
It is normally off; when it appears (fixed) it alarmed node and the alarm code. The
shows the request of programmed alarm code meaning must be present in
maintenance or the Alarm state. In this case the controller user manual.
the relative code will be displayed. The
information supplied by the MDI-CAN can be
extremely useful. Failures can be quickly
identified by the Operator or Service
Technician thereby finding the fastest solution
to the problem.
Hourglass Symbol:
Battery State of charge

It is normally off; it blinks when the Hour Meter

is working.
Hour meter The battery's State of Charge indication is
An alpha-numeric liquid crystal display is integrated in the LCD display; it is shown by

fitted in the centre of the unit that shows the ten notches. Each notch represent the 10% of

Hours Worked. The display is backlight (the the battery charge. As the battery becomes

backlight is normally lighted). discharged, the notches turn off progressively,

one after the other, in proportion to the value of
the residual battery charge. This value, sent to
the MDI-CAN by the controller via CAN-BUS,
is displayed in the Tester Menu of the Zapi
Console connected to the controller. When
BATTERY LOW alarm appears on the
controller, the battery symbol which is under
the notches blinks.

Alarms
The same display can also indicate the
Alarm state, showing a Code corresponding to
the type of Alarm. To attract attention, the Red
LED will start blinking when an Alarm is
generated.
When an Alarm is generated, the Red
LED blinks to attract the attention of the
operator. The symbol of Monkey Wrench also

13
D13L Display characteristics:

Wide voltage input range: 9V~60V;

Built-in anti-reverse circuit;

Beautiful appearance and unique alarm
indication design;

Implement time-limited vehicle speed,
power, hour meter, and fault;

Positive IP65 protection level, able to

adapt to a variety of complex

environments;
4
Instrument graphic

2 3 1
 Paramter
No. Description
name
The number shows the
current accumulated
working hours of the
1 Hour meter
vehicles, with a
maximum of 5 digits; unit:
h
Speed Display current vehicle
2
display speed in km/h
Battery
Display current battery
3 level
level;
display 14
Display the current fault
code, and display
4 Fault code
cyclically when multiple
faults occur;
C2 controller meter 2.3.2 Open or down the safety side
arms
Open the safety side arms:
Push the lock switch with one hand and the
55 55 other hand lift the safety side arms until it rotates
% 1
% to certain angle, releases the lock switch and
press the arm guard to lock position. The safety
side arms has been opened.
The upper part of the instrument used by C2
controller shows the remaining battery power;
the lower part shows the operating time of the
forklift when the forklift is stationary, in unit h;
the driving speed is displayed when the
vehicle is moving, in unit KPH.

Note

1 ) Speed display accuracy and unit: the

Put down the safety side arms:
controller software supports speed unit
Push the lock switch with one hand and the
switching and decimal point measuring
function, D13L can realize corresponding other hand press the safety side arms until it
display; rotates to certain angle, releases the lock switch
2 ) When the battery level is lower than 20%, and press the arm guard to lock position. The
the battery icon flashes; safety side arms has been put down.
3 ) When the hour meter is in the main
interface, it is always displayed;
4 ) Some models are not used, so the speed
is displayed as 0;
5 ) It is panel screen printing color around the
meter;
When there is a fault in one of the controllers
of the vehicle, the red exclamation mark of the
instrument flashes, and the current fault code
is displayed on the interface. See the
corresponding part of the manual for the
specific fault code.

15
 2.4 Standard technical specifications
The following technical specifications are all standard data. Technical modifications and additions
reserved.
CQDB12-AC1S CQDB16-AC1S CQDB20-AC1S
Model CQDB12-AC2S CQDB16-AC2S CQDB30-AC2S
(CQDB12-AZ3S) (CQDB16-AZ3S) (CQDB20-AZ3S)
Characteristics

Operator type Standing Standing Standing

Rated capacity Q (kg) 1200 1600 2000
Load center distance c(mm) 500 500 500
Load distance, centre of load axle to fork x(mm) 450 450 440
Wheelbase y(mm) 1311 1311 1511
Weight Service weight with battery kg 1800 2000 2200
Tyres Polyurethane Polyurethane Polyurethane
Tyres / chassis

Tyre size, front mm Φ250×80 Φ250×80 Φ250×80

Tyre size, rear mm Φ210×85 Φ210×85 Φ210×85
Wheels, mumber front /rear (x=driven wheels) 1×/2 1×/2 1×/2
Tread, rear b11(mm) 981 981 981
Tilt of fork carriage forward/backward α/β(°) 3/5 3/5 3/5
Height, mast lowered h1(mm) 1930 1930 2035
Lift h3(mm) 2700 2700 2700
Height, mast extended h4(mm) 3655 3655 3655
Stand height h7(mm) 170 170 170
Height of wheel arms h8(mm) 226 226 226
Overall length I1(mm) 2202 2202 2412
Length across wheel arms I7(mm) 1704 1704 1904
Dimensions

Length to face of forks I2(mm) 1132 1132 1342

Overall width b1/b2(mm 1040/1074 1040/1074 1040/1074
)
Fork dimensions s/e/L(mm 35/100/1070 35/100/1070 45/100/1070
)
Fork-carriage width b3(mm) 902 902 902
Distance between fork-arms b5(mm) 200～750 200～750 200 ～750
Distance between wheel arms b4(mm) 772 772 772
Reach distance l4(mm) 590 590 590
Ground clearance, centre of wheelbase m2(mm) 55 55 55
Aisle width for pallets 1000×1200 crossways Ast(mm) 2617 2617 2817
Aisle width for pallets 800×1200 lengthways Ast(mm) 2654 2654 2854
Turning radius Wa(mm) 1600 1600 1800
Travel speed, laden/unladen km/h 5.5/6.0 5.5/6.0 5.5/6.0
Lift speed, laden/unladen mm/s 140/200 110/170 100/155
Performance

Lowering speed, laden/unladen mm/s 190/155 175/130 175/130

Reaching speed, laden/unladen mm/s 100/100 100/100 100/100
Gradeability, laden/unladen % 10/16 8/15 6/14
Service brake Electromagnetic braking Electromagnetic braking Electromagnetic braking

Drive motor rating S2 60 min kW 1.5 1.5 1.5

Electric
engine

Lift motor rating at S3 15% kW 3 3 3

Battery voltage/nominal capacity K5 V/Ah 24/280 24/340 24/340
Battery weight kg 250 280 280
AC CURTIS AC CURTIS AC CURTIS
Type of drive control
Other (AC ZAPI) (AC ZAPI) (AC ZAPI)
Steering design Electronic steering Electronic steering Electronic steering

16
 CQDB12-AC1S-I CQDB16-AC1S-I CQDB20-AC1S-I
Model CQDB12-AC2S-I CQDB16-AC2S-I CQDB20-AC2S-I
（CQDB12-AZ3S-I） （CQDB16-AZ3S-I） （CQDB20-AZ3S-I）
Characteristics

Operator type Standing Standing Standing

Rated capacity Q (kg) 1200 1600 2000
Load center distance c(mm) 500 500 500
Load distance, centre of load axle to fork x(mm) 450 450 440
Wheelbase y(mm) 1311 1311 1511
Weight Service weight with battery kg 1800 2000 2200
Tyres Polyurethane Polyurethane Polyurethane
Tyres / chassis

Tyre size, front mm Φ250×80 Φ250×80 Φ250×80

Tyre size, rear mm Φ210×85 Φ210×85 Φ210×85
Wheels, mumber front /rear (x=driven wheels) 1×/2 1×/2 1×/2
Tread, rear b11(mm) 981 981 981
Tilt of fork carriage forward/backward α/β(°) 3/5 3/5 3/5
Height, mast lowered h1(mm) 1930 1930 2035
Lift h3(mm) 2700 2700 2700
Height, mast extended h4(mm) 3655 3655 3655
Stand height h7(mm) 170 170 170
Height of wheel arms h8(mm) 226 226 226
Overall length I1(mm) 2202 2202 2412
Length across wheel arms I7(mm) 1704 1704 1904
Dimensions

Length to face of forks I2(mm) 1132 1132 1342

Overall width b1 1040/1074 1040/1074 1040/1074
)
Fork dimensions s/e/ 35/100/1070 35/100/1070 45/100/1070
)
Fork-carriage width b3(mm) 902 902 902
Distance between fork-arms b5(mm) 200～750 200～750 200 ～750
Distance between wheel arms b4(mm) 772 772 772
Reach distance l4(mm) 590 590 590
Ground clearance, centre of wheelbase m2(mm) 55 55 55
Aisle width for pallets 1000×1200 crossways Ast(mm) 2617 2617 2817
Aisle width for pallets 800×1200 lengthways Ast(mm) 2654 2654 2854
Turning radius Wa(mm) 1600 1600 1800
Travel speed, laden/unladen km/h 5.5/6.0 5.5/6.0 5.5/6.0
Lift speed, laden/unladen mm/s 140/200 110/170 100/155
Performance

Lowering speed, laden/unladen mm/s 190/155 175/130 175/130

Reaching speed, laden/unladen mm/s 100/100 100/100 100/100
Gradeability, laden/unladen % 10/16 8/15 6/14
Service brake Electromagnetic braking Electromagnetic braking Electromagnetic braking

Drive motor rating S2 60 min kW 1.5 1.5 1.5

Electric
engine

Lift motor rating at S3 15% kW 3 3 3

Battery voltage/nominal capacity K5 V/Ah 24/120 24/120 24/120
Battery weight kg 250 280 280
AC CURTIS AC CURTIS AC CURTIS
Type of drive control
Other (AC ZAPI) (AC ZAPI) (AC ZAPI)
Steering design Electronic steering Electronic steering Electronic steering

17
 β
α

18
Mast Specification：1.2t/1.6t
Capacity
Fork lift height Mast lowered Mast extended
Type Free lift height Load capacity at 500mm
h3 h1 h4
1.2t 1.6t
mm mm mm mm kg kg
2000 1580 2955 105 1200 1600
2500 1830 3455 105 1200 1600
2700 1930 3655 105 1200 1600
Wide view duplex mast

3000 2080 3955 105 1200 1500

3300 2230 4255 105 1200 1400
3500 2330 4455 105 1150 1350
3600 2380 4555 105 1150 1350
3700 2430 4655 105 1100 1300
3800 2480 4755 105 1100 1300
4000 2680 4955 105 1050 1250
4300 2830 5255 105 1000 1200
4500 2930 5455 105 950 1150
3500 1875 4455 920 1150 1350
3700 1940 4655 985 1100 1300
Full free triplex mast

4000 2040 4955 1085 1050 1250

4300 2140 5255 1185 1000 1200
4500 2190 5455 1235 950 1150
4700 2290 5655 1335 900 1100
5000 2390 5965 1435 850 1050
5200 2440 6155 1485 800 1000
5500 2540 6455 1585 750 950
Mast Specification：2.0t
Capacity
Fork lift height Mast lowered Mast extended
Type Free lift height Load capacity at 500mm
h3 h1 h4
2.0t
mm mm mm mm kg
2000 1685 2955 115 2000
2500 1935 3455 115 2000
2700 2035 3655 115 2000
Wide view duplex mast

3000 2185 3955 115 1900

3300 2335 4255 115 1820
3500 2435 4455 115 1750
3600 2485 4555 115 1750
3700 2535 4655 115 1700
3800 2585 4755 115 1700
4000 2785 4955 115 1650
4300 2935 5255 115 1600
4500 3035 5455 115 1550
3500 1975 4455 1020 1750
3700 2040 4655 1085 1700
Full free triplex mast

4000 2140 4955 1185 1650

4300 2240 5255 1285 1600
4500 2290 5455 1335 1550
4700 2390 5655 1435 1480
5000 2485 5965 1530 1400
5200 2540 6155 1585 1330
5500 2640 6455 1685 1250

19
2.5 Product plates and warning labels location
Plates and labels such as nameplate, load charts, warnings and strap points must be legible at all
times. Replace if necessary.
The figure below shows the approximate location of the various identity resides. Before operating
the truck, please understand the meaning of the various identities.

31 32

33
30

29
34

28

35

27

36
37

20
Item Description
Nameplate: The rated capacity on the nameplate is the max. load capacity by the label
27 listed equipment. Any change to the forklift or other equipment may change rated
capacity.

28 Series tonnage label: A series, rated capacity is X×100kg

Warning label: it is forbidden that the operator`s foot is not on the platform during
29
operation.

30 “Danger of trapping” warning notice.

31 Rated capacities and load centres graph.

32 Hoist label: Fixed points when using the crane to handle equipment.

33 Warning label: Do not step onto or beneath the load.

34 Do not step onto the platform.

35 Manufacturer ’s logo

36 Key switch：“OFF” position is off，“ON” position is on.

37 Emergency stop label

21
3 Safety Rules – No smoking or any spark, smoke near the
battery when checking.
1) Only trained and authorized operator shall
be permitted to operate the forklift. – Be careful of scald when checking motor
and controller.
8) The controller equips with energy
accumulator, do not touch between B+
and B- to avoid electric injury. If you need
check or clean the controller, connect
load(like contactor coil or horn) between
2) Operator must wear helmet, working controller B+ and B- to discharge the
shoes and uniform. controller capacity.

3) Never take people.

9) Whenever you find the forklift abnormal,
stop the truck, put on the DANGEROUS
or FAULT sign to the truck, remove the
key, and report to the managing person.
Only after eliminating the fault can you
use the truck.

–
If there occurs to fault, battery electrolyte,
4 ) No transporting with a raised load.
hydraulic oil or brake fluid leakage when
5 ) It is not allowed to reconfigure the truck
lifting loads, going up and down the slope,
without manufacturer ’s permission.
please organize staff to repair.
6 ) Do not work in flammable and combustible
environment.
7 ) Check the oil, fluid leakage, deformation,
flexibility in certain time. If neglected, service
life of forklift will be shortened and in serious
condition there will be accident.

–
Make sure change the “safety parts”
during the schedule maintenance.
–
Wipe off the oil, grease or water on the
10) Internal battery may generate explosive
soleplate, foot pedal and control stick. gas, it’s prohibited any flame close the
22
 battery. Never allow the tools close two 18) Cause the wheels of pallet truck is small, it
poles of the battery to avoid spark or short is not allowed to run on the street, and only for
circuit. driving in specified stacking place.
19) It’s forbidden to put the head, hand, foot or
body under the forks. Never stand on the fork.

WARNING

11) The work ground of forklift shall be solid

and smooth concrete surface or similar ones.
Pre-check the ground condition of working site.
Tidy the working site, clean obstacle, sweep 20) It’s forbidden to put the head, hand, foot or
macadam, muddy sand and wipe off greasy body into the space between the chassis and
dirt. lifting component, once clipped, it is dangerous
12) Do not overload. Before operation, first to your life. It’s forbidden to put the head, hand,
know the curve chart on the load curve
foot or body into the space between fork and
plate well, which indicates the relation
link mechanism. Crushing and shearing
between rated load and load center. hazards for the operator of pedestrian-
13) Before start, press the horn and make sure controlled trucks featuring foldable platforms
no people around. and reach trucks, between parts of the
14) Goods are not allowed to deviate the fork environment and the truck during travelling
center, when goods is deviating the fork center, forward
turn or pass uneven road, you are easily to fall.
Meanwhile, possibility of turnover will
increase.

21) Make the loads in front when climbing the

WARNING
slope. It’s prohibited to turn on the slope, or
there’s danger of tipping over. Avoid working on
the slope.
22) Do not use truck under the weather of
sand, snow, thunder, storm, typhoon, etc. Avoid
15) Avoid sudden drive, stop or turn.
using the truck when the wind speed is larger
16) Do not drive the truck when the forks in
than 5m/s.
high position.
17) When handling bulky loads, which restrict
your vision, please operate the machine in
– The weather condition: temperature:
reverse or have a guide.

23
 -5℃～40℃, wind speed: less than 5m/s; air danger to personnel and materials.
relative humidity: less than 90%（20℃）. Additional lighting equipment is necessary
Altitude should not exceed 2000m. to operate the truck in areas of insufficient
lighting.
23) After power off, brake works and the
．．．．．．．．．．．．．．．．．．．．．．．．．．．．
． ．
32) Jump out from the pedal far-away from the
．．．．．．．．．．．．．．．．．．．．．．
truck can not be
truck, When a stand-on end-control truck to
24) As．．．．．．．．．．．．．．．．．．．．．．．．．．．．
to stand-on truck,
． ．stand on firmly
． step off and away from the truck in the event of
．．．．．．．．．．．．．．．．．．．．．． ．．．．．．．．．．．．．．．．．．．．
and hold the handle tightly.
a tip-over or off-dock accident.
．．．．．．．．．．．．
turning, the speed should be 33) Do not step onto the platform.
25) There’s
than warning and operation method on
truck label. Please obey the requirement in this
manual and the truck label when operation.
Check label, identification plate, replace
damaged or fallen ones.
26) Fire extinguisher shall be equipped at the
work site. Users can choose truck equipped
with fire extinguisher. Driver and manger should
34) It’s prohibited to use the truck with not
be familiar with the fire extinguisher position
install the safety guard or the safety guard
and application
removed.
method. 35) When need to maintain the truck at high
altitude, be sure to wear safety equipment to
prevent high-altitude fall risk.

27) Use tray when carrying small items, do not place on the fork directly.
28) Do not wash the inner of the truck, do not place the truck outdoors and exposed to the rain.
29) Before dismantle or repair the truck, remove the battery plug firstly.
30) The truck should be used under the environment of the light is enough.
31) The truck must only be operated in work areas with sufficient lighting to avoid

24
4 Transport
The forklift truck is designed for short-distance lifting, lowering and transporting load units, not
suitable for long-distance travel. If needed, the forklift truck must be transported by using lifting
device or platform to place on truck or trailer.

4.1 Lifting the truck by crane

Procedure:

–
Park the truck securely.
–
Secure the lifting slings to the strap point, and prevent them from slipping. Crane slings
should be fastened in such a way that they do not come into contact with any attachments
when lifting.
–
Load the truck and park it securely at its destination.

WARNING
Wear safety shoes when lifting the truck by crane.
Do not stand under a swaying load.
Only use lifting gear with sufficient capacity (for truck weight see truck nameplate). Always attach the cran
Do not stay under the truck when hoisting the truck.
When hoisting or laying down, it should be stable and slow to avoid collision or accident.

25
4.2 Securing the truck for transport
Correctly fix the forklift truck to avoid move when using truck or trailer.
Procedure:

–
Move the truck onto the transporting truck.
–
Park the truck securely.
–
Strap the belts around the truck and tension them sufficiently. Using the wedge fixed wheels
when necessary.
The truck can now be transported.

WARNING
he lorry or trailer must have fastening rings.
se wedges to prevent the truck from moving.
Only use tension belt or fastening belt of good nominal strength.

26
4.3 Transport
The forklift truck is designed for material handling only and is inappropriate for long-distance
transportation. If needed, the forklift truck must be transported by ship, train or lorry, block tires
with solid chocks, and bind body firmly.

–
Place the truck on the long-distance transportation tool through loading platform or hoisting
device.
–
Fix the belt to the forklift and fully tightened, block the wheels if necessary.
Then the forklift can be transported.

How to remove a broken truck

It’s not allowed to tow the forklift truck on the ground directly when the truck is broken down or
damaged since the brake of the truck is closed under normal circumstances. Appropriate vehicles
should be used to remove the broken trucks.
 ARNING
W
Do not tow the broken trucks on the ground directly, or else the braking system would be damaged.

27
5 Battery – Inspect electrolyte level every week.
When electrolyte level is low, you must
5.1.1 Attention for using add distilled water to the level appointed.
battery
WARNING
1) No firing
 The shortage of the electrolyte will
Explosive gas can be produced in the internal
cause the storage battery
of storage battery, smoking, flame and sparkle
overheated, even cause the system
can easily cause storage battery explosion.
part of storage battery and electric
combustion.
 Vitriol include in the electrolyte can
create burns, see doctor for
emergency treatment quickly if
touch it un-carefully.
Splashing to the skin or eyes ：wash

2) Protection against electric shock with water 15~20 minutes; Splashing

to the clothes ： take it off
CAUTION immediately.
 Storage battery has high voltage
Careless drinking ： drink plenty of
and energy.
water and milk.
 Do not bring short circuit.
 Wearing glasses, rubber overshoes
 Do not approach tools to the
two poles of the storage battery, and rubber glove.

which can cause the sparkle or Keep battery clean

Keep dryness and cleanness on the surface of
short circuit.
3) Correct wire connection storage battery. The poles for connection are
Never allow wrong connect of battery anode also dry and clean. Operator must screw down
and cathode, otherwise it may cause sparkle, the vent-cover of storage battery.
burning or explosion. CAUTION
Do not use dry cloth or fiber cloth to clean the storage
4) Do not over-discharge Pull out storage battery plug.
Clean with wet cloth.
–
Never charge only when the stacker can ’t Wearing glasses, rubber overshoes
and rubber glove.
move, this will shorten the battery working
hours.
–
When two flashing lights of the power
indicator flash, please charge
immediately.
5) Inspection for electrolyte

–
It is forbidden to use the stacker when the
electrolyte is in shortage.
28
 lithium batteries.
4 ) Do not open the lithium battery cover
maintenance, lithium battery failure, timely
contact with the manufacturer.
5 ) The battery is not used at a loss of power.
To ensure the battery life, should avoid the
Measures in summer discharge depth of more than 80% of the rated
In summer, water in the electrolyte is easy to capacity of the battery. Whether it is
evaporate, therefore, electrolyte must often be partially discharged or fully discharged,
inspected if electrolyte is low, you must add the battery should be immediately
distilled water to the level appointed. charged.
6 ) Do not operate the lithium battery vehicle
CAUTION
in a temperature exceeding 55 ℃. When the
 Do not over fill distilled water.
ambient temperature is below 0 ℃,
Spilt electrolyte will cause
corrosion and electricity leakage. please stop charging the lithium battery
Measures in winter vehicle.

–
Keep effective and good surrounding for 7 ) It is strictly prohibited to discharge the
charging. battery below the termination voltage,
– please charge it in time after discharge.
When it is cold, pull out the storage
battery pin to prevent discharging. Avoid overcharging when charging.
– 8 ) The battery inspection and maintenance
Take measures such as covering storage
operations, to be wearing working clothes,
battery for warmth.
– wearing gloves, non-wearing watches,
Don’t park the truck in cold outdoor or cold
metal bracelets, necklaces and other
storage for a long time.
accessories. The electrolyte inside the
–
Charge in time after work. battery is highly corrosive and must be worn
during operation.
5.1.2 Safety precautions for using 9 ) Under no circumstances shall the battery
lithium battery be shorted to the positive and negative
1 ) Users need to create a file for lithium terminals, and any metal or other
batteries in order to better maintain the conductive objects other than the battery post
lithium battery. clamping bolt and the conductive tape
2 ) The new factory battery should not be should be avoided from touching the positive
discharged, it must be fully charged and negative terminals of the battery.
before use. 1 0 ) Do not hit, throw or trample on the battery,
3 ) Lithium batteries have a special charger, do not heat the battery, do not throw the
may not be charged with other types of battery into the water.
battery charger, so as not to charge

29
11) Do not reverse charge the battery, a contact this Company technical
reverse charge can cause the battery department to obtain the correct technical
voltage to zero, scrapped in advance. support.
12) If the battery smells, heat, discoloration, 18) Prohibit the use of this series of products
deformation or use, storage, charging any by children and other people who lack
anomalies, the battery should be knowledge of the safe use of lithium-ion
immediately removed from the device or batteries.
charger and disabled, please contact the 19) Do not disassemble, squeeze, puncture,
relevant technical departments of high temperature shelving or baking the
manufacturing enterprises or After-sales battery, to avoid the battery was too high
service department to get the treatment. amplitude vibration, external impact,
13) If the connection of the battery pole is height drop and so on.
found to be oxidized, wipe it with a dry cloth 20) It is forbidden to charge the battery
and polish it with a fine sandpaper before without a proper charge protection device
use. Otherwise, it may cause poor contact and (lithium-ion battery protection circuit board,
the function fails. battery management system, etc.) or using
14) Do not place the battery near the high a non-battery manufacturer approved
temperature sources, dangerous goods or charging device (charger, DC power supply,
dangerous materials, such as fire, heaters, etc.).
corrosive chemicals, hazardous 21) If there is a lot of dust, metal chips or
machinery and equipment, etc. Use and other debris on the top cover and pole of the
retention; When not in storage, should be battery pack, clean it with compressed air in
placed in a cool dry environment in. time and avoid using water or wet objects.
15) Do not immerse the battery in water or 22) When charging and discharging Try to
other conductive liquids. This operation may avoid splashing water or other conductive
cause personal injury or property damage. objects on the battery cover and pole, such
16) Prohibit the use of strong static electricity as exposure to heavy rain.
and strong magnetic field, otherwise easy to 23) Once inadvertently make some kind of
damage the battery safety protection device, conductor come into contact with the
bringing security risks. positive and negative poles of a single
17) Do not use this series of products with battery or battery pack at the same time to
other models or types of batteries in cause a short circuit, be sure to
series or in parallel; prohibit the entire disconnect the circuit which causes the short
system with lithium-ion battery protection circuit in the shortest time.
circuit board or battery management 24) Once the battery has been destructively
system, the power system in series or in hit, a large amount of energy stored in the
parallel operation, if necessary, please battery will be released in an instant, the

30
 battery can be cooled using a dry powder the battery may cause skin infections,
fire extinguisher. inadvertent contact, take off contaminated
25) Evacuate persons in the danger area if clothing and wash the infection with plenty
the battery is cracked or ignited, and of water and soap for at least 15 minutes,
immediately spray with water or soak a do not rub the ointment.
smoldering, smoldering battery in the 31) Inhalation: When the battery is leaked or
water tank. ruptured, the internal components of the
26) Risk of fire or smoke: LFP batteries can battery may cause mucus, edema and other
leak / evaporate or decompose and respiratory tract problems, inadvertently
release flammable electrolyte under the inhaled, to fresh air and ventilated
condition of 150 ℃ if they are improperly contaminated area. If necessary, oxygen
used or affected by the environment. or artificial respiration.
Hydrogen fluoride (HF) and phosphorus 32) Special Protection Tools: Use breathing
oxides may form during fire, and chemical apparatus to avoid inhalation of irritating
reactions between LIPF6 and water in the gases. Wear protective clothing or other
electrolyte will produce fluoride and devices to prevent body contact with the
carbon dioxide. electrolyte.
27) Extinguishing Media: Spray water or
smoke or fire-burnt batteries in water. Use type
D fire extinguishers, CO2, dry chemical,
or foam fire extinguishers.
28) Swallowing: Ingestion of electrolyte may
cause throat or respiratory tract infections,
swallowing, drinking plenty of water and
getting medical attention immediately.
Make sure the infected person does not use
emetic. Make sure mucus does not block the
respiratory tract, and do not eat other things to
unconscious people.
29) Contact with eyes: Electrolyte inside the
battery will cause eye irritation and
inadvertent contact. Please do not rub it.
Rinse immediately with plenty of water for at
least 15 minutes. If necessary, please go to
the hospital for treatment immediately.
Otherwise it will hurt your eyes.
30) Contact with skin: The electrolyte inside

31
 Item 1.2t 1.6t/2.0t 5.2 Dimension /
Weight
Length (L） mm 650 650

Width (W) mm 297 297

Height (H) mm 625 625

Min. allowable battery weight kg 244 280

H
Max. allowbabl battery weight kg 330 330

L W

WARNING
Battery weight and dimensions have considerable influence on operational safety of the truck.
When installing or replacing battery, be sure that battery in the fixed position.

32
5.3 Charging the battery
Procedures：

–
Drive the truck to appointed charging place,
park the truck and render if safe. 11
–
Open the battery cover（11）.
–
Remove the battery plug(41) from the truck
socket (42).
–
Open the fill cap of each battery cell（43）.
–
Connect the charging cable (44) to battery plug
(41).
–
Start the charging procedure according to the
charger operation instructions.
–
Remove the battery plug(41) from the charger
after the battery is fully charged. 42
41
–
Connect the battery plug （ 41 ） with truck
socket(42).
–
Close the battery cover(11).
After charging, the truck can be used.

WARNING
 Please charge in the well-ventilated and
appointed site.
 Place “No smoking” in the charging site
and prepare extinguisher. 43 11

Before charging, please examine wire and
electrical outlet for damage, otherwise do
not charge. 33

Open the battery cover to release the
explosive gas when charging.

 Never place metal object on the battery. In
the progress of charging, do not take
out power switch or battery plug,
otherwise it may damage plug and
electrical units. Generally press down the
stopping button firstly, and then take out
the plug.
41
44
Lithium battery charging
Model-type: SPC-24100
Input: AC186～260V/50-60Hz/20A
Output: DC29.2/100A

Safety precautions before charging:


Please choose to charge in a relatively safe environment (such as to avoid liquid, fire and
other environment).

The necessary extinguisher (yellow sand and powder fire extinguisher) should be equipped
around the charger so that emergency extinguishing can be carried out under extreme
conditions.

Before charging, confirm that there is no dust, water and other foreign objects in the charging
gun and charging socket. If there is any foreign matter, it should be cleaned before it can be
charged. Otherwise, the charging gun and charging stand may not be well-connected to
cause heat or even fire.

Do not modify or disassemble the charging port and charging equipment, which may result in
charging failure and fire.

After the charging is finished, do not disconnect the charging device when it is wet or standing
in the water, as this may cause electric shock and cause personal injury.

Provide adequate ventilation during charging. To avoid damage to charger cord plug and
receptacle, do not pull on charger cord plug. Do not twist, rock or bend plug sideways. Do not
use if plug or receptacle is damaged. Loose or feels hot otherwise fire, property damage or
personal injury may result.

Connect only properly grounded AC outlet. Do not touch uninsulated protion of output
connector or uninsulated battery terminal. Never try to change a frozen battery. There’s the
danger of explosion! Maintenance and repair must only be carried out by a qualified specialist
who is familiar with the dangers involved and aware of relevance regulations.

CAUTION
When using for the first time, it is recommended that engineers and technicians with lithium battery forkl

34
35
Daily charging with a little harm;
·The storage battery that has been made first e. It often be charged deficient or has not
charging and used in normal condition, then been used for a long time;
charged again, it is named daily charging. ·Its f. Check or clean sediment after taking out
way is almost same as the first charging. ·The the storage battery group
recharging volume is 1.2 times than the last
The way of equalizing charging：
electric discharging. But the new storage
battery’s former five times’ charging volume (PCA Automatic Charger Operation
should be 1.5 times than the last electric Instruction)
discharging. 1 Firstly, charge the storage battery
·During any charge, the temperature of normally, and then rest for 1 hour after the
electrode should not exceed 45 ℃ , otherwise end of charge.
it should be taken measures such as 2 Charge it again with the second phase
reducing artificially charging current or lowing
current of normally charge until the
the temperature. If the temperature still does
electrolyte gives off a large number of
not drop, you should stop charging till the
bubbles, and then stop charging for 1 hour.
temperature drops down.
Adopt intelligent charging to do daily charge, 3 Do it several times as mentioned above until

the former five times of new battery should do the voltage and the density keep invariable
equalizing charging according to operation and the storage battery gives off a large
instructions of intelligent charger. number of bubbles immediately when
Equalizing charging charge again.
·During using of the storage battery, it often Additional charge
occurs to disequilibrium among the voltage, ·If one day’s work cannot be fulfilled in one
density and capacity. charge, carry out additional charge during

·Compared to most of the batteries, several breaks.

·When the temperature of circumstance is
storage batteries’ proportion of voltage and
low, carry out additional charge.
electrolyte rises slowly during the course of
charge and discharge, its storage battery’s Charge for long-term storage
·Carry out equalizing charging before storing.
proportion of voltage and electrolyte
·Carry out equalizing charging once every 15
declines faster than most of other batteries. to 30 days during the storage period.
·Make equalizing charging in the following
The proportion and level of electrolyte
case：
a. discharge voltage often drop down
final voltage; WARNING
b. discharge current is often larger;  If the level of the electrolyte is
c. not charge in time after discharge;
d. the electrolyte is mixed with impurity low, using the storage battery will
cause the storage battery over-heat
and shorten the storage battery’s
36
 1． Inspect electrolyte

The storage battery without a

It is proper to pour the electrolyte 15-20mm
above the electrode plate.

The storage battery with a

According to the dobber of the ventilation
cover, read the level position of the
electrolyte.

The storage battery without a

When the electrolyte is above 15-20mm of
the electrode plate, stop replenishing
4
After replenishing the distilled water,
close the ventilation cover and box cap.
5
Use the damp cloth to clean the
surface of storage battery cells.
2． Replenish the distilled water
·Wear the blinkers, rubber shoes and WARNING
rubber glove.  It is not permitted to exceed the

1 Use the measuring cylinder to take out the

appointed top level when
replenishing the distilled water.
distilled water with a certain quantity.
Adding too much will result in
2 Open the battery ventilation cover or fill

cap. leakage of electrolyte, and it will

3 Imbibe distilled water with injector and

damage the truck when charging or

then supply it into the storage battery. discharging.

 Draw it out with injector if adding too
The storage battery with a dobber much.

When the red dobber rises, the white line 3． Reading the specific gravity
appears, please stop replenishing. 1）The specific gravity of the electrolyte will
change as the temperature changes.

37
1 Use thermometer to measure the
temperature for electrolyte.
2 Put the straw of densimeter into
electrolyte uprightly, extrude rubber tube
with hand and the electrolyte will be sucked
into the glasses tube and then the floater of
the densimeter will float.
3 Numerate the reading of the
densimeter.
3） Conversion of the specific gravity
The specific gravity at the standard
CAUTION temperature of 30 0C should be converted as
 The dobber of densimeter must follow:
rise uprightly without depending
D30= Dt + 0.0007( t - 30 )
on the glass pipe. Therein to：D30 ——the specific gravity at the
standard temperature of 30 C
0

Dt ——the specific gravity at the

temperature of t0C.

t ——the temperature of the distilled

water during convert.
·The specific gravity referred in this book is
measured all at the temperature of 30℃.

Charger：
Storage battery of this truck equips with PCA
Automatic Charger Operation Instruction.
1． The charger is automatic high
frequency charger. The capacity voltage is
220V AC. The input current is not less than
15A. The output voltage is DC 36V.
Maximum charge current is 35A. The total
2） Measuring the proportion charge procedure is automatic. For more
Use gravimeter to calculate the electrolyte information please refer to charger
proportion. manual.
2． Connection with earth wire for using. 3．
When replace the fuse, first plug out
the plug.
4． Non-specialized person can’t open the
hood to check or repair.
5． Do not rebuild or disassembly charger. 6
． Prevent charger overheat in high

38
 temperature seasons, that will hurt
charger, if necessary can pause charge.
If you don’t want use automatic option, you
should adjust the charge current, charge
voltage, charge time and etc. manually. And
you should measure the specific gravity of
electrolyte on time to assure the battery can
be charge at best state. To adjust the
parameter of charger, please see the
following battery charging.

39
5.4 Changing the battery
Procedures：

–
Park the truck and render it safe. 11
–
Open the battery cover（11）.
–
Remove the battery plug(41) from truck
socket(42), and place the battery plug(41) and
cable into the battery box(53), ensure that it does
not scratch cable when removing the battery.
–
Dismantle fixed handle(50) and battery fixing
clip(51).

– 51
Choose proper lifting appliance to hook up two
lifting holes of the battery box(53) and fix them. 50

– Lift out the battery slowly.

42
Battery disassembly is finished. 41
Installation is in the reverse order of operations and
pay attention to the battery placing position. After
installing the new battery, check the cable and plug
joint part for damage.

WARNING
 Battery box is very heavy, be careful
to avoid damage.
 Make sure the lifting capacity of the crane
is larger than battery weight.
 Never drop the lifting hook on the battery
surface.
 Disposal to the waste battery should
accord with local environment regulation. 41
53
 When replacing the battery, ensure that a
battery of the same specification,
dimension and weight is fitted.

40
6 New truck breaking-in
We recommended operating the truck under light load conditions for the first stage of operation to
get the most from it. Especially the requirements given below should be observed while the truck is
in a stage of 100 hours of operation:
－
Avoid the new battery over discharging in early period.
－
Perform specified preventive maintenance services completely.
－
Avoid sudden stop, start or turn.
－
Limited load is 70%～80% of the rated load.
－
Often check and fasten the fasteners of each joint part in running-in period
－
After running-in finished, replace hydraulic oil and gear oil.

41
7 Operation
7.1 Check before operation
In order for the safety truck operation and
keep the truck in good condition, before
starting the truck, you must check it carefully.
1) Oil leak and liquid leak check Park the
truck, and check the truck for hydraulic oil,
gear oil or electrolyte leak. 2) Fork check Close the hood, and open the battery
6) Battery check
Check the fork and see whether bending or – Check the battery cover board. See
crazed. whether the battery fixed reliably.
3) Front/rear wheel and balance wheel – Check proportion of electrolyte. Refer
check to “battery” section.
Check the wheel and see whether there is any Check the terminal for loose or
–
crazed, damaged, or abnormal wearing. damage. Otherwise adjust or replace.
Check the wheel fasteners for looseness.
Inspect whether there is rope on the wheel.

Plug in and turn on the key

7) Instrument display check
Refer to instrument part.
8) Lifting and lowering button
Press the lifting button and check the fork
4) Check front fork and linkage
mechanism lifting condition. Press the lowering button,
check the fork lowering condition. Check if the
Check the fork and linkage mechanism, see
lifting system has abnormal sound.
whether bending or crazed.
9) Forward and reverse running condition
Whether appear interfere when move,
Tilt the handle to some degree, gradually
movement point wear whether severe.
press the accelerator button to the outside of
5) Hydraulic oil check
the body with thumb, and inspect the forward
Open the running condition; gradually press the
Loosen the hydraulic oil filler cap, pull out accelerator button to the inside of the body
dipstick, and check if the oil level within the
with thumb, and inspect the reverse running
scales. Add oil when insufficient.

42
condition.
10) Brake system
When the truck run forward or backward, push
the handle to vertical position or press to level
position to check the brake condition.
11) Steering system
Left or right turn the handle to make the truck
run around 3 turns, and then check if the
steering system is normal.
12) Check chain tensity

–
Lift forks up 100mm-150mm.
–
Press the middle of the chain and see if
the left & right tensity is the same.
–
Tensity adjustment: screw off the nut①,
adjust nut ② to keep the same tensity of
the two chains, and then tighten the nut
①.

13) Horn
Press the horn button to check sound.
14) Appearance
Check the truck appearance for clean, rust or
paint spalling.
15) Others
Check whether there is any abnormal noise,
whether wiring is regular or fastener loosens
etc.

43
7.2 Starting up
Procedures：
－
Fold out the safety arms (4) and folding platform (6).
－
Step on the folding platform (6).
－
Pull the Emergency Disconnect (7) to unlock it.
－
Insert the key in the key switch (8) and turn it as far right as it will go.
The truck is operational.

CAUTION
Make sure the work ground is hard enough to support the truck. Be careful to control the truck’s speed.

44
7.3 Travel
Procedures：

–
Start up the truck.
–
Swivel the control handle into the driving range (F).
–
Place the travel switch to the desired travelling direction, such as forward(V) or backward (R).
–
Control the truck speed by travel switch .
–
The truck brake system is released and travel to the selected direction
Speed is controlled by rotating the driving switch, and the maximum rotation can get fast speed.
Release the thumb, travel switch will return to neutral automatically, and the truck speed will
reduce.
When going uphill and downhill without load, keep the fork to downhill direction; when going uphill
and downhill with load, keep the fork to uphill direction.

WARNING
 Operator must wear protective boots.
 No turn, inclines when going uphill and
 downhill. Never park on the slope.
 Slow down when going downhill and ready for
 braking. Travel according to regulated route.
 Keep road clean and no slipping.
 Do not step onto the platform.

0
V R B1
2° 0° 6°
22 F

B2
V
R
45
Slow down
–
Start up the truck.
–
Unfold the pedal.
–
Step on the pedal.
–
Swivel the control handle to driving range .
–
Adjust the direction speed control button to the desired direction.
–
Control truck speed by direction speed control button .

7.4 Braking
– When the thumb is off the direction speed control button, pull the handle to braking range (B1
or B2) position or vertical position, the truck brakes.

Caution
 When release the control handle, the handle swivel into the braking range slowly
or does not enter braking range, do check the reason and eliminate the fault.
Replace gas spring if necessary.

7.5 Steering
– Hold the left and right handle of control handle with both hands, and decline to some degree,
move the handle to left or right to release truck steering.
When turn to left, the truck turns left.
When turn to right, the truck turns right.
Truck decelerates to low speed mode when cornering.

7.6 Parking
– Release the direction-speed knob. Decrease the speed.

– Return the control handle to vertical position

– Drop the fork to the lowest position.

– Turn off the switch to “OFF” position, press down the emergency disconnect switch, pull out
the battery plug, and take off the key.

– Fold up.

7.7 Loading
– Drive the truck carefully up to the loads.

– Adjust fork height against the tray.

– Go forward and insert the forks in the tray.

– Raise the loads several centimeters to make sure if the loads are firm.

– Travel the truck off the area.

– Drop the load to lower position.

46
47
 7.8 Unloading
– Approach the deposit area.

– Raise the loads to correct height.

– Travel forward, put the load on the unloading position and then stop.

– Make sure the loads are right above, drop the forks slowly until the forks are out of the load.

– Travel backward and make the forks out of the load.

– Drop down the forks to proper position.

7.9 Parking the truck as required
Procedures：

–
Park the truck to rendered place.
–
Lower the fork to the lowest position.
–
Tilt the mast forward.(with tilting function)
–
Adjust control handle to “straight driving position”.
–
Turn off key switch and remove key.
–
Press the emergency stop switch.
–
Fold up side safety extension.
–
Fold up foldable pedal.
Truck is parked.
Warning
Never park the truck on the slop or park when the lifting mast with loads.
When choosing parking place, make sure that does not affect the surrounding normal traffic and the lowe

48
8 Deposit the truck
8.1 Deposit the truck for long time
－
Fully check the truck, especially check the wheel damage.
－
Check fluid oil and electrolyte for leakage.
－
Apply lubrication grease.
－
Check the joint face of cylinder piston rod for looseness, and if scratch on the piston rod
surface. Apply anti-rust oil to piston rod or easily rusty axle.
－
Cover the whole truck.
－
Check specific gravity of electrolyte and liquid level once a month.
－ Do equalizing charge to the battery once a month.

8.2 Start running after deposit for a long time

－
Remove rust preventive oil on exposed parts.
－
Clean impurity and water of the hydraulic oil tank.
－
Recharge battery, fit on truck and connect.
－
Carefully check before start. Inspect starting, travelling, slowing down, steering, braking and
parking etc. function.

49
9 Maintenance
9.1 Maintenance general
– The forklift truck needs inspection and maintenance periodically, to make it in good working
condition.

– Inspection and maintenance are usually ignored, you’d better find the problems early and
solve it in time.

– Use authentic parts of Hangcha Group.

– Don’t use different oil when changing or adding oil. Don’t rave about oil and electrolyte used at
will, and carry on handling according to the local environmental protection laws and
regulations.

– Draw up complete maintenance plan.

– After you make maintenance, you’d better make a record.

– Forbid to repair the forklift truck if you haven’t been trained.

CAUTION
 No fire.
 You should shut off key switch and pull off the plug before service. (except
some trouble shooting).
 Clean the electric part with compress air, and do not with water.
 Do not stretch your hands, feet or any part of body into the gap between the
lifting assembly.
 When the working environment is severe, maintain in advance.
 When need to maintain the truck at high altitude, be sure to wear safety equipment
to prevent high-altitude fall risk.

50
9.2 Periodic maintenance schedule
The service intervals stated are based on single shift operation under normal operating conditions.
They must be reduced accordingly if the truck is to be used in conditions of extreme dust,
temperature fluctuations or multiple shifts.
The following servicing checklist indicates the operations to be performed and the respective
intervals to be observed. Maintenance intervals are defined as:
= Every 8 service hours, at least daily
D
= Every 40 service hours, at least weekly
W
= Every 250 service hours, or at least every 1.5 months
M
= Every 500 service hours, or at least trimonthly
T
= Every 1000 service hours, or at least semiannually
S
= Every 2000 service hours, or at least annually
Y
● Standard maintenance interval
=Cold store maintenance interval (in addition to standard maintenance interval)

Battery D W M T S Y

1 Electrolyte level ●

2 Electrolyte proportion ●

3 Battery quantity ●

4 Terminal looseness ●

5 Looseness of connecting wire ●

6 Cleanness of the battery surface ●

7 If there are tools on the battery ●

8 The tightness and smoothness of air cap ●

9 Far away from firing ●

Controller D W M T S Y

1 Check connector for worn ●

2 Check contactor for running ●

3 Check micromove switch for running ●

4 Check the connection among motor, battery and power unit. ●

5 Check the controller error diagnose system (First check 2 years) ●

51
Motor D W M T S Y

1 Clean the foreign body on the motor ●

2 Clean or replace the bearing ●

3 Check the carbon brush and commutater for worn, whether spring is normal ●

4 Whether the connection is correct and firm. ●

5 Brush carbon powder on shift plate and shift device. ●

Transmission D W M T S Y

1 Check for noise ●

2 Check for leakage ●

3 Change oil ●

Brakes D W M T S Y

1 Test brakes. ●

2 Check magnetic brake air gap. ●

Steering D W M T S Y

1 Test electric steering and its components. ●

2 Check tiller recuperating function. ●

3 Bearing lubrication ●

Wheels D W M T S Y

1 Check whether the wheels fastening ●

2 Check wheels for wear and damage ●

Electrical system D W M T S Y

1 Test displays and controls. ●

2 Check the function of micro switch and sensor. ●

3 Check fuse ratings. ●

Check electric wiring for damage. Make sure wire connections are ●
4
secure.

5 Test Emergency Disconnect switch. ●

52
Hydraulic system D W M T S Y

1 Test hydraulic system. ●

Check that hydraulic ports, hose and pipe lines are secure, check for
2 ●
leaks and damage.
Check cylinders and piston rods for damage and leaks, and make sure ●
3
they are secure.

4 Check hydraulic oil level and top up if necessary. ●

5 Test emergency lowering system. ●

6 Test relief valve and adjust if necessary. ●

7 Replace hydraulic oil. ●

8 Clean hydraulic oil filter. ●

Mast D W M T S Y

1 Visually inspect the mast rollers and check contact surface wear level. ●

2 Check lateral clearance of the mast connections and the fork carriage. ●

3 Check the load chain setting and tension if necessary. ●

4 Check forks or load handler for wear and damage. ●

5 Check the load chain lubrication and lubricate if necessary. ●

6 Test the lift sensor system in the mast and check for damage. ●

53
9.3 Truck used oil and lubrication

Code Designation Mark, code Remark

Normally：L- HM32
A Hydraulic oil Hydraulic oil tank
High and cold environment：L- HV32
B Gear oil GL-5 85W/90 Reduction box
3#Automobile general lithium base Nipples and gliding
C Grease
lubricant surfaces
D Anti-rust oil Chain spray or engine oil Chain

54
Change the gear oil

–
Park the truck at level ground.
–
Wipe off oil add and drain plug.
–
Unscrew oil add plug (65).
– 65
Place an appropriate container under oil
drain plug (66), unscrew oil drain plug (66),
and drain the oil to the container.
–
After oil in the reduction box drains,
re-tighten the drain plug (66).
66

–
Add appointed gear oil （GL-5 85W/90 ）. In
order to add oil easily, add with help of
funnel and tube. When oil overflows from the
65
oil filler, it means oil is enough.

–
Re-tighten oil add plug (65), and clean the
 ARNING
W
Handle the exhaust
residual oil on theoil according
reduction box to relevant rules of the state and never dump at will.
surface.
66

65

66

55
9.4 Replace the key safe parts periodically
Users should replace the parts periodically according to the following table. If the part is abnormal
before the replacing time, it should be replaced immediately.

Key safe part’s description Term of using (year)

Hydraulic hose for lifting system 1～2

High-pressure hose, hose for hydraulic system 2

Inner sealing element, rubber matter of the hydrulic system 2

9.5 Screw down the wheel retaining nut

Retighten the wheel fixing nut after running-in. Periodically check and tighten wheel fixing nut
later.

–
Tighten the wheel nut(45) with torque spanner according to specified order.
–
First tighten with 10N.m torque.
–
Then tighten with 80N.m torque.

2
45
4

5
1
3

56
9.6 Removing the rear panel assy
Procedure:

–
Park the truck securely.
–
Fold out the safety arms and folding platform.
–
Undo the four groups of bolts (42) on the rear panel assy (5) with a wrench.
–
Lift the rear panel assy (10), remove it from the truck and place it securely next to the truck.
The panel is now disassembled.
Mounting is performed in reverse order.

42

10

42

WARNING
It’s prohibited to operating the truck with the rear panel assy removed.
When the rear panel was removed, before the repair, must to discharge (such as controller) energy storag

57
9.7 Removing the safety guard
Procedure:

–
Park the truck securely.
–
Undo the six groups of screws (60) on the safety guard (61,62) with a wrench.
–
Lift the safety guard (61,62), remove it from the mast and place it securely next to the truck.
The satety guard (61,62) is now disassembled.
Mounting is performed in reverse order.

WARNING
 It’s prohibited to use the truck with not install safety guard or safety guard
 removed. When the safety guard removed, there is a risk of trapping when mast
extended. It is forbidden to any parts of the body reach through the mast.

62

60

60
61

58
9.8 Install the load bracket
Procedure:

–
This truck does not equip with load backrest as standard, but leaves four threaded holes for
installment. If load bracket (59) is needed, tighten with four combined bolts (58).

Warning
Be careful when installing the load bracket.

59

58

59
9.9 Adjust the forks
Adjust fork distance
In order to guarantee safe operation of picking loads, before operation, adjust the fork distance to
proper position according to the tray dimension.
Procedures:
– Pull up the fork locating pin upward, and rotate180° in random direction, then fork is unlocked.
–
Based on fork carriage center line, adjust the fork position to both ends symmetrically.
–
After adjusting the fork distance, pull up the fork locating pin upward, rotate to original position,
and then slide the forks left or right a little to make sure the fork locating pin get in the slot of
fork carriage.
Fork distance is adjusted.
1

Caution
 Be careful when adjusting forks.
 Fork locating pin must be locked (keep in the slot of fork carriage), otherwise
forks are easy to move during driving and loads may fall down.
 There is an opening on the lower beam of the fork carriage to assemble
and dissemble forks.
 It’s prohibited to fix forks on the fork carriage opening, prevent forks dropping
from the opening.
 There installs a bolt in the middle of upper beam to prevent forks working
here. Replace in time if bolt is damaged.

60
 Part Ⅱ: Structure, Principle and Maintenance
1 Drive system
Drive system is vertically arranged and rigid coupled with the frame. Drive system is mainly
consisted of drive seat, reduction box, drive wheel, drive motor and electromagnetic brake etc.

8
2

4
6

1. Electromagnetic brake
2. Drive motor
3. Steering gear wheel (only for electric steering)
4. Steering pinion (only for electric steering)
5. Reduction box
6. Drive wheel
7. Steering motor (only for electric steering)
8. Encoder
9. Drive seat
Fig. 2-1 Drive diagram of drive unit

61
1.1 Reduction gearbox
Reduction gearbox of this truck is a small and light controllable wheel driving device, which adopts
double reduction, the first stage adopts cylindric spiral gear reduction and the second stage
adopts planetary reduction. This reduction gear box owns traits like small size, light weight, large
transmission ratio, small radius of gyration, high efficient and simple structure, which enables turn
on site and equip with motor vertically thus cause the radius of gyration on the carriage small.
Moreover, this reduction gear box does not need to shift, but realize direction shift (forward or
reverse) directly by motor positive inversion, and is easy to use and maintain.

1.1.1 Working principle

Simple picture of reduction gearbox refers to Fig.2-1, motor driving gear(1) drives driven gear (2),
driven gear (2) drives drive spiral bevel gear (3) to transfer to driven spiral bevel gear (4), then the
driven spiral bevel gear (4) drives the output of output flange (5). Drive unit transmission circuit:
drive unit directly drives the driving gear through motor. Power transmission order is that from 1
（drive motor） to 2 (driving gear) to 3 (driven gear) to 4(gear shaft) to 5(annular gear) to drive the
wheel output. Drive system does not need gear shift, reversing, but realize direction shift (forward
or reverse) directly by motor positive inversion.

1. Drive gear(pinion gear)

2. Driven gear
3. Driving spiral bevel gear
4. Driven spiral bevel gear
5. Output flange
Fig.2-1 Drive diagram of reduction
gear box

62
1.1.2 Dismount and assemble order
Dismount and disassemble the reduction box according to the following order:
－
Dismantle driving wheel (wheels);
－
Open oil discharging bolt and discharge the oil;
－
Disassemble swing bearing and top shell articles;
－
Disassemble driven cylindrical gear;
－
Open the cover, disassemble driven spiral bevel gear and output flange etc.
1.1.3 Notice to installment and use
－
Before installing, you should wipe the oil on the surface of the shell.
－
In case that the oil leaks during use, you are not allowed to dismount and disassemble the
product.
－
Prevent the assembling surface and exposed flange from being knocked or damaged,
otherwise it may influence the installment and use precision.
－
Working oil should keep clean, the new machine should change new oil in 50 hours for the
first use and every 1000 hours later.
－
Working oil should in accordance with brand no.(GL-5 85W/90).
1.1.4 Fault and troubleshooting
Fault Probably cause Method of Fault eliminating

Lack of oil Add oil

Low efficient transmission and

Quantity of the oil is ineligible Replace
overheat oil temperature

Gear or bearing is damaged Replace

Unstable running Gear or bearing is damaged Replace

Wear or damage of oil seal Replace

Oil leakage
Leakage from the gasket Screw bolt or replace

63
1.2 Motor
Traction motor

Three phase AC motor, maintenance free, but need check and clean periodically. When fastening
the upper nut, lock the lower nut to avoid looseness, recommended tightening torque is T=10.2 ～
12.4N.m.
Model Rated Rated Rated Rated Insulation Frequency Duty Temperature Remark
power voltage current speed grade Hz
kW V A r/min ℃
min

YDQ1.5-
1.5 16 90 2295 H 79.6 S2-60 40 1.2t/1.6t
4-4820

W V U

Lifting bolt

Speed sensor

Thermistor

64
Steering motor
DC steering motor is permanent magnet brush motor with planetary reduction box.
①Output shaft
②Output shaft bearing
③Annular gear
④Second stage planet gear ⑤Split type planet carrier ⑥First stage planet gear ⑦Motor shaft
⑧Motor shaft bearing
⑨Motor housing
⑩Motor stator
⑪Motor rotor
⑫Motor rear cover

Technical parameter
Rated Rated Rated Rated Brush Rated Quota Insulatio Protectio Temperature
power voltage current speed service life torque n grade n grade
kW V A r/min h N.m min ℃

0.4 24 24 3200 1500 1.19 S2-10 B IP20 -10～+40

Motor wiring and direction of rotation

Check motor turn from motor output shaft:

Red outgoing line connects power positive, black outgoing line connects

power negative, output shaft rotates in clockwise.

Red outgoing line connects power negative, black outgoing line

connects positive power, output shaft rotates in counterclockwise.

Replace brush

Brush service life is 2000hrs. When replace brush, use “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 with load should run with low voltage and

limited speed, in order for safety, till the brush’s working face is shined.

65
Motor use notice
－
Parts of stator have been adjusted; users mustn’t unpack and adjust randomly.
－
Keep clean and dry around the motor, place no other material on its inner or outer.
－
Wipe off the sand and other adhesion on the housing in order not to affect heat dissipation.
－
It’s prohibited to use with overload.
－
It’s prohibited to coexist with strong magnetic object.
－
Make sure the correct of input voltage grade.
－
If there is abnormal odor in use, park to check immediately.
－
The cabling between motor and controller should be as short as possible.
－
During motor travelling, if there happen electric leakage, speed drops suddenly, severely

vibrate, too hot with smoke, or electric contact sparking smoke, turn off the power
immediately for check.
－
Often check if the motor over heats.
－
Often check motor wiring contact screw for looseness, sparking smoke or insulation aging.

Replace brush:

Brush service life is 2000hrs. When replace brush, use “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 with load should run with low voltage and
limited speed, in order for safety, till the brush’s working face is shined.

66
AC Motor fault diagnosis
Fault Probable cause
Power is not on(at least two phase off)
After power is on, the motor does not
Fuse fusing(at least two phase fusing)
rotate, but without noise, odor or
Overcurrent relay adjusts too small
smoke.
Wiring error of control equipment
Lack one phase power, or reverse connection of stator
coil one phase
After power is on, the motor does not Short circuit of stator winding
rotate and fuse burnout. Grounding of stator winding
Wiring error of stator winding
Fuse section too small.
Open circuit of stator, rotor winding(one phase
disconnection) or one phase power is off.
Start and end of the winding outgoing line wrongly
connect or internal winding oppositely connect.
Power return contact loosens and contact resistance is
After power is on, the motor does not large.
rotate but with buzzing noise.
Motor load too large or rotator locks.
Power voltage too low.
Small motor assembles too tight or bearing grease too
hard.
Bearing seizing-up.
Power voltage too low.
△Motor wrongly connected to Y
Cage rotor open weld or crack
Motor starts hard, and the motor Local coil of stator and rotor wrongly or oppositely
speed is much lower than rated
connected.
speed with rated load.
Add too much number of windings when repair motor
winding.
Motor overload.
When rewind, numbers of stator three-phase winding is
not equal.
Current is unbalance when motor
Two ends of winding wrongly connected
without load and three phases differ a
Unbalance power voltage.
lot.
There is interturn short circuit or coil oppositely
connected in the winding.
Motor without load, while loaded, Guide bar of cage rotor open weld or crack
ammeter indicator is unstable and Wound rotor fault(one phase open circuit) or bad brush
swings. and collecting ring short circuiting device contact.

67
 Fault Probable cause
Reduce too much number of stator windings when
repair motor winding.
Power voltage too high.
Y connected motor wrongly connect to Δ
Motor without load, current is During motor assemble, rotor oppositely connects,
balance, but the value is large
make stator core unaligned, effective length shortens.
Air gap over large or uneven.
When remove old winding for overhaul, use improper
way that burn the iron core.
Insulation paper of rotor and stator or slot wedge rubs.
There is foreign body as sand in oil or bearing wear.
Stator and rotor core loosen.
Bearing lack oil.
Abnormal noise when motor runs
Air duct stuffing or fan rubs the fan housing.
Stator and rotor core rub.
Power voltage too high or imbalance.
Wrongly stator winding or short circuit.
Too big wear bearing clearance
Uneven air gap
Rotor imbalance
Revolving shaft bend.
Big motor vibration during running Iron core deforms or loosens.
Housing or basic capacity is insufficient.
Motor foot screw loosen
Open circuit of cage rotor open welding, open circuit of
wound rotor, or winding fault with stator.
Over much or few grease
Bad oil quantity and contains impurity.
Mismatch between bearing and journal or end cap(too
loose or too tight)
Bearing overheat. Eccentricity of bearing bore, rub with the axle.
Motor end cap or bearing cap not even assembled
Coupling between motor and load not adjust
Too large or too small bearing clearance
Motor axle bend.
Too high power voltage, greatly increase the core
Motor overheating or smoking heating.
Too low power voltage, the motor drives rated load,

68
 Fault Probable cause
over large current heats the winding.
When remove winding for overhaul, use improper way
that burn the iron core.
Rotor and stator core rub.
Motor overloads or start up frequently.
Cage rotor break.
Motor overheating or smoking
Motor lacks phase, two phases run.
After rewinding, dipping paint of stator winding is
improper.
In high temperature, much dirt on the motor surface or
ventilation duct block.

69
DC Motor fault diagnosis
Fault Probable cause Correctives

Small brush contact surface Grind brush

Over brush wear Replace new brush

Oil stain on commutator surface Clean commutator surface

Commutator decentration or commutator
Process commutator outer circle
segment extrusion
Large spark
Motor overload Motor overload

Large mechanical vibration Eliminate vibration source

The welding of armature coils is not good
Repair welding
or open weld
Short circuit armature coils or
Eliminate short circuit.
commutator segment

Abnormal Large loading moment Reduce loading moment

speed Brush is not in neutral position Adjust brush to neutral position

Overload run Reduce overload

Coil overheat
Eliminate short circuit and
Armature coils short circuit
reinforce insulation
Basis unstable or motor fixed on the Reinforce basis firmness and fix
basis unstable the motor.
Decentraction of axis Adjust concentricity
Large vibration
Armature imbalance Re-adjust armature balance
Reduce loading moment or
Overload or overspeed
reduce speed

70
1.3 Electromagnetic brake
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 brake torque through compressed spring
in the state of power off, and electromagnetic induction realizes brake release.

6
5
4
3

1. Mounting screw
2.Stator
3. Friction disk assembly
4.Shaftsleeve
5. Friction disk
6.Dust cover
Fig. 2-4 Parts of electromagnetic brake

71
1.3.1 Working principle
Shaft(9) connects shaft sleeve(4)through flat key; shaft sleeve(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 friction disk assembly(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.

6 1. Mounting screw

3. Friction disk assembly

4. Shaft sleeve
1
5. Friction disk
7

5 6. Dust cover
3 7. Hollow screw
8
9 8. Armature
4 9. Motor shaft
10
11 10. Spring

11. Stator

Z Z. Air gap
Fig.2-5 Structure chart of electromagnetic brake

72
1.3.2 Brake installment
13
– Place flat key(12) to the key groove of motor shaft(9), press
4 12

shaft sleeve(4) to the shaft(9), and fix with inner snap 9

ring(13).

– Place friction disc(5) on the end face of motor.

– Cover friction brake disc(3) to the shaft sleeve.

– Install stator module(2) and three mounting screws(1). Note:

remove three fixed rubber gasket on the stator module(2)

before install.

–
Screw down three mounting screws(1) with spanner, and

check air gap ”Z”.

6

– Put dust cover（6）.

– Connect brake wiring.

73
 WARNING
 No damage on the outer of wire to avoid circuit damage.

 Never process the locating face and hold of the product to avoid magnetic

return path.

 Mount on the motor shaft lightly, no damage the friction surface, get rid of burr
from

mounting hold and face, install shaft sleeve on the shaft, and fix with snap spring.

Measure brake connected DC voltage and compare it with the voltage given on

the nameplate. Deviation within 10% is allowable.



U=x V DC±10%

OIL

74
1.3.3 Brake air gap adjustment
Rated air gap ”Z” will be large for wear. Make sure the brake get enough brake torque, readjust air

gap before the air gap reach 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 assembly.

When the air gas exceeds maximum air gas value, it may cause the brake unable to release,

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

cause severe accident. So it needs periodic check and re-adjust the air gap, and it must cut off the
truck general power.
Specifications
Tightening torque of
Rated torque Rated power Rated air gap Max. air gap
mounting screw

16Nm 24V 30W 0.2mm 0.3mm

When the brake is off power, adjust three hollow screw(7), with the help of feeler gauge, adjust the

air gap between armature and friction plate to rated value “Z”, ensure that air gap of each direction
is the same. Here follows the adjusting procedure:

– Screw off three mounting screws（1）.

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

– Screw down three mounting screws（1）.

– Use feeler gauge to check if air gap ”Z” is rated air gap value. Repeatedly adjust “Z” to
specified value.

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 every 6 months. In severe working condition,

like frequently brake, repeatedly sudden brake, the first adjustment can be shortened and adjust
the interval.

75
1.3.4 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.

76
1.3.5 Common fault and troubleshooting
Fault Probable cause Corrective action
Power is obstructed Connect

Too low exciting voltage Check voltage and adjust.

Brake does not
Improper air gap Adjust air gap
work
Stator coil breaks Replace stator

Oil dirt mixed in Clean oil dirt

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

Oil dirt mixed in Clean oil dirt

Unstable operation in previous use Running-in for a while

Oil dirt mixed in Clean oil dirt

Slipping Reduce load or replace large
Large load
specification
Adjust load peak or large the
Large load change
specification
Too high exciting voltage Check voltage and adjust.
Clutch or motor interfere to the Check control circuit, eliminate
brake interference
High temperature High environment temperature Set ventilation

High operating frequency Adjust to proper frequency

Over large load Reduce load

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

77
1.4 Schematic diagram of braking
The forklift truck motor is equipped with an electromagnetic brake. When the forklift is parked, the

electromagnetic brake is released. The brake pads firmly lock the motor shaft and the forklift is in
a mechanical braking state.

battery

Traction
Brake motor
switch

Electromagnetic brake

78
2 Hydraulic system
2.1 Hydraulic system working principle

79
2.2 Hydraulic unit
The truck adopts combined hydraulic unit, and is composed of DC motor, relay, coupling, valve

seat and valves (solenoid directional valve, safety valve, one-way valve, governor valve and oil
blockage), gear pump, pipeline, oil filter and fuel tank etc.

Notice

－ Examine motor and solenoid valve wiring, virtual earth is prohibited.

－ When install for the first time, notice inner oil in the oil tank, add enough oil after one working
cycle.

－ When wiring motor and solenoid valve, notice the power voltage is in accordance with the

marked one. AC motor shell should ground reliably and never run un-grounded. Prevent water

and humidity to motor connection box. When connect for the first time, start motor and check

motor direction, it rotates in counterclockwise seen from the rear motor. It is strictly prohibited
motor reverse rotation and no oil rotation.

－ When add oil, hydraulic oil must be filtered and the filter fineness is no lower than 25µm.

－ Power unit cannot filter out the impurity in the inner cylinder, so the inner cylinder should keep
clean to avoid control valve invalid. Pipeline should also be clean.

Maintenance

－ Keep clean on the element and the pipeline, avoid dirty go into the system.

－
Keep the oil level in the oil tank, add oil after certain working cycle. If pump absorbs air, it may
damage the pump and the sealer.

－
Replace new oil after truck adds hydraulic oil for the first time and travel 100 hours. And then
replace new oil every year (about 1500hrs).

－ 2 ～46mm /s.
Hydraulic oil viscosity is 22mm /s 2

－
Working temperature with high temperature needs oil with high viscosity and low temperature
needs oil with low viscosity.

80
 2.3 Hydraulic system fault diagnosis and correction
Fault Probable cause Corrective action

No oil Low oil level Fill to the specified oil level.

pumps from
Clean oil pipe and oil tank. If hydraulic oil is
the pump Blocking of strainer
dirty, please change it.
Bearing worn; retainer, O-ring
Change the bad spare parts
Low oil damage
pressure of Adjustment failure of safety
Rise pressure with pressure gage.
oil pump valve
output Fill hydraulic oil to the oil tank, use the pump
Air in the oil pump
after bubble vanishing
Cavitation arising from the Adjust or replace soft tube and clean the
strainer blocking strainer
Noise of oil Replace new hydraulic oil, whose viscosity
Cavity caused by the high
suits pump running speed. Work only when the
pump viscosity of hydraulic oil
oil temperature is normal
Check the reason for the bubble and then take
Bubble in the hydraulic oil
measures
Gear
pump Oil way block or damage Repair or replace
Forks can’t lift

works
Lifting inching switch loosen or
Gear Re-fix or replace
damage
pump
no work Motor or circuit fault Repair

Forks do not Solenoid valve block or

Repair or replace
drop down damage
Pressure adjusting screw
Re-adjust and lock.
loosen
Pressure of
safety valve Pressure adjusting spring
Replace
deformation or damage.
is unstable
Safety valve spool wear or
or can’t be Replace or clean to reassemble.
sticking
adjusted
Pump failure Repair pump

81
3 Electric system

Electric system of this truck is double wire system, all circuits do not ground. Working voltage is DC24V.
3.1 Principles of electrical system

CQDB12/16/20-AC1S Principles of electrical system

82
CQDB12/16/20-AZ3S Principles of electrical system

83
CQDB12/16/20-AC1S-I Principles of electrical system

84
CQDB12/16/20-AZ3S-I Principles of electrical system

85
CQDB12/16/20-AC2S Principles of electrical system

86
CQDB12/16/20-AC2S-I Principles of electrical system

87
3.2 Fault code table
CURTIS traction controller fault code table
Fault Programmer display Deep fault
Probable fault reason
code Fault display reason/troubleshooting
12 Controller Overcurrent 1. External short of phase U,V,W Reason ： Phase current exceeds
Motor stops working motor connections. limited current
Main connector disconnects 2. Motor parameters do not match. Troubleshooting ： restart the key
EM brake shutdown 3. Controller malfunction. switch
Throttle invalid
Brake
Pump stops working
13 Current Sensor Fault 1. Leakage to vehicle frame from Reason ： Deviation reads out to
Motor stops working phase U,V, or W controller current sensor.
Main connector disconnects 2. Controller malfunction Troubleshooting ： restart the key
Electromagnetic brake disconnects switch
Throttle invalid
Brake, Pump stops working
14 Precharge Failed 1. External load on positive Reason：Key switch input voltage
Motor stops working terminal of the capacitor that failed to charge the capacitor.
Main connector disconnects prevents the capacitor from Troubleshooting ： Reset or
Electromagnetic brake disconnects charging. re-input interlock switch through
Throttle invalid VCL function precharge().
Brake
Pump stops working
15 Controller Severe Undertemp 1. Severe controller working Radiator temperature is lower
Motor stops working environment. than -40℃.
Main contactor disconnects Troubleshooting ： Raise the temp
Electromagnetic brake disconnects above -40 ℃ , restart the key
Throttle failure switch or interlock switch.
Brake
Pump stops working
16 Controller Severe Overtemp 1. Severe controller working Reason ： Radiator temperature is
Motor stops working environment. higher than 95℃.
Main contactor disconnects 2. Truck overloads. Troubleshooting ： Drop the temp
Electromagnetic brake disconnects 3. Incorrect controller mounting below 95 ℃ . Restart the key
Throttle failure switch or interlock switch.
Brake, pump stops working
17 Severe Undervoltage 1. Setup error of battery parameter. Reason ： When MOSFEET axle
Too low voltage 2. Power consumption of non working, capacitor voltage is
Driving torque reduce controller system. lower than the minimum voltage
3. Too large battery impedance. limit.
4. Battery disconnects. Troubleshooting ： Raise the
5. Fuse protector disconnect, or the capacitor voltage.

88
Fault Programmer display Deep fault
Probable fault reason
code Fault display reason/troubleshooting
main contactor disconnect.

18 Severe Overvoltage 1. Setup error of battery parameter. Reason ： When MOSFEET axle
Overhigh voltage 2. High battery impedance. working, capacitor voltage
Motor stops working 3. Battery disconnects when exceeds the minimum voltage
Main contactor disconnects regenerative breaking. limit.
Electromagnetic brake disconnects Troubleshooting ： Reduce the
Throttle invalid voltage and then restart the key
Brake switch.
Pump stops working
21 Controller Undertemp Cutback 1. Controller works in limited Reason ： Radiator temperature is
No fault(unless VCL set the condition. lower than-25℃.
incurred fault) 2. Severe controller working Troubleshooting ： Make the
environment. radiator temperature higher than
-25℃.
22 Controller Overtemp Cutback 1. Severe controller working Reason ： Radiator temperature
Drive or regenerative braking environment. exceeds 85℃.
torque reduces. 2. Truck overloads. Troubleshooting ： Reduce the
3. Incorrect controller mounting temperature.
23 Undervoltage Cutback 1. Insufficient battery power. Reason ： Too low capacitor
Driving torque reduces 2. Setup error of battery parameter. voltage.
3. Power consumption of non Troubleshooting ：Raise capacitor
controller system. voltage.
4. Too large battery impedance.
5. Battery disconnects.
6. Fuse protector disconnects or
main contactor disconnects.

24 Overvoltage Cutback 1. During regenerative braking, Reason ： When MOSFEET axle

Regenerative braking torque regenerative braking current cause working, capacitor voltage
reduces the raising of battery voltage. exceeds the maximum voltage
2. Setup error of battery parameter. limit.
3. Too large battery impedance. Troubleshooting: Reduce
4. When regenerating braking, capacitor voltage.
battery disconnects.
25 +5V Supply Failure 1. External load impedance is Reason ： 5V supply outside the
too
No fault(unless VCL set the 5V±10% range
low.
incurred fault) Troubleshooting ： Adjust voltage
within range.
26 Digital Out 6 Failure 1. External load impedance is Reason： Digital Output 6 current
too
Digital Out 6 driver is not active. exceeds15mA.
low.
Troubleshooting ：Adjust load, set
“set_digout()” by VCL, and restart.

89
Fault Programmer display Deep fault
Probable fault reason
code Fault display reason/troubleshooting
27 Digital Out 7 Overcurrent 1. External load impedance is Reason ： Digital Output 7 current
too
The Digital Out 7 driver is not exceeds15mA.
low.
active Troubleshooting ：Adjust load, set
“set_digout()” by VCL, and restart.
28 Motor Temp Hot Cutback 1. M otor temperature reaches or Reason ： Input voltage value of
Driving torque reduced. exceeds parameter limit, thus motor temperature sensor is 0 or
cause current output reduce. larger than 10V.
2. Motor temperature parameters Troubleshooting ： Return the
incorrect. motor temperature to be within
3. If motor does not apply the permitted limits.
temperature sensor, programming
parameter “Temp compensation”
and “Temp cutback ” must
set
“OFF”.
29 Motor Temp Sensor Fault 1. Motor temperature sensor is Reason ： Input voltage value of
Max. speed drops to LOS status connected wrongly. motor temperature sensor is 0 or
and motor temperature cutback 2. If motor does not apply larger than 10V.
invalid. temperature sensor, programming Troubleshooting: Adjust input
parameter “Temp compensation” voltage value of motor
and “Temp cutback ” must temperature sensor to the normal
set scope.
31 Coil 1 Driver Open/Short 1. Connected load open or short. Reason： Driver 1 (pin 6) is either
Driver 1 output shut 2. Connecting pin stained. open or shorted. This fault can be
3. Wrong wiring. set only when “Main Enable ”
set to “OFF”.
Troubleshooting ：Correct open or
short circuit, restart output.
31 Main Open/Short 1. Connected load open or short. Reason ： Main contactor driver
Motor stops working 2. Connecting pin stained. (pin 6) is either open or shorted.
Main contactor disconnects 3. Wrong wiring. This fault can be set only when
Electromagnetic brake disconnects “Main Enable ” set to “ON ”.
Throttle invalid Troubleshooting ： Correct open
Brake circuit/short circuit, restart output.
Pump stops working
32 Coil2 Driver Open/Short 1. Connected load open or short. Reason： Driver 2 output(pin 5) is
Driver 2 output shut 2. Connecting pin stained. either open or shorted. This fault
3. Wrong wiring. can be set only when “EM brake
Type” set to 0.
Troubleshooting ：Correct open or
short circuit, restart output.
32 EMBrake Open/Short 1. Connected load open or short. Reason： EM Brake output(pin 5)
Electromagnetic brake disconnects 2. Connecting pin stained. is either open or shorted. This

90
Fault Programmer display Deep fault
Probable fault reason
code Fault display reason/troubleshooting
Throttle invalid 3. Wrong wiring. fault only occurs when “EM brake
Brake Type” set to 0.
Troubleshooting ：Correct open or
short circuit, restart output.

33 Coil3 Driver Open/Short 1. Connected load open or short. Reason：Driver 3 output (pin 4) is
Driver 3 output shut 2. Connecting pin stained. either open or shorted
3. Wrong wiring. Troubleshooting ：Correct open or
short circuit, restart output.
34 Coil4 Driver Open/Short 1. Connected load open or short. Reason： Driver 3 output (pin 3) is
Driver 4 output shut 2. Connecting pin stained. either open or shorted
3. Wrong wiring. Troubleshooting ：Correct open or
short circuit, restart output.
35 PD Open/Short 1. Connected load open or short. Reason ：PD(pin 2) is either open
PD shut 2. Connecting pin stained. or shorted
3. Wrong wiring. Troubleshooting ：Correct open or
short circuit, restart output.
36 Encoder Fault 1. Motor encoder error. Reason：Encoder fault
Electromagnetic brake disconnects 2. Wrong wiring. Troubleshooting ： Restart key
switch.
37 Motor Open 1. Motor phases is open. Reason ： Motor phase, U,V,W
Motor stops working 2. Wrong wiring. detected open
Main contactor disconnects Troubleshooting ： Check phase
Electromagnetic brake disconnects and restart the key switch.
Throttle invalid
Brake
Pump stops working
38 Main Contactor Welded 1. Main contactor tips are welded. Reason：Main contactor keep too
Motor stops working 2. Motor phases U and V is much connecting, capacitor
Main contactor disconnects disconnected or open. voltage can ’t discharge.
Electromagnetic brake disconnects 3. An alternate voltage path is Troubleshooting ： Restart the key
Throttle invalid providing a current to capacitor( B+ switch
Brake connection terminal)
Pump stops working
39 Main Contactor Did Not Close 1. Main contactor does not close Reason：When the main contactor
Motor stops working 2. Contactor contacts have is closed, capacitor voltage does
Main contactor disconnects oxidized, melted, or connection not charge B+ voltage.
Electromagnetic brake disconnects status is unstable. Troubleshooting ： Check the
Throttle invalid 3. External load on the capacitor. contactor, restart the key switch.
Brake 4. Fuse protector disconnects.
Pump stops working
41 Throttle Wiper High 1. Throttle pot wiper voltage too Reason ： Throttle pot wiper(pin
Throttle invalid high 16) voltage is higher than the
high

91
Fault Programmer display Deep fault
Probable fault reason
code Fault display reason/troubleshooting
fault threshold(can be changed
with the VCL function
setup_pot_faults()）
Troubleshooting ： Reduce the
throttle pot wiper voltage
42 Throttle Wiper Low 1. Throttle pot wiper voltage too low Reason ： Throttle pot wiper(pin
Throttle invalid 16) voltage is lower than the low
fault threshold(can be changed
with the VCL function
setup_pot_faults()）
Troubleshooting ： Raise the
throttle pot wiper voltage
43 Pot2 Wiper High 1. Pot 2 wiper voltage too high Reason ： Pot 2 wiper(pin 17)
Full brake voltage is higher than the
high fault threshold(can be
changed
with the VCL function
setup_pot_faults()）
Troubleshooting ： Reduce the pot

44 Pot2 Wiper Low 1. Pot 2 wiper voltage too low. wiper

Reasonvoltage
： Pot 2 wiper(pin 17)
Full brake voltage is lower than the low fault
threshold(can be changed with
the VCL function
setup_pot_faults()）
Troubleshooting ：Increase the pot
wiper voltage
45 Pot Low Overcurrent 1. Potentiometer impedance is too Reason ： Pot low end (pin 18)
Throttle invalid low. exceeds 10mA.
Full brake Troubleshooting: Reduce low end
current, restart the key switch
46 EEPROM Failure 1. Error writing to the EEPROM. It Reason：Controller system tries to
Motor stops may be caused by VCL writing to write into EEPROM but failed.
Main contractor stops. EEPROM, or CANBUS, or Troubleshooting ： Download
EM brake stops incorrect parameter editing. correct software(OS), set correct
Throttle stops parameter, and then restart
Interlock stops the key switch.
Driver1-4 stop
PD stops
Brake
Pump stops
47 HPD/Sequencing Fault 1. Wrong sequence setting of key Reason ： The wrong input of key
Throttle invalid start, interlock, direction and start, interlock, direction and

92
Fault Programmer display Deep fault
Probable fault reason
code Fault display reason/troubleshooting
throttle input sequence setting. throttle cause HPD and
2. Wiring, switch key, interlock, sequencing fault.
direction or throttle input fault. Troubleshooting ： Re-input
according to correct sequence.
47 Emer Rev HPD 1. Emer Rev already finished, but Reason：After Emer Rev finishes,
Throttle invalid the throttle, forward or reverse each input does not return to
input and interlock do not return to neutral, that cause the fault.
neutral. Troubleshooting ： Re-input
according to correct sequence.
49 Parameter Change Fault 1. In order to protect truck Reason ： Parameter change
safety,
Motor stops working needs restart of the key switch.
change of certain special
Main contractor stops working Troubleshooting ： Restart the key
parameter is only valid after restart
EM brake stops working switch
the key switch.
Throttle invalid
Brake
Pump stops working
52 TH PDO Timeout 1. Communication fault Handle damage or bad contact of
Motor stops communication loop
Pump stops
Handle control button invalid
68 VCL RunTime Error 1. VCL runtime. Reason：VCL runtime error.
Motor stops Troubleshooting ： Edit VCL
Main contactor stops software and correct, check new
EM brake stops software to make correct
Accelerator stops parameter matching; restart the
Interlock stops key switch.
Driver 1-4 stop
PD stops
Brake
Pump stops
69 External Supply Out of Range 1. External load on 5V and 12V Reason ： Upper limit of external
supplies too high or too low. power supply(total current: 5V(pin
2. Parameter error in the Checking 26) and 12V(pin 25) is defined by
Menu, like “ExtSupply Max”, “Ext External Supply Max and lower
Supply Min ” limit is defined by External Supply
Min
Troubleshooting ： Adjust external
current.
71 OS General 1. Inner controller invalid. Reason：Inner controller invalid.
Motor stops Troubleshooting ： Restart the key
Main contactor stops switch.
EM brake stops

93
Fault Programmer display Deep fault
Probable fault reason
code Fault display reason/troubleshooting
Accelerator stops
Interlock stops
Driver 1-4 stop
PD stops
Brake
Pump stops
72 PDO Timeout 1. Time between CAN PDO Reason：Time between CAN PDO
Interlock stops messages received exceeds PDO messages received exceeds PDO
CAN NMT State set to Timeout Period Timeout Period
Preoperational Troubleshooting ： Restart the key
switch, or accept CAN NMT
message

73 Stall Detected 1. Motor is stalled. Reason ： No motor encoder is

EM brake stops 2. Motor encoder fault. detected.
Switch the control mode to 3. Wiring damaged. Troubleshooting ： Restart the key
LOS(Limited operation status) 4. Problem with power supply for switch, or detect the effective
motor encoder. signal of motor encoder in LOS
mode, and set the parameter
to Throttle
Command=0,Motor

87 Motor Characterization Fault 1. Refer to the following Reason ： Motor matching

code
Motor stops process failure.
during motor matching：
Main contactor stops Troubleshooting ：Correct the fault
0=Normal
EM brake stops and restart the key switch.
1= Controller receives encoder
Accelerator stops
signal, but pulse value not defined.
Brake
Set pulse value manually
Pump stops
2= Motor temperature sensor
failure
3= Motor high temperature cutback
failure
4= Motor overtemp cutback failure
5= Motor low temperature cutback
failure
6= Low voltage cutback failure
7= High pressure cutback failure
8= Controller can’t detect encoder
signal and passage signal
disappears.
9= Motor parameter setting
exceeds the scope.
89 Motor Type Fault 1. Motor type parameter values Reason ： Motor Type parameter
exceed the range setting value is an illegal value.

94
Fault Programmer display Deep fault
Probable fault reason
code Fault display reason/troubleshooting
Troubleshooting ： Reset and
restart the key switch.
91 VCl/OS Mismatch 1. The controller VCL does not Reason：The controller VCL does
Motor stops match OS. not match OS.
Main contactor stops Troubleshooting ： Update new
EM brake stops VCL and OS.
Accelerator stops
Interlock stops
1-4 output stops
PD stops
Brake
Pump stops
92 EM Brake Failed to Set 1. Truck continues to move after Reason：After EM brake locks, the
EM Brake failure the EM brake has been truck still moves.
Throttle invalid commanded to set Troubleshooting ： Check if the
2. Small EM braking force. throttle works normal.

93 Encoder LOS (Limited Operating 1. LOS activated due to motor Reason ： LOS activated due to
Strategy) installing or encoder fault. motor installing or encoder fault.
2. Wrong wiring. Troubleshooting ： Restart the key
3. Truck is stalled. switch, if it is caused by
motor installing, make sure
encoder
work under normal condition,
Throttle Command=0,Motor
94 Emer Rev Timeout 1. Emer Rev timeout activated due Reason ： Emer Rev function
EM Brake failure to EMR Timer overdue activated to operate until Emer
Throttle invalid 2. Emer Rev switch is always at Rev timing end.
ON position. Troubleshooting ： Check Emer
Rev switch.
98 Illegal Model Number 1. Controller model can ’t Reason：Controller model can ’t be
be
Motor stops identified
identified.
Main contactor stops Troubleshooting ：Choose correct
2. Software and hardware do not
EM brake stops controller, and download correct
match.
Throttle stops controller software.
3. Controller damage.
Brake
Pump stops
99 Dualmotor Parameter Mismatch Enable parameter of dualmotor is Reason ： When the dual drive
Close main contactor set as ON, and control software enabled, control mode
Close EM brake mode selecting parameter not set should set as 0 （ Speed Mode
Close accelerator as 0 （ Speed Mode Express) Express) or 1 （ Speed Mode ） ,
Brake and close the pump or 1 otherwise there will be fault.
（Speed Mode） Troubleshooting ：Adjust to proper

95
Fault Programmer display Deep fault
Probable fault reason
code Fault display reason/troubleshooting
value and switch KSI.

96
Code Fault reason and display Fault reason CURTIS steering
controller fault code
23 motor polarity fault 1. Steering motor positive and table
steering stop negative polarity reversal
traction stop 2. Encoder phase sequence
reversal
36 motor stalled 1. Big steering system resistance
steering stop 2. Steering meet mechanical limit
traction stop 3. Neutral position detector switch
invalid
37 motor open 1. Bad contact of steering motor
steering stop cable connector
traction stop 2. Bad contact of steering motor
brush
41 command analog1 out of range 1. Direction angle sensor open
steering stop 2. Direction angle sensor damage
traction stop
42 command analog2out of range 1. Direction angle sensor open
steering stop 2. Direction angle sensor damage
traction stop 97
47 encoder fault 1. Encode open
steering stop 2. Steering encode is disturbed
traction stop 3. Steering encode damage
53 home position not found 1. Home position is far from test
steering stop strip
traction stop 2.Home position damage
73 following error 1. Big steering resistance
steering stop 2. Steering motor malfunction
traction stop
ZAPI controller fault code table
Machine status
Restart Alarm/
Alarms Error Code Description Effect when the test is
procedure Warning
done

One of two (or both)

Valve, pump, traction
Watchdog circuit outputs Valve or pump or
02A08 Watchdog stopped, Lc opened, start-up,stby, traction Alarm
becomes high due to an traction request
Eb applied
HW or SW problem
The software is corrupted Valve, pump, traction
02A08 Flash Checksum or the flash on the inverter stopped, Lc opened, continuous Alarm
is damaged. Eb applied
The software is corrupted Valve, pump, traction
Valve or pump or
02A09 Flash Checksum or the flash on theinverter is stopped, Lc opened, start-up,stby, traction Alarm
traction request
damaged. Eb applied
The software is corrupted Valve, pump, traction
Valve or pump or
02A10 WRONG RAM or the flash on theinverter is stopped, Lc opened, start-up,stby, traction Alarm
traction request
damaged. Eb applied
The traction rotor is stuck Valve, pump, traction
02A11 Stall rotor or the encoder is not stopped, Lc opened, Alarm
working Eb applied
The software is not Valve, pump, traction
02A12 Controller Mism compatible with the stopped, Lc opened, start-up key-recycle Alarm
controller. Eb applied
A parameters set restore Traction, pump
02A13 Param. Restore was made since the last No effect start-up or Warning
keyoff EVP request
The program checks the
Valve, pump, traction
contents of main EEPROM Valve or pump or
02A13 Eeprom Ko stopped, Lc opened, start-up,stby, traction Alarm
registers and find corrupted traction request
Eb applied
values
Valve, pump, traction
Failure in the high current Valve or pump or
02A17 Logic failure #3 stopped, Lc opened, start-up, stby Alarm
HW protection circuit traction request
Eb applied
Pump motor output is too Valve, pump, traction start-up, stby,during
Valve or pump or
02A28 Pump Vmn Low low, with respect to pwm stopped, Lc opened, pump Alarm
traction request
applied Eb applied function
Pump motor output is too Valve, pump, traction
Valve or pump or
02A29 Pump Vmn High high, with respect to pwm stopped, Lc opened, during pump function Alarm
traction request
applied Eb applied
Valve, pump, traction
Motor output voltage higher Valve or pump or
02A31 Vmn high stopped, Lc opened, start-up, traction
than expected traction request
Eb applied
Valve, pump, traction
When the mos of EB is Valve or pump or
02A40 Aux driv. Shrt. stopped, Lc opened, start-up,stby,marcia Alarm
shorted traction request
Eb applied
start-up,
The battery voltage is too Valve, pump, traction
stand-by(only Valve or pump or
02A41 Wrong Battery low or too high (< 0,8 Vbatt stopped, Lc opened, Alarm
immediatelyafter Lc traction request
OR > 1,2 Vbatt) Eb applied
closing)
Driver of EB coil is Valve, pump, traction
Valve or pump or
02A42 Aux driver open damaged (not able to stopped, Lc opened, stby, traction Alarm
traction request
close) Eb applied
The EVP driver isdamaged
02A48 EVP driver open or the EVP coil impedance EVP stopped Continuous Key-on recycle Warning
is too low
Press the lift and drop
02A49 LIFT + LOWER Pump stopped Continuous Key-on recycle Warning
buttons simultaneously
There are too many pump
02A49 Many pump reqs Pump stopped Continuous Pump request Warning
requests at the same time
Evp driver is failed shorted
Valve, pump, traction
(always ON) mismatch Valve or pump or
02A50 Evp driv. short stopped, Lc opened, start-up, stby Alarm
between the valve set-point traction request
Eb applied
and its feedback
The Evp1 coil is not
connected between PAUX
02A50 Evp coil open EVP stopped Continuous Key-on recycle Warning
and EVP output, and the
parameter EVP TYPE in

98
 Machine status
Restart Alarm/
Alarms Error Code Description Effect when the test is
procedure Warning
done

the set-option menu is set

Analog or Digital
The truck is in stby with Valve or pump or
02A51 Tiller open tiller switch LC opens standby traction Warning
opened for more than 30s request
Pump current feedback is
02A52 Pump I=0 ever always 0A even when Pump motor stopped pump function pump request Warning
pump motor is running
In stby condition (no
current applied to the Valve, pump, traction
Valve or pump or
02A53 Stby i high traction motor) the current stopped, Lc opened, start-up, stby Alarm
traction request
feedbacks are aout of Eb applied
permitted stby range
The outputs of the
amplifiers (used to
measure the motor voltage) Valve, pump, traction Valve or pump or
02A53 Wrong Zero are cheked this alarm stopped, Lc opened, init Alarm
traction request
occurs when voltage Eb applied
signals >3V or <2V at the
init
Overvoltage/Undervoltage Valve, pump, traction
Valve or pump or
02A54 Logic Failure #1 condition has been stopped, Lc opened, start-up Alarm
traction request
detected Eb applied
Valve, pump, traction
Motor voltage feedback stby, immediately Valve or pump or
02A55 Logic Failure #2 stopped, Lc opened, Alarm
circuits are damaged after Lc closing traction request
Eb applied
Pump chopper current
02A56 Pump I NO zero sensor feedback is out of Pump motor stopped start-up, stby pump request Warning
permitted stby range
Valve, pump, traction
Power capacitors voltage Valve or pump or
02A60 Capacitor charge stopped, Lc opened, start-up Alarm
does not increase traction request
Eb applied
The maximum
The output of the controller
currentis reduced to
02A61 Thermic sens ko thermal sensor is out of continuous Warning
half and speed is
range.
reduced
Traction controller
The controller has reached
reduces the maximum
the thermal cutback
02A62 Th. Protection current linearly from continuous Warning
temperature of 85°C when
Imax (85°C) down to
the current is IMAX
0A (105°C)
Input mismatch between Valve, pump, traction
Valve or pump or
02A64 Tiller error hard&soft switch input and stopped, Lc opened, start-up,stby, traction Alarm
traction request
tiller input Eb applied
Traction motor temperature
The maximum
sensor is opened (if digital)
currentis reduced to
02A65 Motor temperat or has overtaken the continuous Warning
half and speed is
threshold of 150°C (if
reduced
analog)
Battery is <= 20% when the Valve, pump, traction
Valve or pump or
02A66 Battery Low parameter BATTERY stopped, Lc opened, start-up,stby, traction Alarm
traction request
CHECK is set>0 Eb applied
The controller can not Valve, pump, traction
Valve or pump or
02A67 NO CAN MSG. receive the signal from the stopped, Lc opened, start-up,stby, traction Alarm
traction request
handle Eb applied
Valve, pump, traction
Smart driver is open, not
02A68 Smart driver KO stopped, Lc opened, start-up Key re-cycle Alarm
able to provide EB positive
Eb applied
A Canbus network node is
in alarm condition. uC is
02A68 Waiting for node continuous Warning
waiting for it to resolve its
error condition.
Sens. Mot. The motor temperature Valve, pump, traction Valve or pump or
02A69 start-up,stby, traction Alarm
Temp.KO sensor is damaged stopped, Lc opened, traction request

99
 Machine status
Restart Alarm/
Alarms Error Code Description Effect when the test is
procedure Warning
done

Eb applied
Error is detected in eeprom Controller works using
02A71 Eeprom ko continuous Warning
or in eeprom management Deafult parameters
Valve, pump, traction
Motor output voltage lower Valve or pump or
02A72 Vmn low stopped, Lc opened, start-up, traction Alarm
than expected traction request
Eb applied
When the positive of the
Valve, pump, traction
AUX OUTPUT isdriven by
02A74 Aux Batt. Short stopped, Lc opened, start-up, stby Alarm
the tiller, the positive is high
Eb applied
and the tiller is released.
EV1 on/off valve drivers
Drv. Shor. EV1 valve on/off
02A74 shorted On/off valves stopped start-up, stby Warning
dri request
(always ON)
EV2 on/off valve drivers
Drv. Shor. EV2 valve on/off
02A74 shorted On/off valves stopped start-up, stby Warning
dri request
(always ON)
EV3 on/off valve drivers
Drv. Shor. EV3 valve on/off
02A74 shorted On/off valves stopped start-up, stby Warning
dri request
(always ON)
Driver of LC coil is shorted,
Valve, pump, traction
so it is not able to open the Valve or pump or
02A74 Driver shorted stopped, Lc opened, start-up Alarm
LC, or LC coil is traction request
Eb applied
disconnected
Driver of Ev1 is open, not valve Ev1
02A75 Cont. Drv. Ev1 Ev1 stopped during Ev1 function Warning
able to close request
Driver of Ev2 is open, not valve Ev2
02A75 Cont. Drv. Ev2 Ev1 stopped during Ev2 function Warning
able to close request
Driver of Ev3 is open, not valve Ev3
02A75 Cont. Drv. Ev3 Ev1 stopped during Ev3 function Warning
able to close request
Driver of LC coil is Valve, pump, traction
Valve or pump or
02A75 Contactor Driver damaged (not able to stopped, Lc opened, start-up Alarm
traction request
close) Eb applied
Valve, pump, traction
Valve or pump or
02A75 Contactor closed LC contact is stuck stopped, Lc opened, start-up Alarm
traction request
Eb applied
Valve, pump, traction
Key-off signal is Shortcircuit on LC or EB
02A76 stopped, Lc opened, start-up Key re-cycle Alarm
low at Key-on coil
Eb applied
Valve, pump, traction
Coil short. Shortcircuit on LC or EB Valve or pump or
02A76 stopped, Lc opened, stby, traction Alarm
MC-EB coil traction request
Eb applied
start-up, stby,during
Shortcircuit on On/off valve on/off
02A76 Coil shor. Ev. On/off valves stopped valve Warning
valves coil reques
function
The LC coil has been Valve, pump, traction
Valve or pump or
02A77 Contactor Open driven but LC does not stopped, Lc opened, stby, traction Alarm
traction request
close Eb applied
The acceleretor value is
higher than the minimum
start-up,
02A78 Vacc not ok value recorded, and the Traction is stopped Traction request Warning
stand-by,traction
direction/enable switches
are opened.
Incorrect pump starting start-up, standby,
02A79 Pump inc start Pump stopped Pump request Warning
sequence traction
start-up,
02A79 Incorrect start Incorrect starting sequence Traction is stopped Traction request Warning
stand-by,traction
The travel demands are
start-up,
02A80 Forw+backward active in bothdirections at Traction is stopped Traction request Warning
stand-by,traction
the same time
Valve, pump, traction
Valve or pump or
02A82 Encoder Error Problem on the encoder stopped, Lc opened, traction Alarm
traction request
Eb applied
The voltage on CNC#4 is
02A85 Vacc out range Pump stopped Continuous Pump request Warning
out of the parameters

100
 Machine status
Restart Alarm/
Alarms Error Code Description Effect when the test is
procedure Warning
done

range ，The accelerator

input is out of the range
Vacc_min ÷ Vacc_max,
which has been acquired
with “PROGRAMM VACC”
function
Output of built in Smart
Driver, which supplies Eb Valve, pump, traction Valve or pump or
02A86 Pos. EB shorted coil positive, is high (= stopped, Lc opened, start-up Alarm
traction request
+batt) when the tiller switch Eb applied
is opened.
Accelerator poti negative
(Npot) voltage is out of start-up,
02A86 Pedal wire ko Traction is stopped Traction request Warning
range (less than 0,3V stand-by,traction
or >2V)
The pump accelerator
value is
Pump Vacc not
02A89 higher than the minimum Pump stopped Continuous Pump request Warning
OK
value recorded, and the
lift/lower switches are open
Valve, pump, traction
short circuit on the power Valve or pump or
02A89 Power mos short stopped, Lc opened, start-up Alarm
mosfets traction request
Eb applied
The voltage on CNC#9 is
Pump Vacc Pump stopped, EVP
02A90 out of the parameters Continuous Pump request Warning
range stopped
range
The Maximum current gain
parameters are the default
Controller works,
values,which means the
02A92 Current gain butwith low maximum start-up, stanby Warning
maximum current
current
adjustment procedure has
not been carried out yet
Valve, pump, traction
Problem on the A/D Valve or pump or
02A96 Analog input stopped, Lc opened, traction Alarm
conversion of uC traction request
Eb applied
valve
stopped,(eventually)
The PEV connector (B2) is pumpstopped,
not connected to the
02A98 Pev not OK (eventually)traction continuous Alarm
battery or the voltage is
stopped,(eventually)
different.
Lc opened and MC
applied
Error on the parameters of
the slip profile setting ，The start-up,
02A99 Slip profile Traction is stopped Traction request Warning
slip profile inside the stand-by,traction
controller is not correct
Switch OFF the
interlock switch again
after emergency Valve or pump or
06A00 EMERGENCY Emergency reverse start-up,stby, traction Alarm
reverse finished, and traction request
then this fault
disappears.
1) Check if zero
proximity switch is
correctly installed;
2) Check if zero
EPS NOT Valve or pump or
06A00 Zero is not found proximity switch start-up,stby, traction Alarm
ALIGNED traction request
selection is correct;
3) Check if zero
proximity switch
output data is correct;
This warning is
signaled when low Valve or pump or
06A00 KEYOFF Key switch short start-up,stby, traction Alarm
logic level signal is traction request
detected by the

101
 Machine status
Restart Alarm/
Alarms Error Code Description Effect when the test is
procedure Warning
done

control during
initialization phase.
Fault analysis：It may
be caused by too low
voltage, and is
suggested to check
the following items:
-Key switch is based
on external loading
(like DC-DC converter
activates, relay or
contactor switch input
signal is lower than
starting voltage);
- Check the
connection of power
cable with battery
positive and negative
electrode as well as
main contactor and
controller –BATT and
+BATT. Connect with
screw and the torque
range is
13NM÷15NM.
- If the pressure drop
is not detected on the
power supply line, this
warning is signaled
once the key switch is
ON. The fault may
occur on the controller
hardware, so it's
necessary to replace
the controller.
Exceed current exceeds Check if the motor
limit hardware circuit suits for eps-dc0 (not Valve or pump or
06A01 HIGH CURRENT start-up,stby, traction Alarm
current hardware to large), if so, replace traction request
limitations the controller.
When the motor
receives the travelling
command, the motor
V phase current is 0.
1) Check if the
controller fuse is
POWER normal;2) Check if the Valve or pump or
06A02 POWER FAILURE#1 start-up,stby, traction Alarm
FAILURE #1 power line and traction request
controller is firmly
connected;3) Check if
controller V phase is
well connected;4)
Replace the
controller.
When the motor
receives the travelling
command, the motor
W phase current is 0.
1)Check if the
POWER controller fuse is Valve or pump or
06A03 POWER FAILURE#2 start-up,stby, traction Alarm
FAILURE #2 normal; 2)Check if the traction request
power line and
controller is firmly
connected; 3)Check if
controller W phase is
well connected;

102
 Machine status
Restart Alarm/
Alarms Error Code Description Effect when the test is
procedure Warning
done

4)Replace the
controller.
When the motor
receives the travelling
command, the motor
W phase current is 0.
1) Check if the
controller fuse is
POWER normal; 2)Check if the Valve or pump or
06A04 POWER FAILURE#3 start-up,stby, traction Alarm
FAILURE #3 power line and traction request
controller is firmly
connected; 3)Check if
controller W phase is
well connected;
4)Replace the
controller.
Possible causes:
1) After switching on,
the current amplifier is
detected not within
2.2-2.8V during
Valve or pump or
06A05 STBY I HIGH Standby current is high initialization; start-up,stby, traction Alarm
traction request
2) Current amplifier
output exceeds 0.15V
drifting after
initialization. Solution:
replace the controller.
1) Check if stepper
motor connecting line
D LINE SENSOR Stepper motor Q LINE is well; 2) Resistance Valve or pump or
06A06 start-up,stby, traction Alarm
KO voltage is invalid between Q line and B- traction request
is too small(approach
30Ω).
1. Check if stepper
motor connecting line
is well;
Q LINE SENSOR Stepper motor D LINE Valve or pump or
06A07 2. Resistance start-up,stby, traction Alarm
KO voltage is invalid traction request
between D line and B-
is too small(approach
30Ω)
Possible causes:1.
EEPROM address
read-write error;2.
Hourmeter gets over
three hour records;3.
Valve or pump or
06A08 EEPROM KO EEPROM damage It occurs also when start-up,stby, traction Alarm
traction request
the busy bit of the
EEPROM does not
rise within 12 msec.
Solution: replace the
controller.
This warning is
signaled if the
detected motor
voltage amplifier Valve or pump or
06A09 VMN NOT OK VMN fault start-up,stby, traction Alarm
output is not between traction request
2.2V and 2.8V when
startup. Please
replace the controller.
This warning is signaled Improve controller
HIGH Valve or pump or
06A10 once the controller cooling; or replace start-up,stby, traction Alarm
TEMPERATURE traction request
temperature exceeds 75℃. controller.
Once this fault is
DATA Valve or pump or
06A11 Data acquisition signaled, please wait start-up,stby, traction Alarm
ACQUISITION traction request
until the data is

103
 Machine status
Restart Alarm/
Alarms Error Code Description Effect when the test is
procedure Warning
done

acquired.
Voltage of W and U is
LOGIC FAILURE inconsistent with Valve or pump or
06A12 LOGIC FAILURE #1 start-up,stby, traction Alarm
#1 demand voltage, traction request
replace the controller.
Voltage of W and V is
LOGIC FAILURE inconsistent with Valve or pump or
06A13 LOGIC FAILURE #2 start-up,stby, traction Alarm
#2 demand voltage, traction request
replace the controller.
W and U voltage
LOGIC FAILURE amplifier output Valve or pump or
06A14 LOGIC FAILURE #3 start-up,stby, traction Alarm
#3 exceed 0.25V drifting, traction request
replace the controller.
W and V voltage
LOGIC FAILURE amplifier output Valve or pump or
06A15 LOGIC FAILURE #4 start-up,stby, traction Alarm
#4 exceed 0.25V drifting, traction request
replace the controller.
The safety contactor
of the slave contactor
The safety contactor of the is detected closed
Valve or pump or
06A16 KS CLOSED slave contactor is closed ahead of time by the start-up,stby, traction Alarm
traction request
ahead of time. main contactor,
please replace the
controller.
The safety contactor
of the main contactor
The safety contactor of the is detected closed
Valve or pump or
06A17 KM CLOSED main contactor is closed ahead of time by the start-up,stby, traction Alarm
traction request
ahead of time. slave contactor,
please replace the
controller.
The safety contactor
of the slave contactor
The safety contactor of the is detected not closed Valve or pump or
06A18 KS OPEN slave contactor is not start-up,stby, traction Alarm
in time by the main traction request
closed in time.
contactor, please
replace the controller.
The safety contactor
of the main contactor
The safety contactor of the is detected not closed Valve or pump or
06A19 KM OPEN main contactor is not start-up,stby, traction Alarm
in time by the slave traction request
closed in time.
contactor, please
replace the controller.
This warning is signaled
when CAN BUS is set to
PRESENT. eps-dc0 wait
for the message that
Find reasons from
MAIN CONT. traction controller had Valve or pump or
06A20 traction controller and start-up,stby, traction Alarm
OPEN closed main contactor traction request
keep controller open.
through CAN. This warning
is signaled when no closing
message within 1.5
second.
Bus messages between Replace the
main and slave controller. Valve or pump or
06A21 MICRO SLAVE start-up,stby, traction Alarm
microprocessors have traction request
frozen to OXFF value.
Disconnect angle Check steering
S.P OUT OF Valve or pump or
06A22 sensor,angle input voltageencoder hardware or start-up,stby, traction Alarm
RANGE traction request
is out of range. line.
Check steering
F.B OUT OF Disconnect steering Valve or pump or
06A23 encoder hardware or start-up,stby, traction Alarm
RANGE encoder. traction request
line.
MICRO SLAVE Main and slave 1) The detected Valve or pump or
06A24 start-up,stby, traction Alarm
KO microprocessors mismatch. stepper motor traction request

104
 Machine status
Restart Alarm/
Alarms Error Code Description Effect when the test is
procedure Warning
done

directions from main

microprocessor and
slave microprocessor
are different when
using the stepper
motor;2) In the
closed-loop control
system, main
contactor detected
stepper motor
direction is wrong,
and also is different
from the one detected
from the main
contactor;3) Steering
limit is not detected by
main contactor, but by
the slave contactor.
Controller detects that
two continuous speed
readings on the
encoder differs a lot:
as the system
encoder cannot
change speed a lot in
a short time, so it
maybe the encoder
error(one or two
encoder lines damage
or break), check the
encoder mechanical
and circuit function; or
the electromagnetic
ENCODER interference on the Valve or pump or
06A25 Encoder error start-up,stby, traction Alarm
ERROR sensor bearing traction request
causes the Alarm; if
not the above
reasons, please
replace the controller.
Please notice that
human operation can
also cause this failure,
such as the following
condition:1)The truck
bumped into barrier
accidentally and
cannot travel;2)
Depress the brake
suddenly when the
truck in high speed.
BAD ENCODER Encoder phase sequence Interchange encoder Valve or pump or
06A26 start-up,stby, traction Alarm
SIGN is wrong. A and B phases. traction request
GAIN EEPROM EEPROM memory current Replace the Valve or pump or
06A27 start-up,stby, traction Alarm
KO value is different. controller. traction request
1) Check if CAN BUS
communication lines
are well connected;
2) Check if the
communication
CAN BUS communication Valve or pump or
06A28 CAN BUS KO baudrate is start-up,stby, traction Alarm
fault. traction request
consistent.
3) Check if the CAN
communication is
open.
4) Check if the CAN

105
 Machine status
Restart Alarm/
Alarms Error Code Description Effect when the test is
procedure Warning
done

communication loop
resistance is 60Ω.
Disconnect angle sensor,
when the senor is using
with feedback
potentiometer, feedback
encoder measures that
POSITION steering wheel angle Check coupling, angle Valve or pump or
06A38 start-up,stby, traction Alarm
ERROR equals the FEEDBACK sensor hardware link. traction request
ENC and FEEDBACK POT
in the test menu as
expected. This warning is
signaled when the
difference is above 20°.
Controller slave chip
SERIAL ERROR did not receive master Valve or pump or
06A39 start-up,stby, traction Alarm
#1 chip message, traction request
Serial error. replace the controller.
Steering motor current is
MICRO SLAVE Valve or pump or
06A40 opposite to the command start-up,stby, traction Alarm
#4 traction request
direction. Replace controller
Main contactor does not
SLAVE COM. Valve or pump or
06A41 receive messages from start-up,stby, traction Alarm
ERROR traction request
slave contactor. Replace controller
Valve or pump or
06A42 NO SYNC Replace controller start-up,stby, traction Alarm
Out of sync fault. traction request
Maximum current gain
parameter is factory
default. It indicates
that the maximum
current adjustment
Valve or pump or
06A43 CURRENT GAIN Current gain fault. parameter program start-up,stby, traction Alarm
traction request
has not yet operated.
Solution: ZAPI
technician will set the
current gain
parameter correctly.
CLOCK PAL Valve or pump or
06A44 Replace controller start-up,stby, traction Alarm
NOT OK Clock fault traction request
STEER Two voltage signals of Check lines or replace Valve or pump or
06A45 start-up,stby, traction Alarm
SENSOR KO angle sensor mismatch. angle sensor. traction request
This signal is alarmed
when the feedback
Replace steering Valve or pump or
06A46 JERKING FB potentiometer(CPOT open) start-up,stby, traction Alarm
encoder. traction request
changes larger than 0.3V
within 16 millisecond.
If steering encoder
FB POT mechanical link is normal Valve or pump or
06A47 start-up,stby, traction Alarm
LOCKED or something block the traction request
wheel.
MOTOR Valve or pump or
06A48 motor temperature hot start-up,stby, traction Alarm
TEMPERAT. traction request
This signal is alarmed
MOTOR when the steering motor Check the controller Valve or pump or
06A49 start-up,stby, traction Alarm
LOCKED current and max. current mechanical part. traction request
keep close over 1 second.
Stepper motor Q and D line
STEPPER MOT Valve or pump or
06A50 frequency do not match Replace controller start-up,stby, traction Alarm
MISM traction request
with the voltage value.
MICRO SLAVE Valve or pump or
06A51 start-up,stby, traction Alarm
#3 traction request
Main microprocessor
MICRO SLAVE encoder is different from Valve or pump or
06A52 Replace controller start-up,stby, traction Alarm
#8 slave microprocessor traction request
encoder.

106
 Machine status
Restart Alarm/
Alarms Error Code Description Effect when the test is
procedure Warning
done

INPUT ERROR Valve or pump or

06A53 Harness connection error. start-up,stby, traction Alarm
#1 traction request
CAN BUS KO Slave CAN BUS Valve or pump or
06A54 Replace controller start-up,stby, traction Alarm
SL. communication fault. traction request
SL EPS NOT Valve or pump or
06A55 Controller malfunction. Replace controller start-up,stby, traction Alarm
ALL. traction request
Valve or pump or
06A56 SL CENTERING Controller malfunction. Replace controller start-up,stby, traction Alarm
traction request
MICRO SLAVE Valve or pump or
Replace controller start-up,stby, traction Alarm
#8 traction request

107
 Fault Code (Flash Failure name (Fault Name)
Code)
1-2 Controller Overflow (Controller Overcurrent)
1-3 Current sensor fault (Current Sensor)
1-4 Pre-charging fault (Precharge Failed)
1-5 Controller at severe low temperature (Controller
Severe
1-6 Undertemperature)
Controller with severe high temperature (Controller
Severe
1-7 Overtemperature)
Control B + end severe LV (Severe B + Undervoltage)
1-7 Controller KSI End Severe Low Pressure (Severe
KSI
1-8 Undervoltage)
B + (Severe B + Overvoltage)
1-8 KSI (Severe KSI Overvoltage)
1-9 Speed limit regulatory fault (Speed Limit Supervision)
1-10 Operational control regulatory fault (Travel Control Supervision)
2-2 Controller overtemperature reduction (Controller
Overtemperature
2-3 Cutback)
Low pressure reduction (Undervoltage Cutback)
2-4 High pressure reduction (Overvoltage Cutback)
2-5 5V output fault (Ext 5V Supply Failure)
2-6 12V output fault (Ext 12V Supply Failure)
2-8 Motor high temperature reduction (Motor Temp Hot Cutback)
2-9 Motor temperature sensor fault (Motor Temp Sensor)
3-1 Main Contactor Drive fault (Main Driver)
3-2 Electromagnetic brake drive fault (EM Brake Driver)
3-4 Load-holding drive fault (Load Hold Driver Fault)
3-5 Drop proportional valve drive fault (Lower Driver)
3-6 Encoder fault (Encoder Fault)
3-7 Motor open circuit (Motor Open)
3-8 Main contactor adhesion (Main Contactor Welded)
3-9 Main contactor nonsuction closing (Main Contactor Did Not Close)
4-2 Accelerator input fault (Throttle Input)
4-4 Brake input fault (Brake Input)
4-6 Memory data read and write fault (NV Memory Failure)
4-7 High Pedal Protection (HPD Sequencing)
4-7 Emergency Reverse high pedal protection (EMR Rev HPD)
4-7 Oil pump high pedal protection (Pump HPD)
4-9 Parameter modification fault (Parameter Change)
4-10 Emergency reverse switch redundancy fault (EMR
Switch
5-1 Redundancy)
Custom fault 1
5-2 Custom fault 2
5-3 Custom fault 3
5-4 Custom fault 4
5-5 Custom fault 5
5-6 Custom fault 6
5-7 Custom fault 7
5-8 Custom fault 8
5-9 Custom fault 9
F2C Trouault menu: Repair Index (TROUBLESHOOTING CHART INDEX)

108
6-1 Custom fault 10
6-2 Custom fault 11
6-3 Custom fault 12
6-4 Custom fault 13
6-5 Custom fault 14
6-6 Custom fault 15
6-7 Custom fault 16
5-10 Custom fault 17
5-11 Custom fault 18
5-12 Custom fault 19
5-13 Custom fault 20
5-14 Custom fault 21
5-15 Custom fault 22
6-10 Custom fault 23
6-11 Custom fault 24
6-12 Custom fault 25
6-13 Custom fault 26
6-14 Custom fault 27
6-15 Custom fault 28
7-10 Custom fault 29
7-11 Custom fault number 30
7-12 Custom fault set 31
7-13 Custom fault # 32
6-8 VCL run timeout (VCL Run Time Error)
7-2 CAN Communication Timeout (PDO Timeout)
7-3 Motor blocking (Stall Detected)
7-7 Monitoring-detected fault (Supervision)
7-9 Monitoring the input check fault (Supervision Input Check)
8-2 PDO mapping failure (PDO Mapping Error)
8-3 Internal hardware failure (Internal hardware)
8-7 Motor Match Failure (Motor Characterization Error)
8-8 Incoder pulse fault (Encoder Pulse Error)
8-9 Parameter Setting Over-Range (Parameter Out Of Range)
9-1 Firmware damage (Bad Firmware)
9-2 Electromagnetic brake setting brake failure (EM Brake Failed
to
9-3 Set)
Encoder failure, motor enters speed limit mode (Encoder LOS)
9-4 Emergency reverse timeout (Emer Rev Timeout)
9-5 Oil pump overcurrent (Pump Overcurrent)
9-6 Oil pump low power failure (Pump BDI)
9-7 Oil pump hardware failure (Pump Hardware)
9-9 Monitoring the emergency reverse discovery fault
(EMR
9-10 Supervision)the interlock brake discovery fault (Interlock
Monitoring
Braking
9-11 Supervision)
Monitoring emergency discovery fault (EMR Supervision)
10-1 Drive 1 fault (Driver 1 Fault)
10-2 Drive 2 fault (Driver 2 Fault)
10-3 Drive 3 fault (Driver 3 Fault)
10-4 Drive 4 fault (Driver 4 Fault)
10-5 Drive 5 fault (Driver 5 Fault)
10-6 Drive 6 fault (Driver 6 Fault)

109
 10-7 Drive 7 fault (Driver 7 Fault)
10-8 Driver assignment handling fault (Driver Assignment)
10-9 Coil power failure (Coil Supply Fault)
11-1 Analog Volume 1 Over-Range (Analog 1 Out of Range)
11-2 Analog Volume 2 Over-Range (Analog 2 Out of Range)
11-3 Simog 3 Over Range (Analog 3 Out of Range)
11-4 Simog 4 Over range (Analog 4 Out of Range)
B-5 Simog 5 over range (Analog 5 Out of Range)
11-6 Simog 6 over range (Analog 6 Out of Range)
11-7 Analog Volume 7 Over-Range (Analog 7 Out of Range)
11-8 Simog 8 over range (Analog 8 Out of Range)
11-9 Analog Volume 9 Over-Range (Analog 9 Out of Range)
11-11 Analog Volume 14 Over-Range (Analog 14 Out of Range)
11-12 Analog quantity allocation Handling fault (Analog Assignment)
11-13 Analog Volume 18 Over-Range (Analog 18 Out of Range)
11-15 Oil pump current sensor fault (Pump Current Sensor)
12-1 Branding Error
12-3 Hardware Incompatible (Hardware Compatibility)
12-5 Lift-up input fault (Lift Input)
12-6 Drop-down input fault (Lower Input)

110
 Failure Diagnosis menu: AC F2C controller troubleshooting table (AC F2C Controller
Troubleshooting Chart)
fault code Fault name Possible cause Trigger and Action
clear the perform
conditions ed by
the
controlle
r during
a failure
1-2 Controller over current 1. Short circuit for Trigger: phase Turn off the
(Controller Overcurrent) Failure type: external connection current overcurrent motor,
1 of motor U, V and detection upper main
= U phase overcurrent W limit contactor,
2 = W phase overcurrent phase clearance: electromagn
3 = V phase overcurrent 2. Motor encoder reset controller etic
4 = Controller current> 135% limit signal is disturbed brake,
flow value 3. Misadjusted the accelerator,
parameters of full power
the brake
motor
1-3 Current sensor fault (Current Sensor) 1, U, V, or W phase Trigger: Turn off the
Fault type: 1 to vehicle body The motor,
leakage (short current sensor has
main
circuit an invalid offsetcontactor,
in the stator) reading electromagn
2. Controller failure Clear: Reset
etic
control brake,
implement accelerator,
all
Power
1-4 Pre-charging fault 1. The load Trigger: Turn off the
（Precharge Failed） connected to The motor,
fault type: the controller main
1. Disruption controller B capacitance contactor,
+ charging has failed electromagn
2. Energy limit
terminal suppresses Clear: on- etic
3. Time limit
the controller off brake,
internal interlock or reset accelerator,
capacitor charge controller full power
2. Check the brake
voltage
displayed by
Programmer
1-5 Controller at severe low \
1, The controller Trigger: Turn off the
temperature works in an The motor,
(Controller Severe Undertemp) extreme radiator main
Fault type: 1 environment 2, temperature is contactor,
check below-40°C electromagn
the Programmer Clear: etic
\ radiator brake,
System Monitor temperature accelerator,
Menu\Controller\Cont above-40°C, all
roller Temperature Then you reset Power

111
1-6 Controller severe high 1, The controller Trigger: the Turn off the
temperature works in radiator motor,
(Controller Severe Overtemp) extreme temperature is main
failure environments contactor,
below + 95°C
type: 1 2. Heavy load electromagn
Clear: If
3. The controller the etic
is radiator brake,
not installed temperature is accelerator,
4, Check for below + 95°C, full power
Programmer and then reset electric
\ brake
the
System Monitor
controller
Menu \ Controller
\
Controller
1-7 Controller B + end has a severely 1. The non-controller Trigger: after the The
low system main drive-free
voltage consumes contactor torque
（Severe B+ Undervoltage the photobattery suction, the output
） 2. High internal FET
Fault type: 1 resistance in the bridge road works:
battery or because the low
3. The battery is not voltage off
current
connected when
output exceeds
driving the motor
64ms, or if the
4. The fuse
low voltage off
connecting B +
is voltage
broken or the main value of
the
contactor is not
controller
engaged is
5, Controller reached
battery
Clear:
parameter set controller
error
current output>
6, check 0%
for
over 100ms, or
Programmer
\ capacitance
1-7 Controller KSI end is severely 1. The non-controller Trigger: the KSI No, unless
low system voltage is below specific
pressure consumes the LV off voltage measures
（Severe KSI Undervoltage the photobattery for 2 seconds are included
） 2. The KSI input line Clear: in the
Fault type: 1 has a high resistance KSI VCL
3. The KSI line is voltage> LV off software
disconnected when voltage value
driving the motor
4. The fuse is broken
5, Check for
the
Programmer
\
System Monitor
Menu \ Controller
\

112
1-8 Control B + terminal has severe 1. The controller Trigger: the Turn off the
high battery capacitor voltage motor,
pressure parameters exceeds the setting main
(Severe B + Overvoltage) Failure type: are wrongly set value of contactor,
1 2. FET electromagn
Regenerative voltage etic
braking, with Clear: brake,
a the accelerator,
current to recharge capacitance full power
the battery, the voltage is below brake
battery resistance is the severe
too high high
3. The battery is not voltage setting
connected during value, and
the the
regenerative braking reset to control
4. Check the implement
voltage
displayed by
1-8 High controller KSI terminal 1. The Trigger: The KSI Turn off the
(Severe KSI Overvoltage) Failure battery voltage exceeds motor,
type: voltage to the severe main
1 the high contactor,
controller KSI voltage setting electromagn
(pin1)
value etic
exceeds the brake,
severe Clear:
the accelerator,
high voltage setting
capacitance full power
2. Check the
voltage voltage is below brake
displayed by the severe
high
Programmer
\ voltage setting
System Monitor value, and
1-9 Monitor to the speed limit fault 1. The motor speed Trigger: The motor Close
Fault type: 1 exceeds the Max speed exceeds the the
Speed set value, and interlock,
Supervision the electromagn
setting duration also etic brake,
2, Max Speed exceeds the set
Supervision setting value
value error 3, Clear: Reset
check control
the Programmer implement
\
Application Setup
\

113
1-10 Monitor operational control failure 1. When the Trigger: In the Turn off the
Fault type: 1 vehicle shutdown state, motor,
is stopped, the the main
controller output motor contactor,
frequency and phase frequency and electromagn
current exceed phase current etic
the exceed the brake,
parameter parameter accelerator,
setting setting full power
value at value under Travel brake
Travel
Control
Control Supervision
Supervision
2. The
parameter Clear: Reset
under the Travel control
Control Supervision implement
is set incorrectly
3, Check the
2-2 Controller high temperature Programmer
1, The controller Trigger: Down-drive
reduction works in The and
(Controller Overtemp Cutback) extreme radiator braking
Fault type: 1 environments temperature is torque
2. Heavy load below + 85°C
3. The controller Clear: If
is the
not installed radiator
4, temperature is
Controller below + 85°C,
performance and
is then reset
limited at the
this controller
temperature 5,
check
Programmer
\

114
2- Low voltage reduction 1. The battery needs Trigger: the Drop drive
(Undervoltag e Cutback) Failure type: to be charged, and capacitor voltage is torqu
the controller below the
performance is UndervoltageCut
limited at this voltage back limit after FET
2. The controller bridge operation
battery parameters Clear: Capacitance
are set incorrectly voltage above the
3. The non-controller UndervoltageCut
system consumes back limit
photocells
4. High internal
resistance in the
battery
5. The battery is not
connected when
driving the motor
6. The fuse
connecting B + is
broken or the main
contactor is not
engaged
7, Check for
Programmer \
System Monitor
Menu \ Controller \
Currents \
UndervoltageC
utback
8, Check the voltage
displayed by
Programmer \
System Monitor
Menu \ Controller \
Capacitor Voltage

115
2-4 High pressure reduction 1. During normal Trigger: after the Downke
（Overvoltage Cutback） operation, the current FET bridge torque Note:
Fault type: 1 generated by the road This fault
regenerative brake operation, is
is the only
recharged to capacitance detected
the voltage exceeds during
battery. Too OvervoltageCutb regenerativ
high ack, the limit value e
battery voltage fails, Clear: braking
the Capitance
controller voltage above
performance OvervoltageCutb
is
ack, limit value
limited 2, and the
controller
battery
parameters are
not
set correctly
3.
Regenerative
braking, with
a
current recharge
battery, the battery
internal resistance is
too high
4. The battery is not
connected during
the
regenerative braking
5, Check for
Programmer
\
System Monitor
Menu \ Controller
\
2-5 The 5V output failure has occurred 1. External 5V load is Trigger: 1,5V Turn off the
(Ext 5V Supply Failure) Fault type: too small (pin16) 2. output over 5V ± 5V output
1. The output of 5V voltage exceeds Check the voltage 10%; 2,5V
the and current of the 5V current
range of 2,5V voltage output displayed by is limited by
The current exceeds the range the
Programmer
\ parameter
setting;,
System Monitor
clear: reset
2-6 A 12V output failure Menu \ Outputs
1. External 12V Trigger: 1,12V Turn off the
（Ext 12V load Output super 12V loss
Supply Failure) Fault type: 1, of is small (pin23) 12V±15%；2， go out
the 2. Check the The 12V current is
output voltage
limited by
The 12V voltage exceeds the range and current of the the
2,12 Voltage of the 12V output shown parameter setting;
The current exceeds the range from Programmer Clear: reset
\
controller, or
System Monitor VCL

116
2-8 Motor high temperature reduction fault 1. The motor Trigger: If the 1. Lower the
type: 1 temperature is motor drive torque
greater than or equal temperature 2,
to the Temperature is greater than or If
Hot setting equal to MotorBrakin
value, Temperature g
resulting in the output Hot, Thermal
of the controller set the value CutBack_E
flow Clear: Reduce n
limit 2, the motor the a ble =
temperature to the On,
temperature and
normal value drop
sensor parameters
brake
are set wrong 3,
torque
check Programmer
\
2-9 Motor temperature sensor (Motor 1. Motor temperature Trigger: Motor Enter
Temp sensor is not well temperature the
Sensor) connected; sensor input LOS
Fault type: 1 mode,
2. Improper (pin9)
sensor Conversion reduce
the
polar voltage value
connection motor
beyond the range
(pin9 and speed, the
clearance:
pin12） motor motor
high
3. Motor temperature temperature
reduction
and sensor sensor
input function
parameters set is
correctly 4. Check voltage
off
Programmer Return to
\ normal
System Monitor range
3-1 Main contactor drive fault (Main Driver) 1. Drive load is open Trigger: Main Turn off the
fault type: or short circuit Enable = On motor,
1. Drive short circuit 2, The connector When the main
2. Drive the current pin main contactor,
3, Open circuit / short circuit foot or contactor contactor drives an electromagn
coil open or short etic
(High detected, should be low) 4, open /
is dirty circuit brake,
short circuit
3. Wrong connector clearance: accelerator,
(Low detected, should be high)
clamping or wrong repair the reset full power
5. Break the line
wiring controller brake

3-2 Electromagnetic brake drive fault 1. Drive load is open Trigger: At EM Turn off the
(EM or short circuit Brake Type> 0, the electromagn
Brake Driver) fault type: 1, short 2, The connector electromagnetic etic
circuit to drive pin brake (pin 4) brake,
2. Drive the current foot or contactor drives accelerator,
3, Open circuit / short circuit coil the open or short full power
(High detected, should be low) 4, open / is dirty circuit brake
short circuit 3. Wrong connector clearance:
(Low detected, should be high) clamping or wrong the
wiring repaired
5. Break the line
post-reset
3-4 Load-holding drive fault (Load Hold Equivalent to Equivalent to Turn off the
Diver the the currently
Fault） Driver 1 Fault Driver 1 Fault assigned
driver

117
3-5 Down drive failure Equivalent to
（Lower Fault） the
3-6 Encoder failure Driver 1 Fault
1. Motor encoder Trigger: the motor Turn off the
（Encoder Fault） fails encoder signal electromagn
fault type: 2. Wrong pressing or detection failure etic
1. Check the loss wiring clearance: reset brake,
2. Overcurrent causes pulse loss 3, 3, Check for the controller, or if accelerator,
speed pulse signal loss 4, and Programmer the parameter full power
motor \ LOS brake
matching System Monitor Upon Encoder
5. Encoder for Menu \ AC Motor Fault = On, reset
Electrical part failure \ Motor RPM the
4, Check for interlocking switch
Programmer \ after the
AC fault
Motor Setup clearance,
\ enter the LOS
3-7 The motor open 1. Motor phase Trigger: Motor U, Turn off the
（Motor Open） is V, motor,
Fault type: 1 open circuit and W main
2. Wrong pressing or phases contactor,
wiring open circuit are electromagn
detected etic
Clear: Switch KSI brake,
accelerator,
full power
3-8 Main contactor adhesion 1. Main Trigger: the Turn off the
（Main Contactor Welded） contactor main motor,
Fault type: 1 contact is contactor main
often is contactor,
connected released after electromagn
2. Motor V phase absorption, and etic
or U phase open the brake,
circuit capacitor voltage is accelerator,
3. An external not lowered all
voltage Clear: Reset Power

118
3-9 Main contactor non-suction- Type 1: Trigger: After the Turn off the
suction 1. The main contactor motor,
(Main Contactor Did Not Close) fault main is main
type: 1, the main contactor non- contactor does not controlled, contactor,
suction in 2 after the control command, engage the electromagn
the main contactor is disconnected 2. The capacitor voltage etic
when working main does not charged brake,
contactor contact to the accelerator,
is battery full power
defective voltage clearance: brake
3. The controller B + reset controller
terminal column is
connected with
a
large load outside, so
that the
capacitor
cannot be effectively
charged
4. Burning of the
high current fuse
5. Main
contactor
parameter set wrong
type 2:
1. The
main
contactor
is
4-2 Accelerator input fault (Throttle Input) 1, The Trigger: Turn off the
Fault type: 1, too low or too high accelerator Accelerator accelerator
input voltage input
is voltage is beyond
beyond the range of the range of
the Analog Low and Analog Low and
Analog High settings, Analog High
and settings
the
Clear:
corresponding the
analog input accelerator
is input
defined as voltage is back
the to
accelerator input the normal range,
2, Check reset control
Programmer implement
\
Controller Setup
\
Analog Inputs
4-4 Brake input fault (Brake Input) Corresponding Note: Input 1 Full power
Fault type: 1 fault troubleshooting braking
triggered by the may also be
brake input the
source input voltage
(allocated exceeding
analog the

119
4-6 Memory data read and write fault 1. Memory data Trigger: Turn off the
(NV read The motor,
Memory and write failure controller will read main
Failure） 2. Internal failure of and write contactor,
fault type: the controller the electromagn
1. Invalid verification EEPROM number etic brake,
2, Data write error 3, data read out error According to the Accelerator,
4, data write failure Interlock,
It was not completed due to the Clear: Download Drive
power failure the 1,2,3,4,5,
correct
proportional
software and the
drive,
corresponding full
parameter settings, power
4-7 High Pedal Sequential Protection 1. The key Trigger: Key Turn off the
(HPD switch, switch, accelerator
Sequencing) Failure type: 1 interlock, interlocking,
direction
direction
switch switch
and
and
accelerator input accelerator
are
input
incorrectly sequence
2. Wiring or pressing trigger HPD or
error in the SRO failure
key
Clear: Count back
switch,
interlocking, in the correct order
direction switch
and
accelerator input
break 3, the
key
switch,
interlocking,
direction switch
and
accelerator input
are
damp
4, Check for
Programmer

120
4-7 Emergency Reverse high pedal 1. Emergency Trigger: Turn off the
protection (EMR Rev HPD) reverse operation Emergency accelerator
Fault type: 1 has ended, but the reverse operation and
accelerator has ended, but the the
input, accelerator electromagn
direction switch input, etic brake
and direction
interlock are not switch,
returned interlock are not
reset
Clear: If
EMR
Interlock is set to
ON,
the
accelerator,
direction
switch,
interlocking
input
need to be cleared;
if EMR Interlock is
set to OFF, a clear
4-7 Oil pump high pedal protection Wrong up / down Trigger: 1, lift Turn off the
(Pump accelerator input accelerator output oil pump
HPD) conditions is 2 high at start,
fault type: （>25%） drop
1. Just rise Setting accelerator output
2. It's just a drop the is 3 high at start,
3. Rising and falling parameter in error: and rise at
1. Hydraulic start
suppression type The drop
2. The HPD / accelerator output
SRO determines is all high
the Clear:
hardware failure of Accelerator
the time oil output is back
pump to
accelerator small on startup
4-9 Parameter change failure 1. After Trigger: adjust the Turn off the
(Parameter Change) Fault type:, record interlocking parameter motor,
the parameter closure, modify the clearance main
CAN ID safety-related requiring contactor,
parameters, switch KSI: reset electromagn
namely controller, etic
are labeled PCF switch brake,
KSI accelerator,
full power
4-10 Emergency reverse switch redundancy 1, One or two of the Trigger: the Close
fault two emergency emergency reverse the
（EMR Switch Redundancy） reverse switches do switch is interlock
Fault type: 1 not work, resulting often and
in open and often the
an invalid state 2, closed is not electromagn
and the switch synchronized etic brake
is Clear: Correct
damp or into dirt the
switch
Status, and reset
control

121
5-1 Custom fault User-custom, User custom, The user set
~ 1~32（User implemented via VCL through himself
7-13 1~32 Fault） Over-VCL Righteous,
fault type: implementation through
User Custom VCL realize
6-8 VCL Runtime Error (VCL Run 1. Runtime fault is Trigger: A Close
Time defined by VCL, VCL the
Error) refer runtime error was motor,
to system information detected main
2. The Clear: Modify contactor,
drive the electromagn
command and VCL, and reset etic
the the brake,
drive letter do not controller accelerator,
match when interlock,
controlling the drive
drive 1~5,
with the VCL proportional
7-2 CAN PDO timeout 1. Two adjacent Trigger: Two Turn off the
（PDO PDO's adjacent PDO's accelerator
Timeout) Fault type: 1 receive receive information
information over for more time
the than
set PDO timeout time the set PDO
2. Adjust the timeout
PDO
time
settings to view
the Clear: receive
Programmer The CAN
/ NMT
Application Setup Letter
/ Interest, or reset
CAN Interface / control
7-3 motor stalling 1. Motor plugging Trigger: No motor Turn off the
(Stall Detected) Failure type: 1 2. Motor encoder encoder signal motor,
fails changes are being electromagn
3. Wrong pressing or detected etic
wiring Clear: reset brake,
4, abnormal power controller, or if the and
supply of parameter accelerator,
motor LOS the
encoder 5, check Upon Encoder control
Programmer Fault = On, reset mode
\ is
interlock
System Monitor changed
After switching, to
Menu \ AC Motor the
\ Motor RPM LOS, and
fault is clear
the
Except, enter motor
the
output is
LOS fault
mode limited

122
7-7 Monitoring fault 1. Internal failure of Trigger: InternalTurn off the
（Supervision the controller failure of motor,
） the the
fault type: controller main
The Curtis monitoring code Clear: Reset contactor,
control the
implement solenoid
brake,
Accelerator,
each other
Lock,
drive
1, drive 2,
drive 3,
drive 4,
drive 5,
proportional
drive,
full
power
7-9 Enter the Check monitoring fault 1. Internal failure of Trigger: Turn off the
(Supervision Input Check) Failure the controller The motor,
type: 1 controller main
is contactor,
damaged electromagn
Clear: Reset etic
the brake,
controller accelerator,
interlock,
drive 1,
drive 2,
drive 3,
drive 4,
drive 5, and
ratio
Drive,
full-power
8-2 The PDO mapping error has occurred 1, PDO mapping Trigger: Incorrect close PDO
（PDO has assigned PDO mapping
Mapping Error） excessive was
Fault type: 1 data bits, or detected
incompatible targets Clear: Reset
2. Adjust the control
PDO implement
settings to view
the
Programmer
/
8-3 Internal hardware failure 1. Internal fault Trigger: Turn off the
(Internal Hardware) Failure type: within detected motor,
Curtis the controller controller internal main
hardware code is fault contactor,
detected clearance: electromagn
reset controller etic
brake,
accelerator,
full power

123
8-7 Motor match error 1. Motor Trigger: the motor Turn off the
(Motor Characterizati on Error) matching failed matching has failed motor,
Failure type: 71 write memory RAM during the motor during the main
failure 72 matching motor contactor,
temperature sensor failure process matching process electromagn
The motor overheating Clear: Reset etic
the brake,
Controller temperature reduction
controller accelerator,
Low voltage reduction
full power
High pressure reduction
brake
No encoder signal
Current check exceeds the range
Current check exceeds the range
Encoder signal can be detected, but
cannot automatically detect the number
of pulses per loop
(Encoder steps)
Automatic matching failed
90 / 98 PPM feedback sine /
The cosine signal
91 Permanent magnet synchronous
motor does not turn 92 permanent
magnet synchronization
The Motor does not accelerate or has
a low acceleration
94-97 Permanent magnet synchronous
motor delay compensation beyond
the range
99 Permanent magnet synchronous
motor rotates 102 Permanent
magnet synchronous motor
temperature sensor
fault at starting matching
103 Permanent magnet synchronous
motor high temperature reduction
104, permanent magnet synchronous
motor
controller temperature reduction
LV reduction of the permanent magnet
synchronous motor controller
8-8 Encoder pulse signal error 1. The encoder step Trigger: Encoder Turn off the
(Encoder Pulse Error) Failure type: 1 setting does not step settings motor,
comply with detected main
the Clear: confirm contactor,
actual number. 2. that electromagn
The check the encoder step etic
parameter number setting brake,
setting is accelerator,
checks consistent with full power
Programmer \ the brake
AC actual, reset
Motor Setup control
\
Manufacturer
Quadrature
Encoder
\ Encoder Steps
3. The motor loses its
IFO control, and the

124
8-9 Parameters exceed the range 1. The Trigger: Turn off the
（Parameter Out of Range） parameter Excessive motor,
fault type: values were detected parameter main
Record the target CAN ID s beyond the range values contactor,
2, Check and are detected electromagn
rewrite
Clear: Override etic
the parameters
with the parameter to brake,
the CIT tool the accelerator,
9-1 Firmware bad (Bad Firmware) fault Controller firmware Trigger: The
type: is The controller
1 incorrect downloaded cannot not
1, CRC or OS software fully start
mismatch matches
2, Using an the
controller
incompatible OS
hardware
Clear: download
9-2 Electromagnetic brake setting 1. Vehicle operation Trigger: The standing
braking failure is detected, in the Electromagnetic slope
(EM Brake Failed to Set) Failure type: 1 electromagnetic brake function
brake setting Set the brake, and is
After braking delay it triggered
2. The After that, the after closing
electromagnetic vehicle operation the
brake can not stop is electromagne
the motor detected tic brake
rotation Clear: 1 and
after braking Activate the
Accelerator accelerator
(EM Brake Type = interlock
2); 2 Activate activation
Interlock
9-3 Encoder LOS Mode (Encoder LOS) 1, Encoder 3-6, fault Trigger: Encoder LOS pattern
Fault type: 1 or 7-3, enter 3-6 fault or 7-3
LOS pattern fault, if the
2. Motor encoder parameter
fails LOS
3. Wrong pressing or Upon Encoder
wiring Fault = On, reset
4. Vehicle blockage the
interlocking
switch, and enter
the LOS fault
mode
(9-3 fault),
allowing
for limited
motor
output
Clear: Switch
the
KSI, or if the LOS
is triggered, indeed
After the encoder
is normal

125
9-4 Emergency reverse timeout 1, Emergency Trigger: trigger the Turn off the
(Emer Rev Timeout) Failure type: 1 reverse triggers and emergency accelerator
ends because the reverse, run to the and
emergency reverse expiration period the
time expires Clear: Close electromagn
2. Emergency the etic brake
reverse input is stuck emergency
9-5 Oil pump flow 1. External short inverted
Trigger: input
Oil Turn off the
(Pump Overcurrent) Fault type: 1, circuit of the oil pump oil pump
Oil pump current pump motor current overcurrent
The sensor value is close 2. Controller failure detection upper
Its power supply voltage 2, the oil limit
pump clearance:
current sensor value is close to the switch KSI
sensor ground 3, the oil pump
current overcurrent detection
limit

9-6 Low power of oil pump failure (Pump 1. The power Trigger: When Turn off the
BDI） quantity the oil pump
is lower than the power supply is
setting value of lower than the low
the power supply
low power lock lock
parameter parameter
2, The BDI When the
parameter number
is wrongly set sets the
value,
touch the
9-7 Oil pump hardware failure 1. External short Trigger: 1, the oil Turn off the
(Pump Hardware) Failure type: circuit of the oil pump duty vehicle
1. Duty cycle: 1 pump motor cycle
Straight does not change 2. Controller failure update failed; 2,
2. Duty put and output of oil pump input and
Rather than matching The output duty
cycle is unmatched
join in marriage
Clear: Switch KSI
9-9 Parameter mismatch 1. Incorrect motor Trigger: 1. The Turn off the
(Parameter Mismatch) Fault type: feedback selection is dual-drive motor,
1, dual-drive function 2, SPMSM used for different function main
power is opened in torque mode motor 2 is opened in contactor,
Encoder 3 was selected for the technology torque mode, and electromagn
machine feedback and positive cosine applications the SPMSM etic
2. Dual dual drive is motor brake,
for the AC induction motor feedback
turned on in torque feedback is accelerator,
mode selected full power
3. Dual-drive 3. The AC brake
function induction
is turned on when motor
using a feedback has been
single selected
controller Clear: adjust the
parameter to
the

126
9-10 Monitor the interlock brake fault 1. During Trigger: Turn off the
(Interlock Braking Supervision) interlock During motor,
Fault braking, the motor interlock electromagn
type: 1, motor speed speed exceeds the braking,
etic
Beyond interlock braking parameters set under the motor speed brake,
Monitor the speed limits of the range Interlock Braking exceeds the and
2. Interlock broken Supervision parameters set main
Open, with the electromagnetic 2, View under Interlock contactor
brake within the set time the Braking
No braking is set Programmer Supervision
/ Clear: Reset
3. Interlock is disconnected, with
Application Setup control
an electromagnetic brake
/ Interlock Braking implement
Brakes are not set, /
The rotor position is beyond Supervision
RPM, Position limit Enable.3, View
make the
Programmer
/
9-11 Emergency reverse fault 1. During Trigger: During the Turn off the
(EMR the emergency reverse motor,
Supervision) fault type is monitored: 1 emergency reverse process, the motor electromagn
process, the motor speed exceeds etic
speed exceeds the Emergency brake,
parameters set under Reverse and
Emergency main
Supervision
Reverse contactor
Put the parameters
Supervision
Clear: Reset
2, View
the control
Programmer implement
/
Application Setup
/ Emergency
10-1 Drive 1 fault 1. Drive load is open Trigger: Drive 1 Turn off
（Driver 1 Fault） or short circuit open or short drive 1
fault type: 2, The connector circuit or
1. Drive short circuit pin drive
2. Drive the current foot or contactor over-current,
coil
3, Open circuit / short circuit beyond the
is dirty Driver
(High detected, should be low)
3. Connection 1 Overcurrent
4, Open circuit / short circuit
pressing error or setting
(Low detected, should be high)
wiring error 4, parameter
5, broken line
exceeding the value
6. No current exists in the output limit Driver Clear: repair
Fault Type 3-5 1 Overcurrent setting the
Request that the drive fault detection be parameter value short circuit or
turned on 5, View the
Programmer open circuit
/ Controller Setup after

127
10-2 Drive 2 fault 1. Drive load is open Trigger: Drive 2 Turn off
（Driver 2 Fault） or short circuit open or short drive 2
fault type: 2, The connector circuit or
1. Drive short circuit pin drive
2. Drive the current foot or contactor over-current,
coil
3, Open circuit / short circuit beyond the
is dirty Driver
(High detected, should be low) 4, open /
3. Connection 2 Overcurrent
short circuit
pressing error or setting
(Low detected, should be high)
wiring error 4, parameter
5, broken line
exceeding the value
6. No current exists in the output limit Driver Clear: Repair
Fault Type 3-5 2 Overcurrent setting the
Ask to open the drive parameter value short circuit or
fault detect 5, View the
Programmer open circuit
10-3 Drive 3 fault / Controller
1. Drive load Setup
is open after
Trigger: Drive open Turn off
（Driver 3 Fault） or short circuit or short circuit or drive 3
fault type: 2, The connector drive over-
1. Drive short circuit pin current,
2. Drive the current foot or contactor exceeding
coil the
3, Open circuit / short circuit
is dirty Driver
(High detected, should be low) 4, open /
3. Connection 3
short circuit
pressing error or Overcurrent setting
(Low detected, should be high)
wiring error 4, parameter value
5, broken line
exceeding the Clear: Repair
6. No current exists in the output limit Driver the
Fault Type 3-5 requires the drive fault 3 Overcurrent setting short circuit or
detection to be turned on parameter value the
5, View open circuit
Programmer after
10-4 Drive 4 fault / Controller
1. Drive load Setup
is open the reset controller
Trigger: Drive 4 Turn off
（Driver 4 Fault） or short circuit open or short drive 4
fault type: 2, The connector circuit or
1. Drive short circuit pin drive
2. Drive the current foot or contactor over-current,
coil
3, Open circuit / short circuit beyond the
is dirty Driver
(High detected, should be low) 4, open /
3. Connection 4 Overcurrent
short circuit
pressing error or setting
(Low detection,
wiring error 4, parameter
Should be high)
exceeding the value
5. Break the line Driver Clear: Repair
6. No current exists in the output limit 4 Overcurrent setting the
Fault Type 3-5 parameter value short circuit or
Request that the drive fault detection be 5, View the
turned on Programmer open circuit
/ Controller Setup after

128
10-5 Drive 5 fault 1. Drive load is open Trigger: Drive 5 Turn off
（Driver 5 Fault） or short circuit open or short drive 5
fault type: 2, The connector circuit or
1. Drive short circuit pin drive
2. Drive the current foot or contactor over-current,
coil
3, Open circuit / short circuit beyond the
is dirty Driver
(High detection,
3. Connection 5 Overcurrent
Should be low)
pressing error or setting
4, Open circuit / short circuit
wiring error 4, parameter
(Low detection,
exceeding the value
Should be high) Driver Clear: Repair
5. Break the line 5 Overcurrent setting the
6. Output limit parameter value short circuit
No current 5, View Or reset the
Fault Type 3-5 Programmer control
Request that the drive fault detection be / Controller Setup after having
turned on / Outputs / Driver 5 an
10-6 Drive 6 fault / Driver
1. Drive5load is open open circuit
Trigger: Drive 6 Turn off
（Driver 6 Fault） or short circuit open or short drive 6
fault type: 2, The connector circuit or
1. Drive short circuit pin drive
2. Drive the current foot or contactor over-current,
coil
3, Open circuit / short circuit beyond the
is dirty Driver
(High detection,
3, connector pin error 6 Overcurrent
Should be low)
or wiring error 4, setting
4, Open circuit / short circuit
driving overcurrent, parameter
(Low detected, should be high)
exceeding the value
5. Break the line Driver Clear: Repair
6. No current exists in the output limit 6 Overcurrent setting the
Fault Type 3-5 parameter value short circuit
Ask to open the drive 5, View Or reset the
fault detect Programmer control
/ Controller Setup after having
/ Outputs / Driver 6 an
10-7 Drive 7 failure 1. Drive load is open Trigger: Drive 7 Turn off
（Driver 7 Fault） or short circuit open circuit or drive 7
fault type: 2, The connector short circuit or
1. Drive short circuit pin drive overcurrent,
2. Drive the current foot or contactor beyond Driver 7
coil
3, Open circuit / short circuit The
is dirty Overcurrent
(High detected, should be low) 4, open /
3. Connecconnector sets the
short circuit
pressing pressing or parameter
(Low detected, should be high)
5, wiring 4, value
drive Clear: Repair
broken line
overcurrent, beyond the
6. No current exists in the output limit
Driver 7 Overcurrent short circuit or
Fault Type 3-5 the
Set parameter
Request that the drive fault detection be open circuit
values
turned on after
5, View
Programmer the reset controller
/ Controller Setup

129
10-8 Drive assignment fault 1, One drive serves Trigger: Drive Turn off the
(Driver as 2 or assignment conflict drive
Assignment) Failure type: 5, drive more Clear: The reset
serial functions 2, view controller
number guide Programmer after
Cause the fault / resolving
Controller Setup / drive
IO allocation conflicts
Assignments /
Coil
Drivers:
Main contactor drive
10-9 Coil power failure 1, Drive load short Trigger: A short Turn off all
（Coil Supply Fault） circuit circuit is detected the output
Fault type: 1, short circuit with B- 2, The connector after the start of
or hardware fault 2, internal short pin check passes. the
circuit to drive, cause the coil power foot or contactor The low side partial controller
coil
supply to be cut off 3, coil power drive short circuit is
is dirty
start detection failure 4, coil power detected, and the
3. Wrong connector
start prohibited detection corresponding fault
clamping or wrong
lose efficacy generated cannot
wiring
cut off the
4. Controller failuredrive
current
11-1 Analog quantity input 1 1. The input voltage Clear:
Trigger:Switch
1 KSI No, except
Super range of the analog input for VCL,
(Analog 1 Out of Range) Failure type: volume 1 is higher voltage is above with added
1. Over the upper limit than the Analog 1 the threshold set special
2. Low is limited to High set by parameter; 2 treatment
value input voltage
is
2, The input voltage
below
of analog quantity the
1
threshold set by
is lower than Analog
parameter;
1 Low
Clear: the
Set the value input
3, View voltage back to the
Programmer
parameter
/ Controller Setup setting
/
range, reset control
Analog Inputs
/ implement
Analog 1
4, View
Programmer

130
11-2 Simog input 2 1, Analog quantity Trigger: 1 No, except
Super range 2 input for VCL,
(Analog 2 Out of Range) Failure type: The input voltage voltage is above with added
is the threshold set
1. Over the upper limit special
higher than by parameter; 2
2. Low is limited to the treatment
input voltage
Analog 2 High set is
value below
2, Analog quantity the
2 threshold set by
The input voltage parameter;
is
Clear: the
lower than Analog 2 input
Low voltage back to the
Set the value parameter
3, View setting
Programmer range, reset control
/ Controller Setup implement
/
Analog Inputs
/
11-3 Analog quantity input: 3 1, Analogue Trigger: 1 No, except
Super range quantity 3 The input input for VCL,
(Analog 3 Out of Range) Failure type: voltage is higher voltage is above with added
1. Over the upper limit than the the threshold set special
2. Low is limited to Analog 3 High set by parameter; 2 treatment
value input voltage
is
2, Analog 3 The
below
input voltage is the
below threshold set by
Analog 3 Low parameter;
Set the value Clear: the
3, View input
Programmer voltage back to the
/ Controller Setup parameter
/ setting
Analog Inputs range, reset the
/
controller
Analog 3
4, View
11-4 Analog quantity input 4 1, Analog volume Trigger: 1 No, except
Super range 4 input for VCL,
(Analog 4 Out of Range) Failure type: The input voltage voltage is above with added
is the threshold set
1. Over the upper limit special
higher than by parameter; 2
2. Low is limited to the treatment
input voltage
Analog 4 High set is
value below
2, Analog 4 The the
input voltage is threshold set by
below parameter;
Analog 4 Low Clear: The
Set the value input
3, View voltage returns
Programmer to
/ Controller Setup the parameter
/ setting pattern
Analog Inputs Enclosure, reset
/ the controller
Analog 4

131
B-5 Analog quantity input 5 1. Analog quantity Trigger: 1 No, except
Super range 5 input for VCL,
(Analog 5 Out of Range) Failure type: The input voltage voltage is above with added
is the threshold set
1. Over the upper limit special
higher than by parameter; 2
2. Low is limited to the treatment
input voltage
Analog 5 High set is
value below
2, The input voltage the
of analog quantity threshold set by
5 parameter;
is lower than Analog Clear: the
5 Low input
Set the value voltage back to the
3, View parameter
Programmer setting
/ Controller Setup range, reset control
/ implement
Analog Inputs
/
Analog 5
11-6 Analog quantity input 6 1, analog 6 Trigger: 1 No, except
Super range input input for VCL,
(Analog 6 Out of Range) Failure type: voltage is higher than voltage is above with added
1. Over the upper limit the Analog 6 High set the threshold set special
2. Low is limited to value by parameter; 2 treatment
2, analog 6 input voltage
input is
voltage is lower than below
Analog 6 Low the
Set the value threshold set by
3, View parameter;
Programmer Clear: the
/ Controller Setup input
/ voltage back to the
Analog Inputs parameter
/ setting
Analog 6 range, reset control
4, View implement
Programmer
11-7 Analog quantity input 7 1. The input voltage Trigger: 1 No, except
Super range of the analog input for VCL,
(Analog 7 Out of Range) Failure type: volume 1 is higher voltage is above with added
1. Over the upper limit than the Analog 7 the threshold set special
2. Low is limited to High set by parameter; 2 treatment
value input voltage
is
2, Analog 7 The
below
input voltage is the
below threshold set by
Analog 7 Low parameter;
Set the value Clear: the
3, View input
Programmer voltage back to the
/ Controller Setup parameter
/ setting
Analog Inputs range, reset the
/
controller
Analog 7
4, View

132
11-8 Analog quantity input 8 1, Analogue 8 Trigger: 1 No, except
Super range The input for VCL,
(Analog 8 Out of Range) Failure type: input voltage voltage is above with added
is the threshold set
1. Over the upper limit special
higher than by parameter; 2
2. Low is limited to the treatment
input voltage
Analog 8 High set is
value below
2, The input voltage the
of analog volume 8 threshold set by
is lower than Analog parameter;
8 Clear: The
Low input
Set the value voltage returns
to
3, View
Programmer the parameter
/ Controller Setup setting pattern
/ Enclosure, reset
Analog Inputs the controller
/
Analog 8
11-9 Analog quantity input 9 1, Analogue volume Trigger: 1 No, except
Super range 9 input for VCL,
(Analog 9 Out of Range) Failure type: The input voltage voltage is above with added
is the threshold set
1. Over the upper limit special
higher than by parameter; 2
2. Low is limited to the treatment
input voltage
Analog 9 High set is
value below
2, The input voltage the
of analog volume 8 threshold set by
is lower than Analog parameter;
9 Clear: the
Low input
Set the value voltage back to the
3, View parameter
Programmer setting
/ Controller Setup range, reset control
/ implement
Analog Inputs
/
Analog 9

133
11-11 read analogue input 1. The Trigger: 1 No, except
14 Over the scope analog amount is 14 input for VCL,
（Analog 14 Out of Range） and the input voltage is above with added
fault type: voltage is the threshold set special
1. Over the upper limit higher than by parameter; 2 treatment
2. Low is limited to the input voltage
Analog 14 High set is
value below
the
2, analog 14
input threshold set by
voltage is lower than parameter;
Analog 14 Low, set Clear: the
input
the value
voltage back to the
3, View
Programmer parameter
setting
/ Controller Setup
/ range, reset control
Analog Inputs implement
/
Analog 14
11-12 Analog allocation fault 4, View
1, An analog Trigger: An analog No, except
(Analog quantity quantity is used as for VCL,
Assignment) Failure type: 9 is used as 2 or 2 or more functions with added
Analog more
or input beyond special
serial number causes this failure functions the treatment
2, An analog range
quantity
Clear: Resolve
is input beyond the
the
driver
range
Reset
3, View controller
11-13 read analogue input Programmer
1. Simog 18 input Trigger: 1 No, except
18 Beyond the scope voltage is higher than input for VCL,
（Analog 18 Out of Range） Analog 18 High voltage is above with added
fault type: setting the threshold set special
1. Over the upper limit 2. The by parameter; 2 treatment
2. Low is limited to analog input voltage
amount 18 is
input below
voltage is lower than the
Analog 18 Low, and threshold set by
set the value parameter;
3, View Clear: the
Programmer input
/ Controller Setup voltage back to the
/ parameter
Analog Inputs setting
/ range, reset the
Analog 18 controller
4, View
Programmer

134
11-15 Oil pump current sensor fault 1. External short Trigger: the oil Turn off the
(Pump Current Sensor) Failure type: circuit of the oil pump current vehicle
1. The oil pump current sensor is close pump motor sensor value
to its supply voltage 2, and the oil 2. Controller failure is
pump current sensor is close to the after the sensor is
sensor ground ground near its
supply voltage,
with no
current
compensation
12-1 Branding error 1. Software and Trigger: Software Turn off the
（Branding hardware brands do and software are motor,
Error） not match incompatible the
Fault type: 1 2. Contact the local Clear: As main
Curtis available, contactor,
technical branded software the
support to deal with should be solenoid
the reason loaded
brake,
block or a branded
Accelerator,
controller and
full-power
configured
braking
correctly
The file and
12-3 Hardware compatibility The OS and Trigger: Incorrect Turn off the
failure the OS motor,
(Hardware Compatibility controller are not Clear: Download main
） compatible the matched OS contactor,
Fault type: 1 1. The downloaded electromagn
software and the etic
controller hardware brake,
are not compatible accelerator,
all
Power
12-5 Input failure of lifting The troubleshooting Trigger: Failure Turn off the
（Lift Input Fault） associated with diagnosis rise
Fault type: 1 the associated with
lift input the
source lift input source
triggers the fault. will
For trigger the fault
example, if the boost Clear: Resolve any
input source is assignment
an
conflicts, or enter
analog input, then all
beyond
faults related to the
Rear reset
12-6 Drop input fault The troubleshooting Trigger: Close down
（Lower Input Fault） associated with The
Fault type: 1 the troubleshooting
drop input associated with
source the
triggers the fault. drop input
For source
example, if a triggers the fault
drop Clear: Resolve any
input source is assignment
an
conflicts, or enter
analog input, then all
beyond
faults related to

135
1220E Diagnostics and Fault Processing
The fault chart below gives a description of all the diagnostics/faults and details the set and clear conditions

Table 4 TROUBLESHOOTING CHART

FLASH NAME POSSIBLE CAUSE CLEAR STEER TRACTION FAULT

CODE CONDITION FAULT ACTION ACTION
12 Controller Overcurrent 1. The steer motor wires shorted. Cycle KSI Shutdown 1 = Stop
2. Controller defective.
13 Current Sense Fault 1. Controller defective. Cycle KSI Shutdown 1 = Stop
14 Precharge Fault 1. Controller defective. Cycle KSI Shutdown 1 = Stop
15 Controller Severe Undertemp 1. Controller is operating in extreme Heatsink Warning Only 3 = No Action
low temperature. temperature above
2. the temperature sensor is broken. –35°C.
16 Controller Severe Overtemp 1. Excessive load on vehicle. Cycle KSI Warning then Shutdown 1 = Stop
2. Controller is operating in
extreme high temperature.
3. Improper mounting of controller.
17 Severe Undervoltage 1. Battery or battery cables or battery Cycle KSI Shutdown 1 = Stop
connections defective.
2. Excessive non-controller hydraulic
system drain on battery.
3. Battery discharged or improper
18 Severe Overvoltage battery. Cycle KSI Shutdown 1 = Stop
1. Battery or battery cable resistance
too
high for a given regen current.
2. Battery disconnected while
regen braking.
23 Motor Polarity Fault 1. The motor polarity is reversed. Cycle KSI Shutdown 1 = Stop
2. The position feedback device
polarity is reversed.
24 5V Supply Failure 1. Overload for the 5V supply Cycle KSI Hold then Shutdown 1= Stop
2. Controller defective
3. Load wiring open for the 5V supply
25 12V Supply Failure 1. Overload for the 12V supply Cycle KSI Warning then Shutdown 1= Stop
2. Controller defective
26 Motor Temp Hot Cutback 1. Excessive load on vehicle. Bring Steering Warning and 2 = Reduce Speed
2. Controller is operating in Motor Reduce Current
extreme high temperature. temperature Limit
backs to range.
31 Main Driver Fault 1. Internal relay coil is broken. Cycle KSI Warning then Shutdown 1 = Stop
2. Internal relay driver is open or
33 Motor Short shorted.
1. The steer motor wires shorted. Cycle KSI Shutdown 1 = Stop
34 Encoder Fault 1. Encoder is broken. Cycle KSI Hold then Shutdown 1 = Stop
2. Encoder wiring isopen.
3. Controller defective.
35 Fault Output Failure 1. Incorrect Fault Output wiring. Cycle KSI Shutdown 1 = Stop
2. Controller defective.
36 Motor Stalled 1. Stalled steer motor. Cycle KSI Shutdown 1 = Stop
2. Steer motor encoder failure or
wires open.
3. Steer motor wires open.
4. Related parameters do not
match with steer motor.
FLASH CLEAR TRACTION FAULT
NAME POSSIBLE CAUSE STEER FAULT ACTION
CODE CONDITION ACTION
37 Motor Open 1. Steer motor wiresopen. Cycle KSI Warning then Shutdown 1 = Stop
2. Faulty motor cable wiring.
3. Controller defective.
38 Relay Welded 1. Internal relay welded. Cycle KSI Shutdown 1 = Stop
2. Controller defective.
39 Relay Did Not Close 1. Internal relay was commanded to Cycle KSI Shutdown 1 = Stop
be close but it did not.
2. Controller defective.
41 Command Analog1 Out of 1. Command Analog Input 1 (J3-6) is Cycle KSI Hold then Shutdown 1 = Stop
Range out of range.
2. Incorrect parameter settings.
42 Command Analog2 Out of 1. Command Analog Input 2 (J3-13) Cycle KSI Hold then Shutdown 1 = Stop
Range is out of range.
2. The crosscheck on Command
Analog Input 1 (J3-6) and
Command Analog Input 2 (J3-13)
failed.
43 3.
1. Incorrect parameter
Analog Input (J3-2) issettings.
out of Cycle KSI Hold then Shutdown 1 = Stop
Feedback Analog1 Out of
Range range. 2. Incorrect parameter
44 Feedback Analog2 Out of settings.
1. Position Analog Input 2 (J3-9) is Cycle KSI Hold then Shutdown 1 = Stop
Range out of range.
2. The crosscheck on Position
Analog Input 1 (J3-2) and
Position Analog Input 2 (J3-9)
failed.
45 CAN Not Operational 3. Incorrect
1. 1220E CANparameter
NMT Statesettings.
did not go Cycle KSI Warning then Shutdown 1 = Stop
operational within 80 ms of
interlock being applied.
46 NV Failure 1. Internal Non-Volatile Cycle KSI Shutdown 1 = Stop
Memory
defective.
47 Parameter Change 1. A parameter value was changed that Cycle KSI Shutdown 1 = Stop
requires a power cycle.
2. Parameters are restored to the
default settings.
51 Interlock Switch Supervision 1. Afault is set if the 2 switch inputs are Cycle KSI Interlock = OFF 1 = Stop
not matched.
2. Interlock switch defective.
52 Home Switch Supervision 1. When the wheel position is not close Cycle KSI Warning then Shutdowm 1 = Stop
to home, the redundant home switch
inputs are checked and a fault is set
if they disagree.
2. Home switch defective.
53 Home Position Not Found 1. Home switch defective. Cycle KSI Shutdown 1 = Stop
2. Mounting or wiring defective.
54 Home Reference Tolerance 1. Home switch defective. Cycle KSI Shutdown 1 = Stop
Fault
55 Steer Command Supervision 1. Command input device defective. Cycle KSI Hold then Shutdown 1 = Stop
56 Wheel Position Supervision 1. Position feedback device defective. Cycle KSI Hold then Shutdown 1 = Stop
71 Software Fault 1. Software defective. Cycle KSI Shutdown 1 = Stop
2. Controller defective.
72 PDO1 Timeout 1. Communication between the Cycle KSI Warning then shutdown 1 = Stop
traction
controller and the 1220E has halted.
FLASH CLEAR TRACTION FAULT
NAME POSSIBLE CAUSE STEER FAULT ACTION
CODE CONDITION ACTION
73 Following Error 1. Incorrect parameter settings. Cycle KSI Shutdown 1 = Stop
2. Position feedback device
defective. 3. Steer motor defective.
74 Hardware Fault A hardware error has been Cycle KSI Shutdown 1 = Stop
detected.
1. Power MOSFETs shorted.
2. MODFETs driver defective.
3. Watchdog cross checking defective.
4. Internal +15V defective.
5. Poor connection to battery terminals
75 Parameter Conflict 1. Parameter settings are selected Cycle KSI Shutdown 1 = Stop
that are in conflict with each
other.

78 CAN Bus Loading 1. CAN bus defective. Cycle KSI Warning then Shutdown 1 = Stop

2. The message sending is too fast.

79 PDO Mapping Error 1. Incorrect CAN mapping data. Cycle KSI Shutdown 1 = Stop
81 Bad Calibrations 1. Calibration data is out of range Cycle KSI Shutdown 1 = Stop
82 Parameter Out of Range 1. Parameter data out of range Cycle KSI Shutdown 1 = Stop
84 Supervision 1. Supervisor defective Cycle KSI Shutdown 1 = Stop
Attachment：Table for bolt’s tightening torque
Unit：N·m
Grade
Bolt’s diameter
4.6 5.6 6.6 8.8
6 4～5 5～7 6～8 9～12

8 10～12 12～15 14～18 22～29

10 20～25 25～31 29～39 44～58

12 35～44 44～54 49～64 76～107

14 54～69 69～88 83～98 121～162

16 88～108 108～137 127～157 189～252

18 118～147 147～186 176～216 260～347

20 167～206 206～265 245～314 369～492

22 225～284 284～343 343～431 502～669

24 294～370 370～441 441～539 638～850

27 441～519 539～686 637～784 933～1244

Note：·Use entirely 8.8 grade bolt in the important joint position.
·Bolt’s grade can be found in the head of the bolt, if it can’t be found, the grade is 8.8.
 Relevant safety directive or standard (CE or optional)
The TRUCKS covered are conform to the following European Directives and standards:
2006/42/EC Machinery Directive
2014/30/EU EMC Directive
EN ISO 12100:2010 Safety of machinery — General principles for design — Risk
assessment and risk reduction
EN ISO 3691-1:2015+A1:2020 Industrial trucks — Safety requirements and verification — Part 1:
Self-propelled industrial trucks, other than driverless trucks, variable
reach trucks and burden-carrier trucks
EN 1175:2020 Safety of industrial trucks – Electrical/electronic requirements
EN 16307-1:2020 Industrial trucks — Safety requirements and verification — Part 1:
Supplementary requirements for self-propelled industrial trucks, other
than driverless trucks, variable-reach trucks and burden-carrier trucks
EN 12053:2001+A1:2008 Safety of industrial trucks — Test methods for measuring noise
emissions
EN 13059:2002+A1:2008 Safety of industrial trucks — Test methods for measuring vibration
EN 12895:2015+A1:2019 Industrial trucks — Electromagnetic compatibility

Appendix: Test value of vibration and noise

Measurement item Measurements Remark

Steering wheel position
u=1.1 m/s ,k=0.33
2 k is the uncertainty
vibration
Driver's standing weighted
u=0.8 m/s ,k=0.23
2
body vibration
≤75dB(A
 Measurement item Measurements standard requirement
dB(A) dB(A)
Environmental noise 50
No-load
68.0
operation
Full load
Ear Noise 68.2
operation
No-load lifting 68.2
Full load lifting 68.3
Left 7m 64.6
No-load operation
Right 7m 64.3
Left 7m 65.7
Full load operation
Right 7m 66.0
Left 7m 64.8
No-load fixed Right 7m 64.6
lifting Front 7m 63.2
Rear7m 66.5
Left 7m 66.8
Full load fixed Right 7m 67.2
lifting Front 7m 66.6
Rear7m 69.2
Remark —
EC DECLARATION OF CONFORMITY

Original Declaration
MANUFACTURER:
Name HANGCHA GROUP CO., LTD.
Address 666 Xiangfu Road, Lin'an District, Hangzhou City, Zhejiang Province 311305, P.R. China

TECHNICAL DOCUMENT WAS COMPILED BY:

Name Andy Yang
Address Die das technische Datenblatt erstellt hat Mariechen-Graulich-Straße 12a,
65439 Flörsheim am main Germany Tel: 0049-61453769188

HEREBY DECLARES THAT THE PRODUCT DESCRIBED BELLOW:

Name Electric Pallet Truck
Model CQDB20-AC2S
Serial No.

COMPLIES WITH THE PROVISIONS OF THE FOLLOWING EUROPEAN DIRECTIVES

2006/42/EC Machinery Directive
2014/30/EU EMC Directive

COMPLIES WITH THE PROVISIONS OF THE FOLLOWING STANDARDS

EN ISO 12100:2010 EN ISO 3691-1:2015+A1:2020
EN 1175:2020 EN 16307-1:2020
EN 12053:2001+A1:2008 EN 13059:2002+A1:2008
EN 12895:2015+A1:2019

Place: Hangzhou, Zhejiang, P.R. China

Date:
Signature and stamp:
Name:
Position: Legal Representative
According to Annex II 1.A of the Directive 2006/42/EC

–
 Maintenance Record

Date Repair, maintenance content Serviceman

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: [email protected]