Electrical Forklift Truck (3-Wheel Counterbalanced Battery Forklift Truck) SERVICE MANUAL

CPDS13J-D1 CPDS13J-C1 CPDS13J-C2

CPDS15J-D1 CPDS15J-C1 CPDS15J-C2

CPDS16J-D1 CPDS16J-C1 CPDS16J-C2

CPDS18J-D1 CPDS18J-C1 CPDS18J-C2

CPDS20J-D1 CPDS20J-C1 CPDS20J-C2

Electrical Forklift Truck (3-Wheel Counterbalanced Battery Forklift Truck)

SERVICE MANUAL

Original Instruction

HANGCHA GROUP CO., LTD. th

Dec. 2010 4 EDITION

Foreword Thanks for your purchasing our 3-Wheel Counterbalanced Battery Forklift Truck.

3 wheel counterbalanced battery forklift truck is our company’s new product. It has the character of small turning radius, beautiful shape, small dimensions, low gravity. This series forklift truck use front 2-motor drive, rear wheel turning, lifting and turning share one pump etc. new technology.

This manual has two parts. First one is how to use, operation and maintenance 3 wheel battery forklift truck. The second part simply introduces the structure and principle of the 3 wheel forklift truck and some of the trouble shooting. Please operator and whom in charge of the truck must read the manual carefully before operate the truck.

We have the right to improve the truck, maybe there are some difference between your product and the description in this manual.

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

3-Wheel counterbalanced battery forklift truck has passed the CE certification.

Model meaning Model

Tow by electronic control

Lift by electronic control

CPDS13/15/16/18/20J-D1

ACS×2(INMOTION)

EVC255

Rated starting weight (t) / Load Center（mm） 1.3/500,1.5/500,1.6/500, 1.8/500,2/500 1.3/500,1.5/500,1.6/500,

CPDS13/15/16/18/20J-C1

1236×2（CURTIS）

EVC255（CURTIS） 1.8/500,2/500 1.3/500,1.5/500,1.6/500,

CPDS13/15/16/18/20J-C2

1236×2（CURTIS）

1236（CURTIS） 1.8/500,2/500

th

© Dec. 2010 4

edition HANGCHA GROUP CO., LTD.

Content 1. Drive system ······································································································1 1.1 GP20 reduction gear box ··········································································1 2. Steering system ·································································································4 2.1Steering device ···························································································4 2.2 Steering axle ······························································································5 3. Brake system ·····································································································7 3.1 Master pump······························································································7 3.2 Hand brake device ····················································································8 4. Hydraulic system································································································9 5. Lifting system ···································································································12 5.1 Mast················································································································13 5.2 Lifting cylinder ··························································································14 5.3 Tilting cylinder ··························································································15 6. Electrical system ······························································································16 6.1 Summary ·································································································16 6.2 CPDS13/15/16/18/20J-D1 forklift····························································18 6.3 CPDS13/15/16/18/20J C1 forklift ····························································26 6.4 CPDS13/15/16/18/20J-C2 forklift····························································32 6.5 Maintenance of controller ········································································34 7. Maintenance record ·························································································35

1. Drive system 3 wheel counter balanced battery forklift truck adapt structure of front two motor driven, each separated excited driven motor rated capacity is 8kW. Each motor’s rotating speed is controlled by the rear wheel rotating angle. Each side motor connects to ZF made GP20 model reduction gear box, wet disk brake system, and solid tire and rim such etc.

GP20 reduction gear box is two grades reduce speed gear, one grade straight gear and one grade planet gear. So the gear box is very small.

Wet disk brake do not need for maintenance on schedule.

Trouble Probably cause Method of troubleshooting The impact noise is too loud Gear clearance is too big.

Adjust.

When traveling or changing Too much worn of gear.

Replace. direction.

Too much noise when traveling Oil level is low.

Add oil.

Gear clearance is too big.

Adjust.

Too much worn of gear.

Replace.

1.1 GP20 reduction gear box

Foot brake

1.1.1 Data Specification Item Service weight (without oil) kg Oil volume l Oil type Brake fluid Oil pressure Normal pressure (continuous working) Max. pressure Normal fluid volume in brake booster Max worn fluid volume in brake booster Hand brake pull force Clearance Hand brake

Max worn limit clearance

Parameter 31 0.35 ATF DEXRON II 60-80 bar 80bar 100bar 1.71cm3 3.71 cm3 100N 6mm 13mm

1

1.1.2 Structure of reduction gear box

2

There are 3 holes on the brake booster of reduction gear box.

1. Air bleed plug. After add brake fluid, please loose the air bleed plug to let the air out of brake oil tube, and then tighten the plug.

2. The parking brake line connects to the head of booster. The maximum worn limit is 13mm, if exceed this limit, please replace a new one.

3. The oil inlet of the braking pump. When oil leak happens, change the braking pump.

3

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

2.1Steering device It consists of steering wheel, upside steering column, downside steering column, bearings, steering gear, priority valve, clamp bolt and hydraulic switch etc. You can adjust the steering angle forward and backward by yourself. Refer to fig. 2-2.

Tilt forward 6 degrees Tilt backward 6 degrees A-A rotation

Neutral position

Release position B direction rotation Lock position

C direction rotation

1. Steering wheel

3.Upside steering column

8.Gimbal

10.Down side steering axle

12. Bearing

13. Snap ring

14. Down side steering column

17. Steering gear

18. Priority valve

19. Clamp bolt

22. Clamp lever

26. Hydraulic switch

Fig. 2-2 Steering device

4

2.2 Steering axle The steering axle is import from Italy. Structure please refers to Fig. 2-3.

More details please refer to spare part lists.

Head body fix to chassis rear end, applied force from ground is accepted by support bearing 10 and 19.

Use nut 8 to adjust pre-tightening force of bearing 10 and 19; cylinder 15 and head body connect together, rack's (11) end acts as piston, when the fluid from priority flow control flow to cylinder 15, hydraulic oil push rack 11 to move left or right, gear axle and rack 11 are engaged, then gear axle make steering wheels turn left or right, the angle of turn both are 0 85 .

Caution when using: 1.

2.

Cylinder leaks oil, check and change seal ring 12 ,14 ,16, check guide sleeve at the same time ,and make sure whether cylinder is damaged or not.

Check bearing 10, 19, and seal ring 9, 20 at regular intervals; if it is damaged, change bearing and seal ring at once; change grease at regular intervals also.

3.

Check bearing 26, 28 and seal ring 25; if it is damaged, change bearing and seal ring at once; change grease at regular intervals at the same time.

4.

Adjust pre-tightening force of steering hub bearing: remove counter weight, and cover etc, lift the back of head body by jack, make wheel leave from ground. Screw down nut 3 to the location till it is not moved, then turn it 1/6~1/4 circle in the opposite direction.

5.

Adjust pre-tightening force of support bearing (10, 19): remove counter weight, and cover etc, lift the back of head body by jack, make wheel leave from ground. Screw down nut 8 to the location till it is not moved, then turn it 1/6~1/4 circle in the opposite direction.

1. Shaft 7.Washer 13.Guide 19. Bearing 25.Seal 31.Nut

2.Support 8.Cover 14.Seal 20.Seal 26.Bearing 32.Cover

3.Nut 9.Seal 15.Liner 21.Shaft 27.Hub 33.Plug

4.Screw 10. Bearing 16.Seal 22.Pin 28. Bearing

5.Washer 11.Rack 17.Head 23.Pin 29.Washer

6.Ring nut 12.Seal 18.Head body 24.Ring 30.Cotter pin

Fig. 2-3 Rear Steering Axle 5

Condition High effort for steering of failure to rotate steering wheel

Difficult to steer

Abnormal noise

oil leak seal ring of wheel hub or supported bearing damaged

Probable cause

Corrective action

pump damaged or trouble

change

priority valve damaged or blocked

change or clean

tube or connect damaged or blocked

change or clean

dividing valve pressure is too low

Adjust pressure

air is in the oil circuit

remove air

steering reposition failure, positioning of spring piece change spring piece break or lack elasticity innner leakage of steering cylinder is too large.

check seal of piston

oil level is lower

Add oil

steering gear axle and rack damaged

Change

wheel hub or supported bearing damaged

Change

not enough lubricate

add grease

suction pipe or oil filter blocked

Clean or change

seal ring of steering cylinder or connect or pipeline Change damaged parameter of controller is not correct

Change seal ring

parameter of controller is not correct

adjust

6

3. Brake system Brake system is composed of hand brake control and foot brake control ;handle of brake control is composed of handle and backstay cable; foot brake control is composed of brake pedal, brake master pump, pipeline and brake; brake is wet disc brake, avoid maintenance.

3.1 Master pump The master pump contains a valve seat, check valve, return spring, primary cup, piston and secondary cup, which are kept in place with stop washer and stop wire. The exterior of the cylinder is protected from dust by means of a rubber dust cover. The piston is actuated through the push rod by operation of the brake pedal. First, as the brake pedal, the push rod pushes the piston forwards. The brake fluid in the cylinder flows back to the reserve tank through the return port until the primary cup blocks up the return port. After the primary cup passes the return port, the brake fluid in the cylinder is pressurized and opens the check valve, flowing through the brake lines to the wheel cylinder. Thus, each wheel cylinder piston is forced outwards. This brings the brake shoes into contact with the wheel drum and slows or stops the lift truck. Meanwhile, the cavity caused behind the piston is filled with brake fluid led through the return port and inlet port to lubricate the piston. When the brake pedal is released, the piston is forced back by the return spring. At the same time, the brake fluid in each wheel cylinder is pressurized by the force of the brake shoe return spring, thus returning into the master through the check valve. With the piston in its original position, the fluid in the cylinder flows into the reserve tank through the return port. The brake fluid in the brake lines and wheel cylinders has a residual pressure proportioned to the set pressure of the check valve, which makes each wheel cylinder piston cup securely seated to prevent oil leakage and eliminates of vapor lock developing when the lift truck is sharply broken.

1. lock nut 7. Piston

2. Rod 8. Primary cup

3. Duct cover 9. Spring

4. Stop wire 10. Check valve

5. Stop washer 11. Valve seat

6.secondary cup 12. Cylinder body

Fig. 3-1 Master cylinder

7

3.2 Hand brake device The hand brake device adopts a hand-pulling soft brake wire device. It makes use of auto-assist pressure linings type brake together with foot brake. Only when parking truck, use the hand brake. If it occurs for foot brake malfunction, use hand brake to stop the truck.

Trouble diagnostic Condition

Probable cause

Corrective action

Oil leakage in brake lines.

Correct and replenish.

Air in brake lines.

Bleed air.

Insufficient brake

Water or oil on linings.

Clean or replace.

force

Uneven wear or contact of brake linings.

Grind or replace.

Improper functioning of master cylinder or

Correct or replace.

wheel cylinder.

Brake dragging

Clogged oil lines.

Clean.

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 return port.

Clean.

Clogged oil lines.

Clean.

Wheel bearing out of adjusting.

Adjust or replace.

8

4. Hydraulic system The high pressure oil from main pump goes to control valve, then goes to lifting cylinder or tilting cylinder.

When the lifting and tilting spools are in neutral, the lifting pump will be off work. When pulling lifting spool, high pressure oil goes to the bottom of lifting cylinder piston and then push piston rod under. When pushing lifting spool, it is that bottom of lifting cylinder piston connects with low pressure line and then piston rod drops by deadweight and weight of cargo. In this time, oil from lifting cylinder goes by unidirectional speed limiting valve so as to control the falling speed, then the lifting pump out off work also. When operating tilting spool, high pressure oil goes to one house of tilting cylinder and another connects with low pressure line so as to make mast tilt forward or backward.

Main pump Trouble No oil from oil pump

Probable cause 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 ring and O-ring.

Low

Maladjusted relief valve.

discharge

Replace faulty parts.

Readjust to specified pressure using pressure gauge.

Retighten suction side pipe.

pressure on oil pump.

Corrective action

Add oil in oil tank.

Air in oil pump.

Checks pump oil seal.

Do not operate pump until bubbles in tank disappear.

Cavitation due to crushed suction hose or clogged strainer.

Air being sucked from loose suction Noisy oil pump

side joint.

Cavitation due to too high oil viscosity.

Bubbles in hydraulic oil.

Oil leaking from oil pump

Faulty oil seal on pump, faulty O-ring or worn sliding surfaces on pump.

Adjust or replace crushed hose and clean strainer.

Retighten each joint. ¡ replace with new oil having proper viscosity for temperature at which pump is to be operate. ¡ to operate when oil temperature is normal.

Determine cause of bubbles and remedy.

Replace faulty parts.

9

Control valve Trouble

Probable cause Loose of pressure-adjust screw.

Pressure of relief Distorted or damaged pressure-adjust valve is not steady spring.

Worn or blocked relief valve core. or too low.

Pump abated.

Fork tilt forward

Worn or damaged tilt lock valve.

when control lever is used while engine is Broken tilting lock spring.

Damaged tilt valve plunger O-ring. off.

Mast is unstable when tilting forward.

Malfunctioning tilt relief valve.

Valve body and spool valve is worn and clearance between them is too great. of mast is big when Spool valve is not in centre. spool valve is in the Cylinder seal abated. centre.

Taper valve is worn or blocked by dirt.

Damaged or distorted reposition-spring.

Spool valve is not Dirt exists between valve body and spool valve. return neutral Blocked control device. position.

Not coaxial parts at reposition Damaged O-ring.

Faulty seal of joint.

Loose seal plate.

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

Lowering

distance

Corrective action Readjusted and retighten.

Replace.

Replace or clean.

Examine and repair pump.

Replace valve core and tilt lock valve as an assembly.

Replace spring.

Replace O-ring.

Replace tilt relief valve assembly.

Replace spool valve with specified clearance.

Keep being in the centre.

Examine and repair cylinder.

Replace or clean taper valve.

Replace spring.

Clean.

Adjusted.

Reinstall，be coaxial Replace.

Check and retighten.

Clean seal plate and retighten blots.

Tighten.

Control valve can not move back and

Back and forward adjust handle intervene

adjust

forward

Main relief valve adjustment: The pressure of main relief valve has been adjusted correctly before leaving the factory, usually not forbidden to adjust by users. This is the way of adjustment with specified load 1600kg, as following steps: （1）

Lay 125% specified load on fork, 2000kg.

（2）

Push the pedal down to end, then lift fork, if fork can lift 0-300mm, the pressure of main relief valve is correct, or adjust according to step 3.

（3）

If fork can not leave from ground, increase the pressure of main relief valve, remove front base plate at first, then screw adjust-bolt in clockwise to increase the pressure of main relief valve. If fork height exceeds 300mm, screw adjust-bolt in counterclockwise to decrease the pressure of main relief valve.

（4）

Push the pedal down to end, the fork lift between 0-300mm. Or adjust according to step 3 till meet requirement.

10

Warning: The load must lay steadily and firmly; do not adjust the pressure randomly after adjusting the required pressure.

Tonnage

1.3t

1.5t

1.6-2.0t

Max pressure of redirector input port

16MP

16MP

16MP

Safety pressure of control valve

14MP

15.5MP

18.5MP

Rated pressure of gear pump

20MP

20MP

20MP

Item

11

5. Lifting system Condition Fork arm carrier or mast tilt by itself.

The fork arms carrier moves up and down sluggishly.

Forks are lifted or lowered unsmooth.

Probable cause 1.Tilt cylinder and ring abraded excessively 2. The hydraulic control valve spring is inoperative.

1. Caused by piston jamming or bent piston rod.

Corrective action Replace piston ring tilt cylinder.

2. Too much dirt is accumulated in the cylinder.

Strip it down and clean.

1. Carriage bracket assembly out of adjustment.

Adjust clearance with thrust metal and carriage side roller.

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

3. Biting foreign materials between moving parts.

4. Insufficient lubrication.

5. Bent carriage bracket assembly.

Forks are lifted 1. Lift chains out of adjustable. unevenly 1. Grease stiffened or dirt accumulated on lift roller Lift roller does and mast sliding surfaces. not rotate 2. Improperly adjusted lift roller.

1. Insufficient lubrication.

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

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

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

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

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

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

Insufficient lift 5. Oil leaks occur between the hydraulic control power or no lift valve sections. movement.

6. Leakage occur in the hydraulic pipe.

7. The hydraulic oil temperature is too high. Oil viscosity is too low and the rate is insufficient.

8. The load carried is beyond the designed capacity.

Replace it.

Replace the faulty parts.

Adjust clearance with rollers.

Remove foreign materials.

Apply grease on contact surfaces of sliding parts.ďźˆbutter Repair or replace.

Adjust lift chains.

Clean and lubricate lift rollers.

Adjust.

Lubricate.

Adjust.

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.

Replace the worn parts or the oil pump.

Replace Yx-ring.

Replace.

Replace.

Dismantle for regrinding the joint surfaces and reassemble the valve.

Tighten the joint nuts and inspect the seal for damage.

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.

Observe the lifting capacity limit.

12

5.1 Mast The basic type mast is 3 meters 2 stages mast. The lifting system is composed of inner and outer mast, fork arm carrier, fork arm, load backrest, chain, roller, lifting jack, and tilt cylinder, etc. Oil line system, hydraulic pressure system and it compose fork lift truck work equipment.

1. Outer mast

2.Inner mast

3.Lifting chain assy.

4.Left Lifting cylinder

5.Fork carriage

6. Fork assy.

7.Tilting cylinder

8.Right lifting cylinder

Fig. 5-1 Mast Dimension and weight of basic type mast (lift height is 3m) Type

Dimension of mast

Weight of mast(kg)

CPDS13J(D1) 、CPDS13J-C1 CPDS15J(D1) 、CPDS15J-C1 CPDS16J(D1)、 CPDS16J-C1

1895╳1050╳287

428

CPDS18J(D1)、CPDS18J-C1 CPDS20J(D1)、CPDS20J-C1

13

5.2 Lifting cylinder

1. Piston

2.AF dust proof

3. B3 dust proof

4.O ring

5.Guide

6. Cylinder body

7. Snap ring

8. Piston

9.Support ring

10.Protector

11.B7 seal ring

12.Valve guide

13.Snap ring

14. Nozzle assy.

(Left cylinder has no nozzle)

15. O ring

16. Pin

Fig. 5-2 Tilting cylinder

14

5.3 Tilting cylinder

1. Support

2.Bearing

3.Lubrication nipple

4.Washer

5.Nut

6.Bolt

7. Pistion rod

8. AM dust proof

9.Guide

10.Guide ring

11.B3 seal ring

12.Bush

13.Snap ring

14. O ring

15.Cylinder body

16.Piston

17.O ring

18.Guide ring

19.Nut

20. Pin

21.OK seal ring

22. O ring

Fig. 5-3 Tilting cylinder

15

6. Electrical system 6.1 Summary The ZAPIMOS chopper family represents ZAPI’s answer to the needs of the 21rst’ century’s. To ensure that products remain on the market, without running the risk of becoming technically obsolescent, the ZAPIMOS family offers the following features: - Advanced technology.

- Economical costs.

- Maximum safety.

- Maximum flexibility.

- Open to future technical innovations.

- Optimum level of protection.

The design has been derived from: - High Frequency Mos Technology.

- Real time control over the internal and external components that influence the behavior of the machine, with self diagnosis of the checking circuits themselves.

- Stored Program Machine (SPC), where the hardware is completely separate from the functions to be configured. The programmer is parametric and can easily be modified by the end user.

- Various chopper configurations can be selected by the user, without the need for hardware modifications.

- Future technological updates are made easy for the user.

- The communication protocol will continue to evolve, thereby offering increased possibilities of interaction and expansion. For this reason, the Zapimos family offers a standard dialogue mode with external systems. This allows interfacing with commercially available systems, and its price will be different with the different performance.

- electrical controller can meet the requirement of IP51, and offer good protection function, which can protect from dust and liquid such as water, acid and so on coming inside. Its control logical can be easily open and it is allowed to do simply change.

6.1.1 Potentiometer of steering angle sensor Front double-wheel drive. A steering angle sensor helps to measure the steering angle to make the controller differential the front two wheel.

Using “SET STEER MIN” and ” SET STEER MAX” functions it is possible to acquire the voltage value corresponding to the two limits of the steering potentiometer’s stroke.

6.1.2 SAFETY & PROTECTION FEATURES - Reverse Polarity of the battery Electrical Circuit diagrams must be consulted in order to avoid damage to the power unit. A Line (Main Contactor), managed by the logic unit, is necessary for protection against reverse battery polarity.

- Connection errors All inputs are protected against connections errors. Contactor drivers are suitable for loads up to 2 Amps, and are protected against overload.

- Thermal protection If the controller temperature exceeds 85°C, the maximum current reduces in proportion to the thermal increase. The temperature can never exceed 95°C. - Low Battery charge 16

When the battery charge is low, the maximum current is reduced proportionally to the battery discharge.

- External Agents The chopper is protected against dust and spray of liquid to a degree of protection meeting IP51.

- Protection against accidental Start Up A precise sequence of operations is necessary before the machine will start.

Operation cannot commence if these operations are not carried out correctly.

Requests for drive must be made after closing the Key Switch.

- Protection against uncontrolled movements.

The Main Contactor will not close if: 路The Power Unit is not functioning 路The Logic Unit is not operating correctly 路The output voltage of the accelerator does not fall below the minimum voltage value stored, with 1Volt added. 路Running micro-switch in closed position.

6.1.3 OPERATIONAL FEATURES - Speed Control.

- Optimum sensitivity at low speeds.

- Speed Reductions in both directions. Levels can be set using Console.

- Regenerative Braking based on deceleration ramps.

- Three different modes of Braking: Release Braking, Inversion Braking, Speed Limit Braking.

- Speed Control during descent: the motor speed follows the accelerator. The chopper automatically brakes if the motor speed overcomes the accelerator set point. This provides optimum performance on a gradient.

- Starts on a Ramp without roll back, even without an electric brake.

- Programmable Anti Roll Back: When the Key Switch is closed, if the motor is rotating, the chopper controls the speed and automatically brakes This keeps the motor at a very low speed during descent on a gradient. This is a very useful safety feature and is not driver dependent.

- Electro-brake management (optional) - Output for hydraulic steering with adjustable delay.

- Self Diagnosis with indication of fault shown via flashing Red Led. ( In addition to Console Display).

- Modification of the parameters via Digital Console. See the specific description.

- Internal Hour Meter that is displayed on the Console.

- Memory of the last 5 Alarms, with relative Hour meter count and chopper temperature all displayed on the Console.

- Test Function within Console for checking main parameters.

See the specific Description.

- Internal Contactor Coil Suppression.

- High motor and battery efficiency due to High Frequency Switching.

- Presence of a second microprocessor for safety that monitors the CPU that controls the motor.

17

6.2 CPDS13/15/16/18/20J-D1 forklift CPDS13/15/16/18/20J-D1 forklift contains ac motor, traction controller, traction controller matches ac motor, traction controller uses two ACS electronic controllers from Inmotion company, lift controller uses Curtis EVC255 electronic control.

6.2.1 AC Motor This truck walk motor uses three-phase AC frequency conversion motor, high electric power transition, without commutator and brush, avoid maintenance.

18

CPDS13/15/16/18/20J D1 ELECTRICAL SYSTEM PRINCIPLE DIAGRAM

6.2.2 Electric system schematic of CPDS13/15/16/18/20JD1 forklift

19

6.2.3 Diagnostics of traction system fault diagnostic error by VMC20 code

source

condition

time

Traction controller

Main contactor

101

Accel switch active at key-on

activate accelerator switch with starting

KEY→ON

cut

close

102

Dir.Switch active at key-on

activate back/forward direction switch with starting

103

Direction error

activate back/forward direction switch at the same time

KEY=ON

cut

close

104

Tract pot error

potentiometer voltage >95% or potentiometer voltage < 5% VX_out

KEY=ON

close

close

105

Tract switch error

before activating accelerator switch, voltage >30%

KEY=ON

close

close

106

Steer pot error

potentiometer voltage >95% or potentiometer voltage < 5% VX_out

KEY=ON

close

close

107

Battery under voltage

48V:<28.2V/.8s

KEY=ON

cut

cut

108

ACS under voltage

voltage< limit continuous time more than 0.8s

KEY=ON

cut

cut

109

Battery over voltage

>65V/0.8s

KEY=ON

cut

cut

110

ACS over voltage

voltage> limit continuous time more than 0.8s

KEY=ON

cut

cut

111

Can comm.

Error

See 1.2.1

KEY=ON

cut

close

KEY=ON

-

close

cut

close

warning 114

Battery low voltage

115

Startup error

cut

battery <

25% Decrease drive speed battery <15% inner error in process

explanation

starting

KEY=ON

20

Checked error by left towing controller（emergency） code

source

Condition

Time

Tractor controller

main contactor

251

Short circuit

short ACS or motor terminal

252

ACS over temperature

253

explanation

KEY=ON

cut

cut

ACS radiator temperature > 125 ℃

KEY=ON

cut

close

Motor over temperature

Motor temperature > 180 ℃

KEY=ON

cut

close

354

ACS current sensor error

ACS current sensor error

KEY→ON

cut

close

255

Cap.not charging

Cap.not charging in 10s after power up

KEY→ON

cut

close

256

ACS no response

ACS has no response in starting process

KEY=ON

cut

close

257

L.tract slave comm. timeout

communication time between ACS and tractor controller exceeds (diagnoses by VMC20 )

KEY=ON

OFF

close

258

ACS SDO error

ACS SDO error (incorrect software edition)

KEY=ON

cut

close

259

L.tract slave comm.timeo ut

communication time between ACS and tractor controller exceeds (diagnoses by VMC20 )

KEY=ON

cut

close

260

ACS low voltage trip

ACS voltage <18V

KEY=ON

cut

close

no use

261

ACS high voltage trip (SW)

ACS voltage > 68V (software)

KEY=ON

cut

close

no use

262

ACS high voltage trip(HW)

ACS voltage >68V (hardware)

KEY=ON

cut

close

no use

364

Other error

KEY=ON

cut

close

no use

21

diagnosed error by left towing controller（warning） code

source

condition

time

201

ACS low temp warning

ACS radiator temperature < -20 ℃

202

ACS high temp warning

ACS radiator temperature> 85 ℃

203

Motor high temp warning

motor temperature > 145 ℃

KEY=ON

204

Heat sink temp sensor error

ACS radiator temperature sensor error

205

Motor low temp warning

206

Tractor controller

main contactor

explanation

close

minimum accelerator value loaded

close

minimum accelerator value loaded

close

close

minimum accelerator value loaded

KEY=ON

close

close

Motor temperature < -50 ℃

KEY=ON

close

close

Motor temp sensor error

disconnect or short motor temperature sensor

KEY=ON

close

close

207

Speed feedback sensor error

disconnect or short speed feedback sensor

KEY=ON

close

close

208

ACS high voltage warning

209

ACS low voltage warning

ACS voltage < 23.4V

KEY=ON

210

ACS default values loaded

default values loaded in ACS

211

KEY=ON

KEY=ON

close

close

close

minimum accelerator value loaded

close

close

minimum accelerator value loaded

KEY=ON

close

close

Power reduce

Power reduce(by some warning condition)

KEY=ON

close

close

212

Checksum error

Checksum error

KEY=ON

close

close

216

Current sensor default error

Current sensor default error

KEY=ON

close

close

ACS voltage > 68V

KEY=ON

close

22

diagnosed error by right towing controller（emergency） code

source

condition

time

tractor controller

main contactor

explanation

351

Short circuit

Short ACS or motor terminal

KEY=ON

cut

cut

352

ACS over temjperature

ACS radiator temprature>125 ℃

KEY=ON

cut

close

353

Motor over temperature

Motor temprature > 180 ℃

KEY=ON

cut

close

354

ACS current sensor error

ACS current sensor error

KEY→ON

cut

close

355

Cap.not charging

Cap.not charging in 10s after power up

KEY→ON

cut

close

356

ACS no response

ACS has no response in starting process

KEY=ON

cut

close

357

R tract slave comm.timeout

communication time between ACS and tractor controller exceeds (diagnoses

by VMC20 )

KEY=ON

cut

close

358

ACS SDO error

ACS SDO error (incorrect software edition)

KEY=ON

cut

close

359

R tract master comm.timeout

communication time between ACS and tractor controller exceeds (diagnoses

by VMC20 )

KEY=ON

cut

close

360

ACS low voltage trip

ACS voltage <18V

KEY=ON

cut

close

no use

361

ACS high voltage trip(SW)

ACS voltage > 68V (softaware)

KEY=ON

cut

close

no use

362

ACS high voltage trip(HW)

ACS voltage >68V (hardware)

KEY=ON

cut

close

no use

364

Other error

KEY=ON

cut

close

no use

23

diagnosed error by right towing controller（warning） code

source

condition

time

Tractor controller

Main controller

301

ACS low temp warning

ACS radiator temprature< -20 ℃

302

ACS high temp warning

303

explanation

KEY=ON

close

close

ACS radiator temprature> 85 ℃

KEY=ON

close

close

Motor high temp warning

motor temprature > 145 ℃

KEY=ON

close

close

304

Heat sink temp sensor error

ACS heat sink temp sensor error

KEY=ON

close

close

305

Motor low temp warning

motor temperature < -50 ℃

KEY=ON

close

close

306

Motor temp sensor error

disconnect or short motor temperature sensor

KEY=ON

close

close

307

Speed feedback sensor error

disconnect or short speed feedback sensor

KEY=ON

close

close

308

ACS high voltage warning

ACS voltage > 68V

KEY=ON

close

close

minimum accelerator value loaded

309

ACS low voltage warning

ACS voltage < 22.5V

KEY=ON

close

close

minimum accelerator value loaded

310

ACS default values loaded

default values loaded in ACS

KEY=ON

close

close

311

Power reduce

Power reduce(by some warning condition)

KEY=ON

close

close

312

Checksum error

Checksum error

KEY=ON

close

close

316

Current sensor default error

Current sensor default error

KEY=ON

close

close

24

6.2.4 The table of EVC255 lift(pump) controller fault Condition code

Condition light

LED OFF SOLID ON 0,1

explanation

May cause

No power or defective controller Controller error（MCUfault） ■¤

Controller operational, no known faults 1.

2.

EEPROM data lose EEPROM data check error, use 311 programme device and change any parameter to banish this fault.

MOSFET short motor cut

1,1

¤¤

EEPROM fault

1,2

¤¤¤

Hardware fault

1.

2.

2,1

¤¤¤

Deep under voltage

battery voltage too low

2,2

¤¤¤¤

Promote and lock

Activate promoted and locked function of controller

2,3

¤¤¤¤¤

Sequence fault（Startup lockout）

Any of SS1-SS4 switch close before KSI or INTERLOCK

3,2

3,3

¤¤¤¤¤

¤¤¤¤¤¤

contactor cement

1.

2.

Main contactor cement The set of “CONTACT CNTRL” is incorrect.

1.

Precharge circuit work irregularly Motor short.

precharge fault 2.

1.

Main contactor loosen, Main contactor irregularly.

circle

3,4

¤¤¤¤¤¤¤

unfixed or cut contactor（DNC）

4,1

¤¤¤¤¤

under voltage protection

Battery voltage is lower than “LOVOLT CUTBACK” value

4,2

¤¤¤¤¤¤

Over voltage protection

Battery voltage is too high.

4,3

¤¤¤¤¤¤¤

2.

Temperature ptotection（over or under 1. temperature） 2.

work

Controller temperature is too high or too low.

Temperature sensor work 25 irregularly.

6.3 CPDS13/15/16/18/20J C1 forklift 6.3.1 CPDS13-20JC1electronic control fault code chart There are red and yellow led light on body case, different flicker means different fault. as followed chart: display condition

meaning

two lights off

controller has no power ,because of no battery or pipeline fault

yellow flicker

controller work normally

red and yellow solid on

software updating

red and yellow both flicker

controller fault

Fault cod chart of left and right towing controller codes

Display fault code by hand unit

May cause

1，2

Controller Overcurrent

1. Short connect terminal of U, V or W of motor outside.

2.Incorrect motor parameter by adjusting 3. Controller fault.

1，3

Current Sensor Fault

1.short between U, V, W phase and truck body.(stator short) 2. Controller fault.

1，4

Precharge Failed

1.The outside load of capacitance group(B+ terminal) prevent capacitance recharging 2. See 1311 battery check menu: capacitance voltage.

1，5

Controller Severe Undertemp

1. Controller work in extreme condition, lower than -40℃.

2. See 1311 controller menu: temperature.

Controller Severe Overtemp

1. Controller work in extreme condition, higher than +95℃.

2.Over loading; 3.Fix controller incorrectly; 4. See 1311 controller menu: temperature.

Severe Undervoltage

1.Adjust battery menu parameter incorrectly; 2.Over loading; 3. Internal impedance of battery is too high.

4.Disconnect battery when driving; 5. See 1311 battery check menu: capacitance voltage.

6. B+ fuse melt or main contactor unclosed.

Severe Overvoltage

1. Adjust battery menu parameter incorrectly; 2.The resistance is too high when battery produce rating rebirth current; 3.Disconnect battery when rebirth brake; 4. See 1311 battery check menu: capacitance voltage.

1，6

1，7

1，8

26

codes

2，1

2，2

Display fault code by hand unit

May cause

Controller Undertemp Cutback

1.Controller does not work at this temperature , lower than -25℃; 2.Controller work in extreme condition; 3. See 1311 controller menu: temperature.

Controller Overtemp Cutback

1.Controller does not work at this temperature , higher than 85℃。 2.Controller work in extreme condition;; 3.Over loading; 4.Fix controller incorrectly; 5. See 311 controller menu: temperature.

1.Normal condition, fault means need recharging, the controller performance is limited at this voltage, 2.Adjust battery menu parameter incorrectly; 3.Check whether is any other load run out of battery or not; 4. Internal impedance of battery is too high.

5. Disconnect battery when driving.

6. See 1311 battery check menu: capacitance voltage.

7. B+ fuse melt or main contactor unclosed.

1. Operate normally. Fault shows rebirth current increase battery voltage when rebirth brake. The controller performance is limited at this voltage, 2.Adjust battery menu parameter incorrectly; 3.Internal impedance of battery is too high.。 4.Disconnect battery when rebirth brake;。 5.See 1311 battery check menu: capacitance voltage.

2，3

Undervoltage Cutback

2，4

Overvoltage Cutback

2，5

+5V Supply Failure

1.Outside load resistance connected with +5v terminal(pin26) is too low; 2. se e 1311 input watch menu: current of 5Vand Ext.

2，6

Digital Out 6 Overcurrent

1.Outside load resistance connected with digital output terminal 6(pin19) is too low;

2，7

Digital Out 7 Overcurrent

1.Outside load resistance connected with digital output terminal 7(pin20) is too low;

2，8

2，9

Motor Temp Hot Cutback

Motor Temp Sensor Fault

1.Motor temperature ≥ seted cut off temperature , motor temperature>145℃ 2.Adjust temperature control parameter of motor incorrectly; 3. See 1311 motor check menu: temperature and motor input:Analog2; 4. If does not use electric heating adjuster, temperature compensate and cut should be OFF.

1.Connect motor electric heating incorrectly; 2. If does not use electric heating adjuster, temperature compensate and cut should be OFF. 3. See 1311 motor check menu: temperature and motor input:Analog2; 27

codes

Display fault code by hand unit

May cause

Coil 1 Driver Open/Short

1.Drive load open or short; 2.Pin connector dirt; 3. Wiring harness damaged or connect wiring incorrectly.

Main Open/Short

1.Drive load open or short; 2.Pin connector dirt; 3. Wiring harness damaged or connect wiring incorrectly.

Coil2 Driver Open/Short

1.Drive load open or short; 2.Pin connector dirt; 3. Wiring harness damaged or connect wiring incorrectly.

EM Brake Open/Short

1.Drive load open or short; 2.Pin connector dirt; 3. Wiring harness damaged or connect wiring incorrectly.

Coil3 Driver Open/Short

1.Drive load open or short; 2.Pin connector dirt; 3. Wiring harness damaged or connect wiring incorrectly.

Coil4 Driver Open/Short

1.Drive load open or short; 2.Pin connector dirt; 3. Wiring harness damaged or connect wiring incorrectly.

PD Open/Short

1.Drive load open or short; 2.Pin connector dirt; 3. Wiring harness damaged or connect wiring incorrectly.

3，6

Encoder Fault

1.Motor coder fault; 2.Wiring harness damaged or connect wiring incorrectly; 3.See 1311 motor watch menu: motor RPM

3，7

Motor Open

1. The U、V、W wiring of motor open; 2. Wiring harness damaged or connect wiring incorrectly.

Main Contactor Welded

1.Main contactor pin cement; 2.The U phase of motor disconnect or open ; 3. There is current which an alternative voltage affords for capacitor group (B+).

Main Contactor Did Not Close

1.Main contactor unclosed; 2.Main contactor pin oxidation; 3.Outside load at capacitor group(B+) prevent capacitor recharging; 4. B+fuse melt.

3，1

3，1

3，2

3，2

3，3

3，4

3，5

3，8

3，9

28

codes

Display fault code by hand unit

May cause

4，1

Throttle Wiper High

1.The input voltage of accelerator is too high; 2. See 1311 input watch menu: accelerator voltage.

4，2

Throttle Wiper Low

1.The input voltage of accelerator is too low; 2. See 1311 input watch menu: accelerator voltage.

4，3

Brake Wiper High

1.The input voltage of brake is too high; 2. See 1311 input watch menu: brake voltage.

4，4

Brake Wiper Low

1.The input voltage of brake is too low; 2. See 1311 input watch menu: brake voltage.

Pot Low Overcurrent

1.The resistance of potentiometer connected with low terminal is too low; 2. See 1311 input check menu: low terminal.

EEPROM Failure

Fail to write in EEPROM .EEPROM may be written by VCL, CAN bus, adjusting parameter of 1311 or loading new software, above all may cause fault.

HPD/Sequencing Fault

1.The sequence of electric door ,interlock , direction and accelerator input is incorrect; 2.The wiring harness or transition switch of electric door, interlock , direction and accelerator input damage.

3. See 1311 input watch menu.

Emer Rev HPD

1.Emergency reverse operating terminates, but accelerator, back and forward input , interlock switch do not revert to empty shift.

Parameter Change Fault

1. Because some parameter setting of 1311 is changed, then this fault appears, it can be eliminated by restarting electric door switch.

For example, if user change accelerator type, it may cause fault, it can be eliminated by restarting electric door switch.

4，5

4，6

4，7

4，7

4，9

29

codes

Display fault code by hand unit

May cause

VCL Runtime Error

1. VCL code run time error; 2. See 1311 controller watch menu: VCL error module and VCL error.

This fault may be compared to error code which is defined in run time VCL module ID and system information file.

6，9

External Supply Out of Range

1.The current of outside load which 5V and 12V input produce is too high or too low, 2.The outside maximum and minimum input of fault check menu parameter is adjusted incorrect, 3. See 1311 input check menu: outside input current.

7，1

OS General

1. Inner controller fault.

7，2

PDO Timeout

1.The communicate receiving time of CAN PDO exceeds the overtime cycle of PDO.

7，3

Stall Detect

1.Motor stop; 2.Motor coder fault; 3.Wiring harness damaged or connection incorrectly; 4.Coder power provide appears matter; 5.See 1311 motor watch menu: motor RPM。

8，7

Motor Characterization Fault

1. Motor performance description of motor description step is wrong.

8，8

Encoder Characterization Fault

1. Coder performance description of coder description step is wrong.

2.Motor coder pulse frequency is not a standard value（32，48，64， 80ppr）

8，9

Motor Type Fault

1. Motor type parameter exceeds range.

9，2

EM Brake Failed to Set

1.Truck remain run when sending out brake signal; 2. EM brake can not grip the rotary motor.

6，8

9，3

9，4

Limited （LOS）

1. No matter coder fault（code 36） or stop check fault （code 73） appear, as a result, limited operation control mode is activated.

OperatingStrategy 2. Motor coder fault.

3.Wiring harness damaged or connection incorrect; 4. Truck stall.

Emer Rev Timeout

1. emergency reverse is activated ,but emergency reverse has stopped work, because emergency reverse time has exceeds required time.

2. Emergency reverse signal cement.

Lift (pump) controller, see fault code 6.2.4 "the fault code chart of EVC255 lift (pump) controller ".

30

6.3.2 The electric system schematic diagram of CPDS13-20JC1

31

6.4 CPDS13/15/16/18/20J-C2 forklift 6.4.1 CPDS13-20JC2Motor controller breakdown codes table CPDS13-20JC2 traction motor 1236×2（CURTIS）is the same to CPDS13-20J-C1，motor break down codes please refer to P76.

32

6.4.2 The electric system schematic diagram of CPDS13-20JC2

33

6.5 Maintenance of controller Controller does not have spare parts, do not try to open, repair or change controller, if users do these, it will damage controller, and guarantee repair is invalid; keep controller clean and dry.

Clean Clean controller outside at regular intervals, it may avoid corrosion or other dirt, dust and electronic control fault chemical caused.

Clean as the following steps: 1. Remove power supply plug; 2. Connect controller B+ and B- (for example contactor circle or horn) with load to recharge capacitance in controller.

3. Clean dirt and corrosion which is at power supply and signal connection poles with wet cloth.

4. Airing controller before fixing power plug.

34

7. Maintenance record DATE

Maintain content

Maintainer

35

HANGCHA GROUP CO. , LTD.

■ ■ ■ ■ ■ ■

Address for: OVERSEAS USERS 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) ■ ZIP :310004 Fax: 0086-571-88926789 0086-571-88132890 Web: http://www.hcforklift.com E-mail: sales@hcforklift.com