HC FORKLIFT NEW SERIES HANGCHA

ELECTRIC

FORKLIFT TRUCK

（1.2-2t ELECTRIC REACH TRUCK）

SERVICE MANUAL

CQD12H-J

CQD14H-J CQD16H-J CQD20H-J

CQD12H-JC2 CQD14H-JC2 CQD16H-JC2 CQD20H-JC2

Original Instruction

HANGCHA GROUP CO., LTD.

Dec.2009 1

st

edition

Foreword Thanks for your purchasing our forklift truck.

1.2-2t series electric reach truck applies to narrow aisle and limited space,it has high lifting and huge loading capacity, so ,it is the ideal truck for loading unloading, and stacking in warehouse, supermarket,plant.

The first section of this manual instructs how to use reach truck correctly, the second section instructs common faults of reach truck. To ensure safety and exert the truck‟s potential, all the personnel that in charge of operation, maintenance and management must read this manual thoroughly before starting work with the forklift.

CQD12/14/16/20H-J series truck improve on CQD12/14/16/20H series; and CQD12/14/16/20H-JC2 series truck improve on CQD12/14/16/20H-C1 series. There are 2 improvements: one is the steering system, the both new series trucks adopt pump-gear steering to replace the chain transmission steering,the corresponding hydraulic system and electrical system have revised; the other is that operation layout is more coincident with Human Factors Engineering.

If you have any questions please keep touches with HANGCHA GROUP CO., LTD. sales department or let the agents know.

Truck models

Controller

Rated lifting weight(t) /load center(mm)

CQD12/14/16/20H-J

CURTIS 1244 and EVC255

1.2/600,1.4/600, 1.6/600,2/600

CQD12/14/16/20H-JC2

1236-5301-T-G00（traction) 1236-5301-P-G00（lifting)

This series trucks have passed CE certification.

HANGCHA GROUP CO., LTD. C Dec.2009 ○

1st edition

1.2/600,1.4/600, 1.6/600,2/600

CONTENT Foreword POWER TRANSMISSION ....................................................................................................................................... 1 STEERING SYSTEM ............................................................................................................................................... 3 BRAKE SYSTEM ...................................................................................................................................................... 4 HYDRAULIC SYSTEM ........................................................................................................................................... 5 LIFTING SYSTEM (MAST) .................................................................................................................................... 8 ELECTRICAL SYSTEM ........................................................................................................................................ 10 MANUAL ABOUT THE AUTOMATIC WATERING SYSTEM OF THE FORKLIFT BATTERY ............. 23

Power transmission The power transmission of reach truck mainly consists of motor, thrust bearing, reduction gear box, drive wheel and brake drum etc. Transmission route is ：Motor drive axle → active gear → pinion → pinion axle → helical gear → drive axle → drive wheel.

1. Drive wheel 2. Washer 3. Drain plug 4. Helical gear 5. Support bush 6.Bearing 7.Locker 8.Hood 9. Drive axle 10.Support ring 11.Adjusting shim 12.gear box 13.Bearing 14. Adjusting shim 15.Pinion 16.Bearing 17.Passive gear 18. Lock nut 19.Air bleed plug 20. Washer 21.Bolt 22.Screw 23.Washer 24. Dc tractor 25. Installation board 26. Big gear assembly 27. Small gear 28. Rotor bearing 29. Box cover 30. O-ring 31. Bearing 32. Mat 33. Initiative gear 34. Check ring 35.Washer 36 . Wheel bolt 37. Oil seal 38. Adjusted mat 39. Bearing 44. Washer 54. Pin 55. Bolt 59. Bolt 61. Oil seal seat 62. O-ring 66. Bolt 67. Washer 68. Pin 69. Bolt 70. Washer 1

Figure 1-1 Power transmission Trouble

Probable cause

Corrective action

Abnormal strike noises from gear box when traveling or change direction.

Side clearance of the couple gear is too big.

Broken or much wearing of couple gear.

Adjust.

Replace.

When traveling abnormal noise.

Gear box oil level is too low.

Side clearance of the couple gear is too big.

Broken or much wearing of couple gear.

Add oil.

Adjust.

Replace.

there

are

1.1 Drive Motor

CQD12/14/16/20H-J Truck use DCMotor, and CQD12/14/16/20H-JC2 use AC Motor.

1.2 Thrust bearing The thrust bearing is mounted on the bracket which is mounted on chassis body through bolts. The cover hood of gear box is connected to outer ring of thrust bearing. When the gear box covers hood rotated by the gear force comes from hydraulic motor. Bearing rotates, so the truck can rotate.

1.3 Motor drive axle assy There is bearing, snap ring, oil seal ring and active gear on motor drive axle. When motor rotates, the axle drive make the passive gear rotate.

1.4 Pinion axle assy The pinion axle consists of pinion, 2 rolling bearings, adjusting shim, passive gear and lock nut etc.

Assembly: (1) Assemble adjusting shim and rolling bearings on the pinion axle.

(2) Push the taper rolling bearing in the hole of gear box.

(3) Put assy (1) into the gear box through end of axle, and into inner ring of taper rolling bearing.

(4) Assemble passive gear into the axle and lock the nut.

1.5 Transmission axle assy It consists of transmission axle, 2 taper rolling bearing, oil seal, passive helical gear, support ring, adjusting shim and lock nut etc.

1.6 Drive wheel Drive wheel material is PU, and it consists of wheel bolts, washer etc. It mounted on the outer of drive axle.

1.7 Motor and Steering Small Gear 26〠27 are a pair of constant mesh gear-pair. Gear 27 can be driven by motorďźŒthen gear 27 drives gear 26, then it can drive truck steering.

1.8 Oil Change in Gear Box (Fig.1-1) Change gear oil every half year: a) Loosen plug screw(SN 3), b) Drain gear oil out, and deal with disused gear oil according to environmental protect rule, it is forbidden to dump at will. c) Loosen tighten component 22, 23, disassemble motor 24. d) Reassemble plug screw, mat and tighten plug screw. e) Fill clean gear oil in gear box. f) Reassemble motor, and fill lubrication till the oil is about to exceed passive gear 17.

2

Steering system Fault

Probable cause

Steering does not feel easy.

No steering action.

Abnormal from

noises steering

system.

Corrective action Lubricate gear

· gear needs lubrication

Tighten every connector of motor

· motor oil line leaks.

oil line

Steering hydraulic motor does not work.

Inspect.

Steering gear damage.

Inspect.

Priority valve damage.

Inspect.

Hydraulic pump damage.

Inspect.

Oil pipe circuit clogged.

Inspect and clean oil pipe.

Main rotate bearing is short of lubrication.

Add lubrication grease.

Main rotate bearing damage.

Replace.

The connecting bolt of main rotate bearing is

Tighten the bolt.

loosening.

The steering system of reach truck consists of steering device, steering motor, motor and gear.

Steering wheel

Steering device

60 degree is the initial neutral position, front 60度为初始中间位置， swing angle is 10 degree, and rear swing 摆动角度为前10度， angle is 8 degree. 后8度。

Motor

Steering device Steering device consist of steering wheel assembly, steering hoses assembly, Orbitrol ,adjusted machine, etc; and adjusted machine consists of clamp handle, clamp bolt, pin shaft, etc. it can adjust angle of steering wheel.

3

Brake system Reach truck has 2 brake systems. One is service brake, the other is parking brake. Service brake is consists of brake booster, brake drum and brake pedal etc. Parking brake is consists of parking brake cable and etc. They all act on the parking brake drum on the top of electric motor drive axle. The model is CA7180A, used in JETTA automobile.

1. Electrical motor 2.Washer 3.Screw 4.Bracket 5. Spline bush

6. Brake shoe 7. Brake drum 8. Screw 9. Washer 10.Bolt Fig. 2-3 parking brake drum Trouble Insufficient force.

Probable cause brake

Brake dragging

Brake noise.

Oil leakage from oil pipe circuit.

Air in the brake oil pipe circuit.

There is oil or water on the brake shoe.

Corrective action

Brake shoe wearing does not equalization.

Brake master cylinder or brake booster damage.

Brake oil pipe clogged.

Inspect and refill oil.

Bleed air.

Dry brake shoe or replace a new one.

Grind or replace.

Replace.

Clean oil pipe.

No free play of brake pedal.

Adjust.

Improper shoe sliding.

Adjust.

Improper operation of wheel cylinder.

Adjust or replace.

Faulty piston cup.

Replace.

Weak or broken return springs.

Replace.

Clogged master cylinder returns port.

Clean.

Clogged oil lines.

Clean.

Lining surface harden or foreign particles on it.

Repair or replace.

Warped back plates or loosed blots.

Repair or replace.

Brake shoes warped or improper install.

Repair or replace.

Replace

Worn linings.

4

Hydraulic system Main Oil Pump Trouble No oil from oil pump

Probable cause

Corrective action

Low oil level in tank.

Add oil to specified level.

Clogged suction pipe or strainer.

Clean oil line and tank. If oil is dirty, change.

Worn bearing, damaged backup

Replace faulty parts.

ring and O-ring.

Readjust to specified pressure using pressure Maladjusted relief valve.

Low discharge

gauge.

pressure on oil

Retighten suction side pipe.

pump.

Add oil in oil tank.

Air in oil pump.

Inspect pump oil seal.

Do not operate pump until bubbles in tank disappear.

Cavitation due to crushed suction Adjust or replace crushed hose and clean strainer. hose or clogged strainer.

Air being sucked from loose Retighten each joint. suction side joint.

Noisy oil pump ¡ Replace with new oil having proper viscosity for Cavitation due to too high oil temperature at which pump is to be operate. viscosity. ¡ To operate when oil temperature is normal.

Bubbles in hydraulic oil.

Determine cause of bubbles and remedy.

Faulty oil seal on pump, faulty Oil leaking from O-ring or worn sliding surfaces on

Replace faulty parts.

oil pump pump.

5

Control valve Trouble Pressure of relief valve is not steady or too low.

Fork tilt forward when control lever is used while engine is off.

Probable cause Loose of pressure-adjust screw.

Corrective action Readjusted and retighten.

Distorted or damaged pressure-adjust spring.

Replace.

Worn or blocked relief valve core.

Replace or clean.

Pump abated.

Examine and repair pump.

Worn or damaged tilt lock valve.

Replace valve core and tilt lock valve as an assemble.

Broken tilting lock spring.

Replace spring.

Damaged tilt valve plunger O-ring.

Replace O-ring.

Mast is unstable Malfunctioning tilt relief valve. when tilting forward.

Lowering distance of mast is big when spool valve is in the centre.

Spool valve is not return neutral position.

Leakage

Replace tilt assembly.

relief

valve

Valve body and spool valve is worn and clearance between them is too great.

Replace spool valve specified clearance.

with

Spool valve is not in centre.

Keep being in the centre.

Cylinder seal abated.

Examine and repair cylinder.

Taper valve is worn or blocked by dirt.

Replace or clean taper valve.

Damaged or distorted reposition-spring.

Replace spring.

Dirt exists between valve body and spool valve.

Clean.

Blocked control device.

Adjusted.

Not coaxial parts at reposition

Reinstall.，be coaxial

Damaged O-ring.

Replace.

Faulty seal of joint.

Check and retighten.

Loose seal plate.

Clean seal plate and retighten blots.

Loosed lock-nut of relief valve and connect-nut between plate and plate.

Tighten.

Adjusting the pressure of the main relieve valve The pressure of the main relieve valve is all ready adjusted in the factory, and it can‟t be adjusted generally.

The following is an example of 1.2t truck to specify how to adjust the pressure.

(1). Put 125 percent of the rated load (1500kg) on the forklift stable.

(2).Step the accelerated pedal to the end, control the lift pole, if the forklift can get the height of 300mm, the main relief valve is all right. Otherwise, adjust it as step (3).

(3).If the forklift can‟t work, enhance the pressure main relieve valve, remove the front soleplate, loosen the tightening nut of the main relieve valve, screw the adjusting nut clockwise to enhance the pressure of the main relieve valve. If the height of lift is higher than 300mm, screw the adjust nut anti-clockwise to reduce the pressure.

(4).Step the accelerated pedal to the end to make the forklift in the height range of 0-300mm. Otherwise, adjust it as step (3).

Warning: · The load should be put stably. ·Don‟t adjust if the pressure is already adjusted correctly.

6

Hydraulic system principle diagram of reach truck

7

Lifting system (Mast) Condition

Probable cause

Fork arm carrier or mast tilt by itself.

The fork arms carrier moves up and down sluggishly.

Forks are lifted or lowered un-smooth.

Forks are unevenly

lifted

Lift roller does not rotate

Excessive mast noise

Corrective action

1.Tilt cylinder and ring abraded excessively

Replace piston ring tilt cylinder.

2. The hydraulic control valve spring is inoperative.

Replace it.

1. Caused by piston jamming or bent piston rod.

Replace the faulty parts.

2. Too much dirt is accumulated in the cylinder.

Strip it down and clean.

1. Carriage adjustment.

Adjust clearance with thrust metal and carriage side roller.

bracket

assembly out

of

2. Insufficient clearance between inner and outer masts or rollers and mast.

Adjust clearance with rollers.

3. Biting foreign materials between moving part.

Remove foreign materials.

4. Insufficient lubrication.

Apply grease on contact surfaces of sliding parts.ďźˆbutter

5. Bent carriage bracket assembly.

Repair or replace.

1. Lift chains out of adjustable.

Adjust lift chains.

1. Grease stiffened or dirt accumulated on lift roller and mast sliding surfaces.

Clean and lubricate lift rollers.

2. Improperly adjusted lift roller.

Adjust.

1. Insufficient lubrication.

Lubricate.

2. Improperly adjusted lift roller, side roller and back-up metal.

Adjust.

3. Rubber pad on lower of outer mast is useless for container fork lift truck.

By adjusting shims and rubber pad, piston rod is in touch with bottom of cylinder body after inner mast is in touch with rubber pad.

8

Condition

Probable cause

Corrective action

1. Excessive wear occurs between the oil pump body and gears, causing too much clearance.

Replace the worn parts or the oil pump.

2. The lifting jack piston Yx-ring has worn, Replace Yx-ring. resulting in excessive inner leaks.

Insufficient lift power or no lift movement.

3. Springs of the multiple control valves and its relief valve are inoperative oil leaks.

Replace.

4. Excessive wear occurs of the hydraulic control valve, resulting in excessive oil leaks.

Replace.

5. Oil leaks occur between the hydraulic control valve sections.

Dismantle for regrinding the joint surfaces and reassemble the valve.

6. Leakage occurs in the hydraulic pipe.

Tighten the joint nuts and inspect the seal for damage.

7. The hydraulic oil temperature is too high.

Oil viscosity is too low and the rate is insufficient.

Change the wrong hydraulic oil or stop operation for reducing the oil temperature. Find out the reasons for high oil temperature and eliminate the trouble.

8. The load carried is beyond the designed capacity.

Observe the lifting capacity limit.

9

Electrical system 1 Controller Trouble CQD12/14/16/20H-J Tractor controller troubleshoot chart LED 码

1，2

1，3

2，1

2，2

Programmer LCD display

Explanation

Possible cause

HW FAIL SAFE1-2-3

Self-test or watchdog fault

1. Controller defective

M-SHORTED

M- shortcut to B-

1. Controller defective

FIELD OPEN

Field winding fault

1. Motor field wiring loose.

2. Motor field winding open.

ARM SENSOR

Armature current sensor fault

1. Controller defective

FLD SENSOR

Field current sensor fault

1. Controller defective

THROTTLE FAULT1

Wiper signal out of range

1. Throttle input wire open 2. Throttle input wire shorted to B+ or B-.

THROTTLE FAULT2

Pot low fault

1. Throttle pot defective.

2. Wrong throttle type selected.

SRO fault

1. Improper sequence of KSI, interlock and direction inputs.

2. Wrong SRO type selected.

3. Interlock or direction inputs circuit open.

4. Sequencing delay too short.

SRO

2，3

HPD

HPD fault

1. Improper sequence of KSI, interlock and direction inputs.

2. Wrong SRO type selected.

3. Interlock or direction inputs circuit open.

4. Sequencing delay too short.

3，1

CONT DRVR OC

Cont drive output over current

1. Contractor coil shorted.

3，2

MAIN CONT WELDED

Welded contactor

1. Pump contactor stuck closed.

2. Pump contactor driver shorted.

Internal voltage low at startup

1. Controller defective 2. External short or leakage path to B- and external B+ connection.

3，3

PRECHARGE FAULT

10

LED 码

3，4

Programmer LCD display

Explanation

Possible cause

MISSING CONTACTOR

Miss contactor Main contactor did not close

1. Main contactor coil open or not connected 2. Main contactor missing or wiring open.

1.

4，1

LOW BATTERY VOLTAGE

Low battery voltage

2.

3.

Battery voltage <under voltage cutback limit.

Corroded battery terminal.

Loose battery or controller terminal.

1.

4，2

4，3

OVERVOLTAGE

THERMAL CUTBACK

Over voltage

Battery voltage > over voltage shutdown limit.

2. Vehicle operating with charger attached.

3. Battery disconnected during regenerate braking.

Over/under temp cutback

1. Temperature >85℃or <-25℃.

2. Excessive load on motor.

3. Improper mounting of controller.

4. Operation in extreme environments.

11

Pump controller troubleshoot chart LED Code

State Indicator

Possible Cause

No Voltage or Controller can not works.

Controller Error(such as MCU Error）

OFF ON

0,1

Explanation

■¤

Controller works normally,this Error not known 1.

2.

EEPROM Data lost EEPROM Check out Error,Use1311 Programmer change any parameter can eliminate MOSFET Shorted Motor Open Circuit

1,1

¤¤

EEPROM Error

1,2

¤¤¤

Hardware Error

1.

2.

2,1

¤¤¤

Under voltage deeply

Battery Voltage too low

2,2

¤¤¤¤

Lifting locked

Controller‟s Lifting Locked function triggered

2,3

¤¤¤¤¤

Sequece Error（Startup lockout）

Any SS1-SS4 closed beforeKSI or INTERLOCK

3,2

¤¤¤¤¤

Contactor stuck closed

1.Main Contactor stuck closed 2.Parameter“CONTACT CNTRL”not correct 1.

3,3

¤¤¤¤¤¤

Precharge Error 2.

1.

Precharge circuit abnormal Motor shorted

works

Main contactor coil connected loosen.

Main contactor works abnormal

3,4

¤¤¤¤¤¤¤

Miss contactor or did not close （DNC）

4,1

¤¤¤¤¤

Under voltage Protection

Battery „s Voltage lower than “LOVOLT CUTBACK” value

4,2

¤¤¤¤¤¤

Over voltage Protection

Battery‟s Voltage too high

2.

1.

4,3

¤¤¤¤¤¤¤

Over/under temp Protection

2.

Controller‟s temperature too high or low Temperature Sensor works abnormal

12

CQD12/14/16/20H—JC2 CURTIS AC Reach Truck Controller Troubleshooting Chart On the controller‟s shell, there are two LED. One is Red, another is Yellow, Indicating the type of information they are providing.

DISPLAY

STATUS

Neither LED illuminated

Controller is not powered on, has a dead battery, or is severely damaged.

Yellow LED flashing

Controller is operating normally.

Yellow and red LEDs both on solid

Controller is in Flash program mode.

Red LED and yellow LED flashing alternately

Controller has detected a fault.

Programmer Lcd Display Troubleshooting Chart CODE

PROGRAMMER LCD DISPLAY

POSSIBLE CAUSE

1，2

Controller Over current

1. External short of phase U,V,or W motor connections.

2. Motor parameters are mis-tuned.

3. Controller defective

1，3

Current Sensor Fault

1. Leakage to vehicle frame from phase U,V,or W(short in motor stator).

2. Controller defective

1，4

Precharge Failed

1. External load on capacitor bank(B+ connection stud) that prevents the capacitor bank from chaging.

2. See 1311 menu Monitor/Controller:Temperature

1，5

Controller Severe Undertemp

1. Controller is operating in an extreme environment,and temperature below -40℃.

2. See 1311 menu Monitor/Controller:Temperature

1，6

Controller Severe Overtemp

1. Controller is operating in an extreme environment,ant temperature above 95℃ 2. Excessive load on vehicle.

3. Improper mounting of controller.

4. See 1311 menu Monitor/Controller: Temperature.

13

CODE

PROGRAMMER LCD DISPLAY

POSSIBLE CAUSE

1，7

Severe Undervoltage

1. Battery Menu parameters are misadjusted.

2. Non-controller system drain on battery.

3. Battery resistance too high.

4. Battery disconnected while driving.

5. See 1311 menu Monitor/Battery:Capacitor Voltage.

6. Blown B+ fuse or main contactor did not close.

1，8

Severe Overvoltage

1. Battery Menu parameters are misadjusted.

2. Battery resistance too high for given regen current.

3. Battery disconnected while regen braking.

4. See 1311 menu Monitor/Battery:Capacitor Voltage.

2，1

Controller Undertemp Cutback

1. Controller is performance-limited at this temperature.

2. controller is operating in an extreme environment.

3. See 1311 menu Monitor/Controller:Temperature

2，2

Controller Overtemp Cutback

1. controller is performance-limited at this temperature.

2. controller

is

operating

in

an

extreme environment.

3. Excessive load on vehicle.

4. Improper mounting of controller.

5. See

1311

menu

Monitor/Controller:Temperature 2，3

Undervoltage Cutback

1. Normal operation.Fault shows that the batteries need recharging.Controller is performance limited at this voltage.

2. Battery parameters are misadjusted.

3. Non-controller system drain on battery.

4. Battery resistance too high.

5. Battery disconnected while driving.

6. See 1311 menu Monitor/Battery:Capacitor Voltage.

7. Blown B+fuse or main contactor did not close.

14

CODE 2，4

PROGRAMMER LCD DISPLAY Overvoltage Cutback

POSSIBLE CAUSE

1. Normal operation.Fault shows that regen braking currents elevated the battery voltage during regen braking.Controller is performance limited at this voltage.

2. Battery parameters are misadjusted.

3. Battery resistance too high for given regen current.

4. Battery disconnected while regen braking.

5. See 1311 menu Monitor/Battery:Capacitor Voltage.

2，5

+5V Supply Failure

1. External load impedance on the +5V supply (pin 26)is too low.

2. See 1311 menu Monitor/outputs:5 Volts and ExtSupply Current.

2，6

Digital Out 1 Overcurrent

1. External load impedance on Digital Output 1 driver(pin 19) is too low.

2，7

Digital Out 2 Overcurrent

1. External load impedance on Digital Output 1 driver(pin 20) is too low.

2，8

Motor Temp Hot Cutback

1. Motor temperature is at or above the programmed Temperature Hot setting,and the requested current is being cut back.

2. Motor Temperature Control Menu parameters are mis-tuned.

3. See

1311

menus

Monitor/Motor:Temperature

and

Monitor/Inputs:Analog2.

4. If the application doesn‟tuse a motor themistor,Temp Compensation and Temp Cutback should be programmed Off. 2，9

Motor Temp Sensor Fault

1. Motor thermistor is not connected properly.

2.

If the application desn‟t use a motor thermistor,Temp

Compensation and Temp Cut bback should be programmed Off. 3.

See

1311

menus

Monitor/Motor:temperature

and

Monitor/Inputs:Analog2.

3，1

Coil1 Driver Open/Short

1 Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，1

Main Open/Short

1 Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，2

Coil2 Driver Open/Short

1 Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，2

EM Brake Open/Short

1 Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

15

CODE

PROGRAMMER

LCD

POSSIBLE CAUSE

DISPLAY 3，3

Coil3 Driver Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，4

Coil4 Driver Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，5

PD Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，6

Encorder Error

1. Motor encorder fault.

2. Bad crimps or faulty wiring.

3.See 1311 menus Monitor/MOTOR:Motor RPM

3，7

Motor Open Circuit

1. External open of phase U、V or W motor connections 2. Bad crimps or faulty wiring.

3，8

Main contactor Welded

1. Main contactor tips are welded closed.

2. Motor phase U is disconnected or open.

3. An alternate voltage path(such as an external precharge resistor) is providing a current to the capacitor bank(B+ connection stud)

3，9

Main Contactor Did Not

1.

Main contactor did not close.

Close

2.

Main contactor tips are oxidized,burned,or not making good contact.

3.

External load on capacitor bank (B+ connection stud) that prevents capacitor bank from charging.

4.

4，1

Throttle Wiper High

Blown B+ fuse or main contactor did not close.

1. Throttle pot wiper voltage too high.

2. See 1311 3. Menus Monitor/Inputs: Throttle Pot.

4，2

hrottle Wiper Low

1. Throttle pot wiper voltage too Low..

2. See 1311 menu Monitor/Inputs: Throttle Pot.

4，3

Brake Wiper High

1. Brake pot wiper voltage too high.

2. See 1311 menu Monitor/Inputs: Brake Pot.

4，4

Brake Wiper Low

1. Brake pot wiper voltage too low.

2. See 1311 menu Monitor/Inputs: Brake Pot.

4，5

Pot Low Overcurrent

1. Combined pot resistance connected to pot low is too low.

2. See 1311 menu Monitor/Outputs: Plot Low.

4，6

EEPROM Failure

1. Failure to Wrote to EEPROM memory This can be caused by EEPROM memory writes initiated by VCL,by CAN,by adjusting parameters with the 1311,or by loading softwar to the controller.

16

CODE

PROGRAMMER

LCD

POSSIBLE CAUSE

DISPLAY 4，7

HPD/Sequencing Fault

1. KSI,interlock,direction,and throttle inputs applied in incorrect sequence.

2. Faulty wiring,crimps,or switches at KSI,interlock,direction,or throttle inputs.

3. See 1311 menu Monitor/Inputs.

4，7

Emer Rev HPD

1.

Emergency

reverse

operation

has

concluded,but

the

throttle,forward and reverse inputs and interlock have not been returned to neutral.

4，9

Parameter Change Fault

1. This is a safety fault caused by a change in certain 1311 parameter settings so that the vehicle will not operate until KSI is cycled.

For example,if a user changes the Throttle Type this fault will appear and require cycling KSI before the vehicle can operate.

51-67

OEM Faults

1. These faults can be defined by the OEM and are implemented in the application-specific VCL code .See OEM documentation.

6，8

VCL Runtime Error

1. VCL code encountered a runtime VCL error.

2. See 1311 menu Monitor/Controller:VCL Error Module and VCL Error.This error can then be compared to the runtime VCL module ID and error code definitions found in the specific OS system information file.

6，9

External

Suply

Out

of

Range

1. External load on the 5V and 12V supplies draws either too much or too little current.

2. Fault Checking Menu parameters Ext Supply Max and Ext Supply Minare mis-tuned.

3. See 1311 menu Monitor/Outputs:Ext Supply Current.

7，1

OS General

1. Internal controller fault.

7，2

PDO Timeout

1. Time between CAN PDO messages received exceeded the PDO timeout period.

7，3

Stall Detect

1 .Stalled motor.

2. Motor encoder failure.

3. Bad crimps or faulty wiring.

4. See 1311 menu Monitor/Motor:Motor RPM

8，7

Motor

characterization

Fault 8，8

Encoder

1. Motor characterization failed during the motor characterization process.

characterization

Fault

1. Encoder

Motor Type Fault

failed

during

the

motor

characterization process.

2. Motor

8，9

characterization encoder

pluse

rate

is

not

a

standard

value(32,64,48,80ppr) 1. The motor Type_parameter is out of range.

17

CODE

PROGRAMMER DISPLAY

LCD

POSSIBLE CAUSE

9，2

EM Brake Failed to Set

1. Vehicle movement sensed after the EM Brake has been commanded to set.

2. EM Brake will not hold the motor form rotating.

9，3

Limited Operating Strategy （LOS）

1. Limited Operating Strategy (LOS) control mode has been activated, as a result of either an Encorder Fault (code 3, 6) or a Stall Detect Fault (code 73).

2. Motor Encoder Failure.

3. Bad crimps or faulty wiring 4. Vehicle is stalled.

9，4

Emer Rev Timeout

1. Emergency Reverse was activated and concluded because the EMR Timeout timer has expired.

2. The Emergency Reverse Input is stuck on.

18

2 Electrical system diagnose Trouble

When turn on key switch, there no voltage

Probable cause

Corrective action

Key switch connect loose.

Open circuit.

Connector loose contact.

Battery terminal loose.

Replace.

Reconnect.

Replace or repair.

Retighten the bolt of the terminal.

When press down the accelerate pedal, reach truck does not move.

Open circuit.

Connector loose contact.

Directions switch loose contact.

Parking brake switch sticky.

Accelerator faulty.

Controller faulty.

Safety pedal open circuit.

Fuse melting.

Cannot move forward.

Directions faulty.

Replace.

Cannot move backward.

Directions faulty.

Replace.

When haven‟t press down the accelerate pedal, the truck still can move forward or backward.

The accelerate pedal cannot restore to origin position.

Replace or repair.

Mast cannot lift.

Main lifting contactor shorted or open circuit.

Lifting speed control potentiometer faulty.

Open circuit.

Connector loose contact.

Contactor tip over current and faulty.

Replace or repair.

Replace or repair.

Reconnect.

Replace or repair.

Replace contactor tip.

No tilting, reaching or side-shift action.

Open circuit.

Connector loose contact.

Micro switch of tilting, reaching or side shift faulty.

Reconnect circuit.

Replace or repair.

Replace or repair.

Replace or repair.

Replace or repair.

Replace or repair.

Reconnect.

Replace.

Reconnect.

Replace or repair.

Replace.

When mast lifting, the speed of pump motor increase too much.

Resistance of lifting potentiometer does not restore to 5K. Tilting micro switch sticky.

Side shift micro switch sticky.

Reaching micro switch sticky.

Hydraulic steering switch sticky.

Adjusting.

No steering action.

Pump motor faulty.

Pump controller faulty.

Lifting fuse melting.

Hydraulic steering switch faulty.

Replace or repair.

Replace or repair.

Replace or repair.

Replace or repair.

Working lamp doesn‟t turn on.

Working lamp fuse melting.

Connector loose contact.

Bulb faulty.

Replace.

Replace or repair.

Replace.

Horn button doesn‟t beep.

Connector loose contact.

Horn button loose contact.

Horn beeper faulty.

Replace or repair.

Repair or replace.

Replace a new one.

Horn beep

Horn switch closed at all times

Replace or repair.

Replace or repair.

Replace or repair.

Replace or repair.

Repair 19

There are no user serviceable parts in the Curtis controller. No attempt should be made to open, repair, or otherwise modify the controller. Doing so may damage the controller and will void the warranty. It is recommended that the controller‟s diagnostics history file be checked and cleared periodically.

CLEANING Periodically cleaning the controller exterior will help protect it against corrosion and possible electrical control problems created by dirt, grime, and chemicals that are part of the operating environment and that normally exist in battery powered systems.

Use the following cleaning procedure for routine maintenance. ① Remove power by disconnecting the battery. ② Discharge the capacitors in the controller by connecting a load(such as a contactor coil or horn) across the controller‟s B+ and B- terminals. ③ Remove any dirt or corrosion from the power and signal connector areas. The controller should be wiped clean with a moist rag. ④ Dry it before reconnecting the battery.

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3. Electrical Principle and wiring diagrams

21

22

Manual about the Automatic Watering System of the Forklift Battery 1. Automatic Watering System Makeup of the Automatic Watering System：        

Automatic Watering Plug End Plug Floater T-piece & L-piece Flow Indicator（with filter） 6mm, 8mm ,10mm watering pipe Male & Female couplings (Kv10 and KV6, etc.)

Water Tank

2. Application Specification & Installation During the period of development and long-term practical usage, the leak tightness of Froetek automatic watering system has received complete recognition.

But when you use it, you need to keep the automatic watering system clean and there can‟t be any filth on the surface.

How to properly install the automatic watering system of Froetek： Our automatic watering system is easy to operate, no need to finish watering the electrolyte in the storage battery by hand, time saving and labor saving, besides, it can extend the service life.

How to correctly install the water tank, choose proper

23

floaters, how to confirm the specification & quantity of the installed accessories according to different types of battery, including correct application rules for automatic watering plug, watering pipe, T/L-pieces and male/female couplings as well as the cleaning of the flow indicator.

We will give you a brief introduction for the above items as follows: Meanwhile we will offer detailed installation drawings to ensure that the clients can correctly install and standardize the operation. battery spec.

Watering head

T-piece （6-10-6）

T-piece

Flow indicator （filter）

6mm Watering pipe

10mm Watering pipe

end plug

Male/ female K10

Water tank specification

24V

12pcs

1pcs

1pcs

3m

5m

2pcs

1pcs

30L 1pcs

48V

24pcs

1pcs

1pcs

5m

5m

2pcs

1pcs

30L 1pcs

80V

40pcs

1pcs

1pcs

10m

5m

2pcs

1pcs

60L 1pcs

Automatic Watering System of Forklift Storage Battery-48V battery group

Floater How to choose proper floaters correctly：  According to different storage battery, we have five kinds of floaters for you to choose. In order to achieve our expected standard and completely reflect the effectiveness of the automatic watering system, the most important thing is to choose proper floaters.

At present our company can offer a rule for the client to make judgment and choose the type of 24

floater. (see diagram)  The diagram the installation way of the floaters：

Watering Pipe  Our company offers watering pipes of different types and the clients can choose what they need according to the specification of the battery.

The watering pipe must be perfectly sealed with T-piece and L-piece.

Notes during the filling process: 1．In order to ensure a safe watering process, we hereby recommend you to use Froetek flow indicator(with filter), the flow indicator with filter can not only timely indicate whether it finishes watering, but also avoid unclean impurities entering the battery to result interruption.

2．The watering pressure should be within the range of 0.2-0.6, no less than 200mbar。 3．You‟d better conduct watering within the specified periods, because frequent filling will lead to overflowing for too much water, which will do great damage to the storage battery.

Note：Filling after finishing charging is the best ideal state, besides, do not filling before charging.

Cleaning During the period of development and long-term practical application, the leak tightness of Froetek automatic watering system has been completely approved.

When you use it, you must pay much attention to keep the automatic watering system clean. No filth remaining on the surface.

The users should regularly clean the watering plug for the plug is a kind of plastic good. Clean the surface directly with tap water and no need to use other detergent.

Structure Diagram of the Watering Plug：

Close

Open

25

Characteristics of the Automatic Watering System  No need to water by hand, labor saving.  No malfunction factor leading to damage the battery.  Easy & safe operation.  Ensure a precise electrolyte level in every battery cell.  Prevent leakage when watering.  Effectively avoid the acid liquid to erode the storage battery and the electrolytic bath.  Extend the service life of the battery.  Environment protection.  Save energy.

Function Introduction： Function of the automatic watering system: the floater of the automatic watering plug can reach correct water level, when the level rises in the cell, the pressure closes the valves and prevents further water entering the cell. When the system finishes watering, the flow indicator will stop running and you can see the water-level indicator clearly through the top of the watering system.

Besides, the material of Froetek floater can avoid damage and ineffectiveness.

As for the structure of Froetek automatic watering system, there is a terraced step, when the electrolyte gas rises to the watering plug, the terraced part can prevent the leakage of the electrolyte gas as well as quickly cool the electrolyte gas to make them go back to the storage battery in time.

Our automatic watering system is safe, reliable and applicable, besides, from the economic aspect and with the advantage of cost reduction, energy saving and environment protection, it is the first-choice product in the present market.

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HANGCHA GROUP CO., LTD Manufacturing site: 88 Donghuan Road, LinAn Econimic Development zone, Zhejiang, P.R.China ZIP:311305 Registered Address 398 Shi Qiao Road, Hangzhou, P.R. China) Fax: 0086-571-88132890

0086-571-88926789

Web: http://www.hcforklift.com E-mail: sales@hcforklift.com

ZIP :310004