A Series Deluxe Electric Reach Truck

Operation and Maintenance Manual

CQD12/14/16/18/20-AC4 CQD12/14/16/18/20-AC5
CQD12/14/16/18/20-AD2 CQD12/14/16/18/20-AD6
CQD12/14/16/18/20-AC4-I CQD12/14/16/18/20-AC5-I
CQD12/14/16/18/20-AD2-I CQD12/14/16/18/20-AD6-I

Original Instruction

HANGCHA GROUP CO., LTD.

1/2023
 FOREWORD
Thank you very much for purchasing A series electric reach truck of Hangcha Group.
A series electric reach truck is a newly developed product. The adopted advanced technologies as
electric power steering, electromagnetic brake and armrest fingertip have advantages as comfort
operation, safety and security, low maintenance cost. It also has compact structure, small turning
radius, beautiful shape, low gravity, good stability and superior performance. It is an ideal tool for
handling goods in warehouse, supermarket and workshop.
Aefore use the truck, relative persons must read and understand the manual, get to know how to
safely operate and maintain the truck.
This manual is divided into two parts. Part one of this manual is about the brief introduction and
correct operation of the electric reach truck, which will tell you how to operate safely and maintain
preventively; part two will tell you the structure, working principle and maintenance of the electric
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.
Due to the continuous updating and improvement of our products, there may be minor
discrepancies between your forklift truck and this manual.
For any questions, please contact Hangcha or your nearest dealer.
This series truck has been passed CE certification.

1/2023 HANGCHA GROUP CO., LTD.

 Contents
Foreword
PART ONE OPERATION AND MAINTENANCE
1. A PPEARANCE AND MAIN COMPONENTS .......................................................................2
2. INSTRUMENT ............................................................................................................. 3
3. USE OCCASION AND CONDITION ................................................................................19
4. S AFETY INSTRUCTIONS ............................................................................................ 20
5. S TRUCTURE AND STABILITY OF TRUCK ...................................................................... 24
6. DURING BREAK IN .................................................................................................... 27
7. ROUTINE MAINTENANCE ...........................................................................................28
8. DRIVE AND OPERATE ............................................................................................... 31
9. S TORAGE ................................................................................................................ 35
10. B ATTERY - SERVICING, RECHARGING, REPLACEMENT .............................................. 36
11. MAINTENANCE ....................................................................................................... 54
12. F ORKLIFT HOIST AND TRANSPORT ...........................................................................64
13. MAIN TECHNICAL PARAMETERS LIST ........................................................................67
14. NAMEPLATES AND WARNING LABELS ....................................................................... 69
15. T HE USE, INSTALL AND SAFETY RULES OF ATTACHMENT .......................................... 71
16. RELEVANT SAFETY DIRECTIVE OR STANDARD (CE OR OPTIONAL) ............................. 73
PART TWO: STRUCTURE , PRINCIPLE AND MAINTENANCE
1. DRIVE SYSTEM ........................................................................................................ 75
2. F RONT WHEEL ASSEMBLY ........................................................................................ 85
3. S TEERING DEVICE ....................................................................................................87
4. HYDRAULIC SYSTEM .................................................................................................88
5. MAST SYSTEM ......................................................................................................... 90
6. E LECTRICAL SYSTEM ............................................................................................... 95
 Part One Operation and Maintenance
1. Appearance and Main Components

7 9

6
10

3
11
2

14 13 12
1
15

1. Drive wheel 2.Seat 3.Brake pedal 4.Accelerator pedal 5.Steering wheel

6.Instrument 7.Shift lever 8.Overhead guard 9.Mast 10.Load bracket
11.Fork 12.Front wheel 13.Reach device 14.Side plate 15.Cover

2
2. Instrument
The multi-function display shows the battery capacity, the service hours, the operating mode, the
travel speed and fault code information etc. Graphic illustrations on the multi-function display act
as warning indicators. Check fault code and parameter setting through the right button.

Item Display
1 Operating mode display
2 Fault code display
3 Accumulated service hour display
4 Steering angle display
5 Travel speed display
6 Battery capacity display
7 Operating mode key/direction key
8 Direction key
9 Menu key/Enter key
10 Crawl speed indicator
11 Fault indicator
12 Battery low capacity indicator
13 Lifting low speed indicator
14 Seat switch indicator
15 Parking brake applied indicator

3
Main display interface
Operating mode display [1]

Menu key/ Enter key[9]

Truck operating mode can be changed by

pressing the “Mode” 7 on the right.
In the main display interface, press this button
Fault code display [2] to enter the fault inquiry interface.
In the main display interface, long-press this
button and keep 2 seconds, and then enter
submenu interface.
Indicator light
“TRA” is the fault code of traction controller;
“HYD” is the fault code of pump controller; Crawl speed indicator [10]
“STR” is the fault code of steering. OK means
no fault.
When the truck is in crawl speed mode, this
Waning： indicator will light up.
Fault indicator [11]
 Never operate defective truck.
Accumulated service hour display[3]
In the event of an electronic control failure, this
Hourglass stands for the accumulated service lamp will light up and will be off until the fault is
hours of forklift. When the truck is switched on, removed.
it starts timing. Battery low capacity indicator [12]
Steering angle display[4]
When the remaining battery is lower than the
system set value, this indicator will light up.
It displays the steering angle of driving wheel.
Travel speed display[5] Lifting low speed indicator [13]

It displays the truck travel speed. When the remaining battery is lower than the
Battery capacity display [6] system set value, this indicator lights up and
the mast lifting speed reduces to remind the
driver to charge the battery as soon as
possible.
Seat switch indicator [14]

It displays the remaining battery capacity.

The more the bar numbers, the more the This lamp illuminates whenever the driver
battery capacity. When it displays two bars, the leaves the seat. At this point, the vehicle
battery capacity is about 20%, charge in time, cannot move or lift. This feature requires the
otherwise the battery service life will be seat to be fitted with a pressure sensor
influenced. (option).
Operating mode key/Direction key[7] Parking brake applied indicator [15]

For truck equipped with hand brake, pull the

In the main display interface, press this button hand brake, this indicator lights up and the
to change the truck operating mode. parking brake is started.
In the submenu interface, press this button to For truck equipped with electromagnetic brake,
turn up or over. press the parking brake rocker switch, this
Direction key[8] indicator lights up and the parking brake is
started.

4
Led ligts illustration

Instrument Led lights

When the key switch is closed, the meter will first self-check 9 LEDs, which will be lit in
turn and then turned off uniformly.
No. Parameter Name Description Remark

Battery light
1 Light up when the battery level is below 20%

Fault light
2 Light up when a controller in the vehicle is faulty

3 Seat light Light up when the driver leaves the seat 0：light up；1：go out

4 Hand brake light Light up when the driver operates the hand brake

When the power level is lower than or equal to 10%,

5 Lift lock light
the lift lock light is on

5
 Instrument main interface display

No. Parameter name Description Standard type Enhanced type

When the hourglass symbol is lit, it
indicates that it is timing, and the number
shows the current vehicle working time.
Hour meter
① When the key switch is turned on and ● ●
the vehicle starts to work, the work timer
starts counting.
The arrow represents the direction in
which the steering wheel travels: 0
degrees in the left horizontal direction,
Wheel angle
-90 degrees in the vertical direction, +90 ● ●
② indication
degrees in the vertical direction, and
±180 degrees in the right horizontal
direction.
Display the current working mode, there
Working mode
are four gears positions as “1”, “2” “3”, ● ●
③ indication
“S”(turtle speed)
Display current vehicle speed in km/h or
③ Travel speed ● ●
MPH
Display the current battery power icon,
10 grids, for the first 8 grids, per 10%
Battery level power off and one grid off, when the
⑤ display power is less than or equal to 10%, the ● ●
last two grids disappear at the same
time, no grid is displayed.
Show real time of the day:
Real time of the
hour-minute-second(Web version
⑥ day ● ●
display)
When the lift is locked, the icon lights up
Lift lock indicator and does not appear at the same time as
⑦ ● ●
the lift (up) icon.
Fault code
Display the current fault code ● ●
⑧ display

⑨ Fork height Display the fork height, unit: 0.1m ●

The distance
The distance of the fork from the target
⑩ from the fork to ●
height, unit: 0.1m
the ground
Display the direction in which the fork
⑪ Fork movement
moves up, down, forward, backward, tilt ●
direction
forward and backward
The system is performing the automatic
Automatic picking picking function and does not appear at
⑫ icon the same time as the automatic ●
placement icon.
Target height Display target height character code
⑬ character code (A-H): (1-9) ●
The system is performing the automatic
Automatic placement function and does not appear
⑭ placement icon at the same time as the automatic ●
picking icon

Total display items 8 14

6
Note: Battery power display comparison table

Power value range Grids displayed Power value range Grids displayed

90-100 10 40-49 5

80-89 9 30-39 4

70-79 8 21-29 3

60-69 7 11-20 2

50-59 6 0-10 0

7
 Standard interface display content

Enhanced interface display content

Note：
1. In the main interface ：

First press buton 2, the automatic placement icon appears, and then press button 4, the automatic
placement icon disappears, and the automatic picking icon appears;
First press buton 4, the automatic picking icon appears, and then press button 2, the automatic
picking icon disappears, and the automatic placement icon appears;
2. The lift lock icon and the lift (up shift) icon have only one display at a time;

3. The height indicator function needs to be restarted each time powe on and off;

8
 4. For icon 10
No. Group 1 Group 2 Group 3

1 up(lift) Forward Tilt forward The down arrow () is displayed

when the distance of the fork
2 down Backward Tilt backward from the target height is greater
than the set fork height (icon 9);
The up arrow () is displayed when the distance of the fork from the target height is less than the set
fork height (icon 9);
The up and down arrows are not displayed when the distance of the fork from the target height is
equal to the set fork height (icon 9);
5. The fork icon shows that the corresponding icon is displayed when the valve stem is operated, and
the corresponding icon disappears when the valve stem is not operated;

6. Boot LOGO display;

7. Factory boot displays standard interface;

8. Fork movement combination: group 1, group 2 and group 3 can be arbitrarily matched, select 1 or
2 for each group;

Key function

Icon Name Function

Up key Move the cursor up or add 1 to the
selected number

Left key Move the cursor to the left

Right key Move the cursor to the left

Down key Move the cursor down or minus 1 to the

selected number
Cancel key Cancel current content or return to
previous menu
Enter key Confirm the current operation, enter the
menu mode or confirm the address height in
the main interface.
Number key Modify the number of the selected cursor
or set different address heights.

9
Shortcut key

Number key Switch performance mode in the main interface

1
Number key Automatic placement in the main interface
2
Number key Set the address height mode in the main interface,
3 jump to the fork height setting interface

Number key Activate automatic picking function in the main

4 interface
Number key Standard interface and enhanced interface switching
5 in the main interface
Number key When the height indicator function is used, select the
6 character code "A-H" for different target heights.
Number key When the height indicator function is used, select the
7 character code number "1-9" for different target
heights.
Up key In the main interface, increase the contrast

Down key In the main interface, lower the contrast

10
 If the direction lever is not in neutral or the accelerator ped
Steering wheel

Turn
left
Tight
Loose
Turn
right
Hold the steering wheel knob and rotate
counterclockwise, the wheels turn left; rotate
clockwise, the wheels turn right. Steering Hand brake lever(only for truck with cable
wheel height is adjustable to meet operator ’s brake)

need. Unscrew housing knob, move it to

proper position and then tighten the knob.
Caution
 Steering of the forklift truck is drove by the motor. After shutting down the forklift, turn the steering

When braking, pull on the brake lever to

Key switch works on the brake, which generates a
braking force to prevent the motor shaft
rotating. To release the brake, press the
button on the brake and push the lever
forward.
The hand brake is equipped with a
micro-switch on the left side that stops the
forklift from moving when the brake lever is
engaged.
The key switch has two positions: ON and To CE forklift ： If the driver leaves the seat
OFF. First set the direction lever to the without applying the hand brake, then the
neutral position, take your foot off the truck alarms to remind the driver to apply the
accelerator pedal, then turn the key hand brake.
clockwise to the ON position.

Warning
Caution If parking on the slope is

11
 unavoidable, block the wheels
Forward gear
with solid wedge.

Neutral

Reverse gear
Parking rocker switch (only for truck with
electromagnetic brake) Press the horn button, the horn sounds

The direction switch is press-button switch

and is used to switch between forward and
reverse directions of travel. When the
direction lever is pushed forward and the
Parking brake is installed on the instrument accelerator pedal is depressed, the forklift
panel. truck will travel forward. When the direction
lever is pulled back and the accelerator pedal
When braking, press the braking button,
is depressed, the forklift will travel in reverse.
generates a braking force on the drive motor
through electromagnetic brake. Meanwhile
the parking brake indicator illuminates. Caution

To cancel, press the braking button,

electromagnetic brake is released, the
parking brake indicator is off, and the parking
brake is cancelled.

Warning ： When the forklift is moving and the
If parking on the slope is unavoidable, block the wheels with solid wedge.
direction lever is operated, the
hut down the truck, the parking brake engages automatically.
he truck cannot travel under engaged parking brake. electrical brake will be applied and the
forklift will decelerate to a standstill
before gradually moving off in the
opposite direction.
 If the direction lever is not in neutral,
Horn button
the key switch is turned to ON,
instrument displays fault, press the
direction switch and set to neutral, the
fault disappears.

12
 Emergency stop switch

Depress the safety pedal with left foot and

In an emergency, press the red mushroom slowly depress the accelerator pedal with
head button to cut off the vehicle's main right foot, the drive motor will start running
power supply. The vehicle will not be able to and the forklift will move off. The travel speed
move, turn or lift. can be increased gradually based on the
force applied to the pedal.
Caution
aution
 o not depress the accelerator pedal before turning on
Do not use the emergency stop switch
to stop the truck under normal
circumstances as the key switch.

Safety pedal
Safety pedal is a kind of safety device. As to
truck equipped with safety pedal, if need to
go forward/backward, step on the safety
pedal with left foot and accelerator pedal with
right foot. Lever
There are lift lever, reach lever, tilt lever and
Brake pedal
sideshifter lever.

Depressing the brake pedal will slow down or Lift lever

stop the forklift and activate the brake lights.


aution
o not depress the accelerator and brake pedals at the forward
Push same time, as this
to lower thewill damage
forks; Pull the
backdrive
to motor.
raise the forks. The lifting speed is controlled
Accelerator pedal by the distance that the lever is moved
backward. The lowering speed is controlled

13
by the distance that the lever is moved
forward and the speed limit valve.
Reach lever

Push forward to move the mast forward, pull Used when adjusting the spacing of the forks.
backward to move the mast backward. The Pull up the fork stopper and rotate it 90°,
mast movement speed is determined by the then adjust the forks to the desired positions
distance that the lever is moved. according to the load to be handled.
Tilt lever
Caution
 Fork spacing should be adjusted
symmetrically to the truck centreline.
After adjustment, make sure that the
The tilt lever is used to tilt the fork carriage. fork stoppers are securely locked.
Push forward to tilt forward, pull backward to  The lower crossbar of the fork carriage
tilt backward. The tilting speed is determined has an opening for fitting and removing
by the distance that the lever is moved. the forks.
 aution
C
 Dovalve.
The multi-way valve is equipped with a front tilt self-locking
not secure forks at the opening
When the circuit is cut off, the fork carri
position, in order to prevent them falling
through the opening.
 There installs one bolt in the middle of
upper beam to avoid forks working
here. If bolt damaged, replace new one.
Replace forks
Sideshifter lever Remove old forks: place the forks in middle,
drop to the ground, tilt forward the mast, then
the forks are off the fork carriage and reverse
the truck.
Assemble new forks: place forks on the
Push forward to move the forks to left, pull
ground facing the truck, lower the fork
backward to move the forks to right. The fork
carriage to the lowest, truck travels slowly,
movement speed is determined by the
distance that the lever is moved. aim the fork slot to the top-bottom beam and
gag of fork carriage, then lift the fork carriage
Fork stopper
and adjust fork position.

Brake fluid reservoir

14
 Oil filler of hydraulic oil

Brake fluid reservoir installs below the front

baseboard. Translucent reservoir enable us The hydraulic oil tank is located under the
check the brake fluid level from outside. If the hood, unscrew the filler cap, and add
brake fluid level is lower than “MIN”, add hydraulic oil with the same model. Then
brake fluid with the same specification. fasten the cap.

Caution
 When adding brake fluid, prevent
dust and debris from entering the
cup. Brake fluid is corrosive and toxic.
Headlight and its button

The headlight is installed on the front pillars

of the overhead guard; headlight button is
installed on the housing, and is a rocker
switch. Press down the rocker switch, the
light is on.

2.9 Seat
There are several choices for the seat, general seat adjustable functions: seat weight adjustment,
seat level position adjustment, seat backrest adjustment. Make brief introduction to the following
seat adjustment.

15
 Adjust driver
No. Remark seat
according to
weight：
1 Weight adjusting knob In order to get
ideal damping
Seat forward-backward effect, adjust
2
adjusting lever
the seat
according to
3 Seat back adjusting lever
driver ’s
weight. Sit on,
4 Safety belt
rotate the
knob
according to driver ’s weight. For heavy driver, rotate the knob to “+”direction; for light driver, rotate
the knob to “－”direction

Adjust seat position：

– Pull the forward-backward adjusting lever 2 upward, and move the seat forward or backward to
proper position.
– Release the adjusting lever, lock driver seat automatically.

Warning
 Never
Adjust adjust seat when
seat back：
– Pull the seat back adjusting lever 3 upward, and adjust back inclination.
– Release the seat back adjusting lever 3 and lock the seat back.

Safety belt
Fasten safety belt 4 before driving. It protects driver when accidents happen. Regularly clean and
check safety belt, avoid dirt.

Correctly use safety belt：

16
– Sit on the seat correctly.
– Check if the safety belt twisted.
– Place the safety belt on the hip.
– Fasten the safety belt and check safety belt lock.
– Adjust safety belt until it reaches the state that it does not squeeze hip or is unable to fix due to
too much looseness.
Periodically check the safety belt：
–
Check if safety belt is off-line, damaged or cracked.
–
Check if the metal pieces of safety belt(including anchor point) wear or damage.
–
Check if lock catch for safety belt or traction machine functions normally.

Warning
 In any case, if there is damage or flaw(insecure lock, damage, wet light) on the safety
belt, please repair or replace immediately.
 Never do any change to the safety belt. Replace new one after each accident.

Adopted measure when special condition incurred：

– Fasten the safety belt and sit on.

– Never jump from the truck.

– Lean forward, hold the steering wheel with

both hands, and support with feet.

– Lean yourself in the opposite direction to

truck tipping over.


Warning
When there is danger of tipping over, do not unfasten the safety belt to escape. It may cause severe bodily i

17
Operator Presence System (option)

OPS (Operator Presence Sensing) system is a safeguard system that installs a sensor in the
driver seat to sense if the driver sits on the seat correctly. If the driver does not sit on the seat
correctly, driving force is cut off, meanwhile, all loading and unloading operations will be stopped. It
helps to reduce accident when the driver leaves. When the driver does not sit correctly, the driver
cannot drive the truck or operate the loading and unloading, thus the accidents by maloperation
will be reduced.
Driving protection function
When the vehicle is travelling, the driver leaves the seat or the safety belt is released (if equip with
safety belt protection switch) over 1 second, truck stops automatically, and the instrument
displayed seat indicator light lights up, meanwhile the buzzer sends out continuous alarm
signal. Only when pulling up the hand brake or the driver sits on the seat correctly and the
direction switch returns to neutral, the seat indicator light goes out, travelling OPS status is
released.
Working protection function
When the vehicle is under working condition, the driver leaves the seat or the safety belt is
released (if equip with safety belt protection switch) over 1 second, working stops automatically,
and the instrument displayed seat indicator light lights up, meanwhile the buzzer sends out
continuous alarm signal. OPS light comes on, buzzer sends out alarm signal, transportation
operation stops automatically. When the driver sits down again, the seat indicator light goes
out, working OPS status is released.
Warning function
Once the seat sensor detects the seat switch is turned off, within 1 second, the buzzer sends out
continuous alarm signal, and the seat indicator light lights up. If the seat indicator light
keeps on when the seat switch is off, it means the OPS in the startup state.
Resume neutral function
If the direction switch does not return to neutral and the seat switch is turned on. The buzzer will
send out continuous alarm signal to remind the driver that the OPS in the startup state.
OPS abnormal function handling
Park the truck in safe place and contact Hangcha agency to check if any below condition is
occurred. a. after the driver leaves the seat, the seat indicator light does not light up; b. when
the driver sits down, the seat indicator light does not go out.

Caution
 As to forklift equipped with safety belt protection switch, driver needs to sit on the
seat correctly and also needs fasten safety belt, and then operate the truck. When driving
on the uphill, starting the OPS will cut off the drive power and make the truck slip. In order
to avoid this accident, the driver must sit correctly when operating on the uphill.

18
Fork locking function after power off
This function means: forks are locked when starting switch is off or power off, forks will not lower
down even operate the control lever.
3. Use occasion and condition
Vehicle use occasion and specified condition：
–
Used in specified area as factory, tourist attraction and recreation place.
–
Used on the flat ground, that is fixed and owns enough carrying capacity(protect
operation and lifting).
–
As the diameter of the wheel is small, it is forbidden to crossing over the bulge or hollow
in case of the truck tipping over.
–
Used on the road with good vision and equipment use license.
–
Use in specified rated load.
–
Max. laden gradeability when driving is 5%.
–
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.
Please read other safety rules in this manual, it is important to your personal safety, working staff
and goods safety.
Warning
It’s prohibited to use this equipment in the anti-explosion area.
Do not over load. Do not carry people.
Cause the forklift adopts normally closed electromagnetic brake, never drag the forklift. Or it may damage the brak
It is prohibited to lift the mast when the mast reaches.
It is prohibited to travel forklift when the forks are in high position.

19
4. Safety instructions and notify a manager. The truck may only be
1. Only trained and accredited operators are used after the fault has been eliminated.
permitted to operate the truck. Arrange for immediate repair in the event of a
fault when lifting or driving uphill or downhill, or
a leakage of battery electrolyte, hydraulic oil or
brake fluid.

2. Inspect the truck at periodic intervals for

Fault
leaks, deformation, defects, etc. the life of the
truck will be shortened or an accident could
occur.
Make sure to replace the “key safety parts”
during periodical inspection.
5. Batteries generate explosive gases. Keep
Wipe off oil, grease or water from the floor sparks and open flames away from the battery.
board and foot and hand controls. Keep tools away from the battery terminals to
Strictly prohibit smoking and spark near the prevent sparks or short-circuits.
storage battery when checking it. 6. The truck is designed to operate on solid
When performing maintenance on the mast, and flat cement, asphalt or concrete surfaces.
front and rear lights, or other high places, be Check the road condition in advance.
safely secured and take care not to slip. The truck is designed to operate in the
Be careful do not be scalded when inspecting following climatic conditions: temperature
the motor, controller and etc. range -20 ℃ to 50 ℃; maximum wind speed
3. Operators must wear a helmet, work shoes 5 m/s; maximum relative air humidity 90% (at
and overalls. 20°C).
The truck is not suitable for use in flammable
or explosive working environments.
7. The overhead guard prevents cargo from
falling onto the operator. The load backrest
ensures the stability of loads. Do not use a
forklift without the overhead guard and load
backrest. Modifications to attachments must
4. Whenever you discover a fault, stop the be authorized by the manufacturer. Do not
forklift, hang a "DANGER" or "OUT OF attempt to modify attachments yourself.
ORDER" sign on it, remove the ignition key 8. Clear up the working site, clean obstacle,

20
sweep macadam, muddy sand, and wipe off departures the center. And the truck may turn
greasy dirt and water. over more probably.
9. Use the safety grip when mounting and
dismounting the truck. Not quick jump or jump
out of forklifts.
10. It is forbidden to drive the truck on other
place else operator ’s seat. Never put your
hand and foot out of the truck body. Especially,
don’t let your foot outside rear of the truck. 11.
It is forbidden to people to enter the
clearance of the mast and truck body, for when 17. Never horseplay.
the mast reaches back, once be clamped, it 18. When the mast of reach truck reaching out,
will cause fatal dangers. do not drive it because of in this status, the
truck has the trend of overturn when a sudden
brake or turning. The truck must be driven
when the mast shrinks to the bottom.
19. It is prohibited to travel with forks in high
position. Keep the forks 30cm above the
ground, drive the forklift with mast tilting
backward in place.
20. When the loads are on the ground, you
cannot make a reaching action.
21. Don’t make a sudden start, sudden brake
or sharp turning. Especially when unlade,

12. Know well the curve chart on the load otherwise it will cause danger of overturning. 22.
curve label, which indicates the relationship In raining days or working on a wet,
between rated load capacity and load centre slippery ground, you’d better turn around truck
distance. Never overload. slowly and avoid sudden brake. Slowly down
13. Other people are not allowed to stand on the reach truck when operating on a slope. 23.
the forks, pallet or operator ’s seat. It is Before turning around, take care of the rear
forbidden to using other things or human as an of the truck. Make sure nobody around the
additional counterbalance weight. truck. Slowly down the speed 1/3 of max
14. Before starting the truck, press the button traveling speed when turn around.
to make sure nobody around. 24. Do not stack loads on forks in such a way
15. Use proper size and enough intensity that the top of the load exceeds the backrest
pallets. Avoid loading goods higher than the height. If unavoidable, make the load stable
height of backrest. and secure. When handling bulky loads which
16. Prohibit load off center. The goods is liable restrict your vision, operate the forklift in
to drop turning or passing rough when it reverse or have a guide. When using a guide,

21
make sure you know and understand the
meaning of all hand, flag, whistle or other
signals being used. When transporting long
loads such as lumber, piping and oversized
cargo, or operating vehicles with elongated Warning

attachments, pay close attention to the front

end when driving around corners or along 28. It is forbidden to lift goods on an incline.
narrow aisles and be aware of other people. Avoid stacking on a slope as possible. It is

25. When operating loaded truck, drive forbidden to turn around suddenly on a slope.

forward to uphill and reverse to downhill. 29. Do not use the truck, when the weather is

When operating unloaded truck, reverse to bad, such as sand blowing by wind, snowing,
thunder, flashing, rainstorm and typhoon etc.
uphill and drive forward to downhill. Do not
Especially when the wind speed is higher than
turn on the ramp to avoid tip-over.
5m/s, you should avoid using the truck.
30. Because the wheel diameter of the reach
truck is small, do not run over uneven road or
obstacle, drive carefully when unavoidable.
Dragging the reach truck is not allowed.
31. When parking, shrink back the mast to
bottom of slide slot and lower the fork to
ground, and take away the key switch.
32. The labels and signs on the vehicle
provide warnings and operating instructions.
During operation, adhere to the requirements
of the manual as well as the labels and signs
on the vehicle.
Inspect the labels and signs, and replace any
26. It is forbidden to stand or walk under the
fork or the attachment. It is forbidden to stand that are damaged or missing.
on the fork. 33. Controller is equipped with accumulator.
Forbid to touch within B+ and B- to prevent
Warnin
g from wounding by electricity. Before checking
or cleaning, please connect loads (contactor
circuit or horn for example) between B+ and B-
first to discharge for capacitor of controller. 34.
The workplace should be equipped with fire
extinguishers. Drivers and managers need to
27. It is forbidden to walk or stand between the be familiar with the location and use of fire
frame and battery box.
extinguishers.
35. Electromagnetic brake is adopted in the

22
front and rear wheel for this series forklift, so it 41. The work place should be bright enough.
is not allowed to be towed. At night, turn on the head lamp and work with
36. When conveying small loads, you should enough light.
use pallet, it is not permitted to put loads on 42. Only in the event that the truck
the forks without pallet. Otherwise the small manufacturer is no longer in business and
loads may fall off easily, and hit the driver. 37. there is no successor in the interest to the
In the process of installment and assembly, business, the user may arrange for a
there will be noise and vibration. Please modification or alteration to a powered
choose the right tool and assembly method. industrial truck provided, however, that the
Depress the noise and vibration as less as user shall: ： ① Arrange for the modification or
possible to reduce the noise pollution to alteration to be designed, tested and
circumstance. implemented by an engineer(s) expert in
38. The truck is designed to operate on solid industrial trucks and their safety; ② Maintain a
and flat cement, asphalt or concrete surfaces. permanent record of the design, test(s) and
When there are snows, ice accretion, hydrops,
implementation of the modification or
or other foreign matter and obstacle, operate
alteration; ③ Approve and make appropriate
the forklift only after cleaning them, otherwise
changes to the capacity plate(s), decals, tags
the truck maybe out of control and even cause
and instruction handbook; ④Affix a permanent
safety accidents.
and readily visible label to the truck stating the
39. Move the truck to the place which respects
manner in which the truck has been modified
traffic when it anchors. And then move it by a
or altered together with the date of the
suitable truck(refer to truck transport).
modification or alteration, the name and
40. After removing the overhead, backrest of
address of the organization that accomplished
mast, do not operate the truck or load cargo.
the tasks.

23
5. Structure and stability of truck （Avoid truck tipping over!）
It is very important for operator to know the truck’s structure and relationship between load and
stability.

The
Cautio structure
The basic structure of the truck is lifting device (include mast
and forks) and truck body.
The lift truck keeps the balance of weight between the truck
body and the load on the forks with the center of the front
wheels as a fulcrum when the rated capacity load is placed
in position.
Due care should be paid to the weight and the center of
gravity of loads to maintain the stability of the truck.

Cautio Load
Forklift transported loads are different, from box to board and
long shape. In order to evaluate the forklift and its stability, it is
very important to distinguish the gravity center of loads in
different shapes.

Warning
If the truck is going to turn over, do not attempt to get out of the truck, because the
speed of overturn is much faster than you. You should hold the steering wheel
handle, and this practice will keep you in the seat. Please tie safety belt.

24
 Gravity
Cautio and
The combined center that is composed of the
barycenter
and the load center determine the stability of lift trucks.
When unloaded, the barycenter does not change;
When loaded, the barycenter is determined by the truck
and the load’s center.
The barycenter is also determined by the tilting, lifting,
reaching of the mast. So the combined gravity center
changes as well.

The combined center is determined by these factors:

– Load’s size, weight and shape.
– The lifting height.
– Mast extension
– Mast tilt angle;
– Acceleration, deceleration and turning radius; –
The road and ground tilting.

– The attachment.

Cautio The stability zone of the

In order to make the truck stable, the combined center

must be in the triangle which is made up of two points that
the two front wheels attach ground and the midpoint of the
back driving axle.
If the combined center is in the front driving axle, two
front wheels become two fulcrums, the truck will overturn.
If the combined center departures the triangle, the trucks
shall overturn in the corresponding direction.

25
 the max load（weight and
Cautio
load center）
The distance between the load center and the front surface of
forklift or load bracket (select the min) on the forklift is called
LOAD CENTER DISTANCE. The max gravity that the truck can load
is called MAX LOAD on condition that the load is on the load center
distance. The relationship of MAX LOAD and LOAD CENTER
DISTANCE is specified on the load capability chart. If the load center
is moved near the front of forklift, the load should be cut down

The load
Cautio capability
This chart shows the relationship of MAX LOAD 载 荷 曲 线
CAPACITY AND LOAD
图 RATED

DIAGRAM

and the location of LOAD CENTER DISTANCE. Check

whether the load and load center distance is in the range
referred by the chart. Put the most important parts near the
载 荷 中 心 距 LOAD CENTER DISTANCE

load bracket if the shape of goods is complex.

Cautio Speed and

One object will keep quiescence until force works on it. Also, a moving object will keep moving
until force works on it .This is just inertia.
According to inertia, when truck starts moving, one force works backwards, and when truck
stops moving, one force works forwards. So, it’s dangerous to brake suddenly, because it
causes one large force works forwards, and it’s easy to cause truck overturn or load slide off.
When the forklift makes a turn, it will exert a centrifugal force outward from the curve center.
This strength pushes forklift outwards and causes it to turn over. About stability region is very
small, so decelerate when turning. If the cargo transported at the high position, it’s easier to turn
over

26
6. During break in
We recommended operating the reach 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 machine is in a stage of 100 hours of operation.：

- In general, the battery should be recharged promptly when the charge level has decreased to
20% of its capacity.

- The periodic maintenance must be operated.

- To avoid sudden start, brake or turning.

- Replace all the oil or lubrication grease by schedule.

- Limit the loading weight not overweight than the 70-80% of load capacity.

- Retighten the wheel bolts and other fasteners.

27
7. Routine Maintenance damaged or be enlaced by rope.
Careful, all-round maintenance will keep the Check whether the tire nut loosens or the tire

forklift truck in good working condition. It bearing is damaged.

guarantees the safety of the forklift and your 6. Electromagnetic brake

personal safety at work. Press the parking brake rocker switch on the
instrument stand, and the parking brake
Warning symbol is displayed on the instrument. Press
 In addition to testing lights and this switch again, then the parking brake
checking operating performance,
symbol disappears, and the parking brake is
before checking the electrical system,
cancelled.
turn off the key switch and disconnect
8. Check hydraulic oil
the battery plug.
 Never use a forklift that has any kind of
fault.
 Even a small fault can cause a serious
accident.
1. Check for leakage of hydraulic oil,
electrolyte and brake fluid
Check for oil spills or leakage around the
hydraulic fittings, battery, and brake systems
by hand feeling or carrying out a visual
inspection. Never use an open flame.
2. Check the load backrest
Inspect the load backrest and see whether the Hydraulic oil tank is below the cover, and the
load backrest is distorted, cracked or any filler cap is behind the seat. Check the oil tank,

loose bolts on it. unscrew the oil filler cap, pull out the dipstick
and check the oil level. Different numbers on
3. Check overhead guard
the dipstick stands for the required hydraulic
Inspect the overhead guard and see whether
oil height of different masts. Add oil if the
there is any crack or deformation on it
actual hydraulic oil level is lower than the mast
4. Check the fork
needed height,
Inspect the fork and see whether there is any
Dipstick scale indication：
distorted or cracked on it. And check the lock
“50” means liquid level for mast with 5M lifting
pin and see whether the lock pin lock the forks
height or below(including duplex full free mast)
credibly.
“65” means liquid level for mast with 6.5M
5. Check the rear wheel and front wheel
lifting height or below(including duplex full free
Check the front and rear wheel and see
mast)
whether the wheels are cracked, distorted,
“80” means liquid level for mast with 8M lifting

28
height or below(including duplex, triplex full your thumb to check whether the tension
free mast) between the left and right chains is
“95” means liquid level for mast with 9.5M identical.
lifting height or below(including duplex, triplex - Tension adjustment: loose the lock nut 1
full free mast) and turn the adjuster nut 2 to adjust the
“110” means liquid level for mast with 11M chains so that they both have the same
lifting height or below tension, then tighten the lock nut 1.
9. Battery check

14. Safety pedal

Check that the lock pin is securely inserted Put your left foot on the safety pedal, inspect if
and the battery is firmly fixed. all functions are normal when the truck is in
Check the specific gravity of the electrolyte. forward/backward position.
See Battery section. 15. Check the brake pedal
Check where the wiring of both terminals is Step down the brake pedal, and check the
loose or damaged. Adjust or replace the wiring electromagnetic brake of the front wheel.
if necessary. 16. Check the accelerator pedal
10. Instrument display check (power, As the accelerator pedal is depressed through
faults) its full stroke, there should be a clear change
See Instrument section. in the rate of acceleration, and the pedal
11. Check the fingertip and mast should return freely to its original position
Check if lift fingertip, reach fingertip, tilt when released.
fingertip, sideshifter fingertip loosen or return 17. Check the steering system
well. Turn the steering wheel to the left and right to
Press forward or pull backward lift fingertip, check the functionality of the steering system.
reach fingertip, tilt fingertip, sideshifter fingertip, 18. Lamp and horn
inspect if the mast lifting, reaching, fork Turn on the headlamp switch and check the
carriage tilting, and fork left/right movement is lamp whether it is ok.
normal, or there is abnormal noise. Press the horn button to check the sound of
13. Check the chain tension the horn.
- Raise the forks to a height of 10–15cm 19. Emergency stop switch
with the mast vertical. Press down the emergency stop switch and
check the power has been cut-off instantly. 20.
- Press the middle section of the chain with
Others

29
Inspect whether there is any abnormal noise.

30
8. Drive and operate
Caution
· Be careful of getting on or off the truck.
Warning Don’t jump out of the truck.
If any damage or fault is found, · Don’t park the reach truck on the
don’t operate truck until being corrected. running route.
Running Pick up
To start the forklift, fist press down the parking
- The forks should be adjusted sidewise to
brake rocker switch to cancel parking brake,
maintain proper balance of load.
then step on the safety pedal with left foot and
- Place the truck right in front of the load to
accelerator pedal with right foot. If the travel
be handled.
direction is in reverse, press down the
direction rocker switch, and change the
direction. .
Steering
The steering wheel of reach truck is rear
wheel.
When steering, decrease the speed of truck.
And rotate the steering wheel to the direction
Travelling approach the
you want and the steering wheel needs to be
turned slightly earlier than it would in a vehicle
with front-wheel steering.

Caution
Slow down the truck when turning around.
Make sure there is enough place
for turning.
Mast reach
Parking - The pallet should be evenly positioned
- The truck stops when right foot moves across both forks.
from accelerator pedal to brake pedal and - Insert forks into the pallet as far as
step down the brake pedal, and then possible.
press down the parking brake rocker
- To raise loads from the ground：
switch, the truck is braked.
1 Once lift the forks 350 to 450mm off
- Shrink the mast backward in place.
the ground or floor and make sure
- Lower down the forks and tilt forward the loads rest stably.
mast.
② Then tilt the mast backwards fully. -
- Turn off the key switch, and plug out the
When handling bulky loads which restrict
battery connector. Be careful of key.

31
 your vision, operate the truck in reverse loads move to the desired deposit
except when climbing grades. position.

- Make sure your load is just over the

desired area. Slowly lower the load into
position. Make sure the load is securely
stacked.

1. Insert the forks into loads and lift loads about

350-450mm off the ground;
2. Backward the mast to the end, and travel to
stacking place.
Stacking load
- When approaching the deposit area, slow
down your truck.
- Stop the truck right in front of the area
where your load is to be deposited. P
- Check the condition of the deposit
position. 1. Slowly press the reach fingertip, and move
- Raise forks until they are a little higher the loads;
2. Put the loads on the shelf, tilt forward or
than the deposit position. backward if necessary.
- Press down reach fingertip to disengage
forks from the load by using necessary
lift-tilt operation and then back away.

- After making sure the fork tips leave the

load, lower the forks to the basic position
(15 to 20cm off the ground).

- Tilt the mast backwards

Backward the mast to the end and raise the

loads to the required height. Slowly travel if
necessary.

- Press down reach fingertip, and get the

32
 tips is about 30cm.
- Check the condition of the load.
- Tilt the mast forward until forks become
horizontal. Elevate forks up to the position
of the pallet or skid.

- Make sure forks are positioned properly

for the pallet. Move forward slowly to
insert forks into the pallet as far as
possible and then stop the truck.

Caution
If the forks are hard to be fully
1. Make sure the loads are placed on the
shelf stably, move the mast backward to the inserted, press reach fingertip to insert
end; 2. Lower the fork and travel the forklift 3/4 of the forks. Raise the forks 5 to
to the other place.
10cm and move backward 10 to 20cm
with the pallet or skid on the forks, and
Warning：
then lower the pallet or skid on the
When mast reaches
out, it is forbidden to stack. Move forward again to insert the
lifting or lowering - Raise the forks 5 to 10cm off the stack,
loads at a high move the mast backward to the end.
position without shelf - Check all around the truck to insure that
protection. the path of travel is unobstructed and
Otherwise it will back away slowly
cause fatal - Lower forks to a height of 15 to 20cm
dangerous. above the ground. Tilt the mast backward
fully and move to the desired area.
Warning
· Never tilt the mast with loads upraised 2 meters or more.
· Don’t leave or dismount from the truck when the load is Warning
raising high.
 It is very dangerous for stacking or
unladen loads to/from a high place. If
you do not obey the step of stacking, it
maybe cause fatal dangerous for
operator.
Remove load
 When loading heavily in high position,
- When approaching the area where the
it is prohibited to tilt mast forward or
load is to be retrieved, slow down your
backward while operating direction. It
truck.
 is prohibited to operate sideshifter
- Stop the truck in front of the load so that
handle without protection of fork
the distance between the load and fork

33
 carriage when loading in high position. cause severe result.
 It is prohibited to lift the mast
meanwhile drive the forklift or move
the mast forward/backward when
loading.
 It is suggested that the driver should
not use united operation, that is, drive
and operate direction while operating
multi-valve handle, otherwise it may

34
9. Storage  Do not use wooden blocks that
Daily storage are more than 300mm (11.81
inches) in height.
- Park the forklift in a designated area,
lower the mast and move it backward in  Raise the forklift just enough to allow

place. it to be placed onto the wooden

support blocks.
- Put the direction switch in neutral, and
 Place wooden blocks of identical
engage the parking brake. Then shut
size under left and right sides of the
down the forklift and block the wheels.
 frame. After supporting the forklift
- Disconnect the power plug
with the wooden blocks, move the
- Remove the key and keep it in secure
forklift back and forth from all four
place. sides to make sure that it is safely
Long-term storage - Start the forklift at least once a week.
Do the following maintenance and check on Raise the forks to their maximum height
the basis of daily storage： several times.

- Disconnect the battery plug to prevent - Measure the specific gravity and level of
discharge and store the vehicle in a dark the battery electrolyte on a monthly basis.
place. - Apply one equalizing charging every
- Apply anti-corrosion agent to shafts, rods month.
and other exposed parts. Forklift operation after long-term
- Cover the breather and other openings storage
where moisture may enter. - Remove anti-corrosion agent from
- Fully cover the vehicle with a sheet or exposed parts.
similar. - Drain out the gear oil in the drive axle,
- Lubricate with oil or grease where then fill with fresh oil.
necessary.
- Clear away foreign matter and water in
- Support the underside of the truck body hydraulic tank, and add new hydraulic oil. -
with wooden blocks to reduce the weight Charge the battery, install it on the forklift
on the rear wheel.
and connect to the battery cables.

Warning
The wooden blocks must be single pieces that- are
Carry out enough
sturdy a carefulto support
inspection before of the forklift.
the weight
using the forklift, checking truck start-up,
forward and reverse drive, steering and
the lifting, lowering, forward/backward
movement and tilt functions.

35
10. Battery- Servicing, Recharging, Replacement
Safety precautions for using lithium battery
1) Users need to create a file for lithium batteries in order to better maintain the lithium battery.
2) The new factory battery should not be discharged, it must be fully charged before use.
3 ) Lithium batteries have a special charger, may not be charged with other types of battery
charger, so as not to charge 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
discharge depth of more than 80% of the rated capacity of the battery. Whether it is partially
discharged or fully discharged, the battery should be immediately charged.
6 ) Do not operate the lithium battery vehicle in a temperature exceeding 55 ℃. When the
ambient temperature is below 0 ℃, please stop charging the lithium battery vehicle.
7 ) It is strictly prohibited to discharge the battery below the termination voltage, please charge it
in time after discharge. Avoid overcharging when charging.
8 ) The battery inspection and maintenance operations, to be wearing working clothes, wearing
gloves, non-wearing watches, metal bracelets, necklaces and other accessories. The
electrolyte inside the battery is highly corrosive and must be worn during operation.
9 ) Under no circumstances shall the battery be shorted to the positive and negative terminals,
and any metal or other conductive objects other than the battery post clamping bolt and the
conductive tape should be avoided from touching the positive and negative terminals of the
battery.
1 0 ) Do not hit, throw or trample on the battery, do not heat the battery, do not throw the battery
into the water.
1 1 ) Do not reverse charge the battery, a reverse charge can cause the battery voltage to zero,
scrapped in advance.
1 2 ) If the battery smells, heat, discoloration, deformation or use, storage, charging any anomalies,
the battery should be immediately removed from the device or charger and disabled, please
contact the relevant technical departments of manufacturing enterprises or After-sales service
department to get the treatment.
1 3 ) If the connection of the battery pole is found to be oxidized, wipe it with a dry cloth and polish
it with a fine sandpaper before use. Otherwise, it may cause poor contact and the function fails.
1 4 ) Do not place the battery near the high temperature sources, dangerous goods or dangerous
materials, such as fire, heaters, corrosive chemicals, hazardous machinery and equipment, etc.
Use and retention; When not in storage, should be placed in a cool dry environment in.
1 5 ) Do not immerse the battery in water or other conductive liquids. This operation may cause

36
 personal injury or property damage.
16) Prohibit the use of strong static electricity and strong magnetic field, otherwise easy to
damage the battery safety protection device, bringing security risks.
17) Do not use this series of products with other models or types of batteries in series or in
parallel; prohibit the entire system with lithium-ion battery protection circuit board or battery
management system, the power system in series or in parallel operation, if necessary, please
contact this Company technical department to obtain the correct technical support.
18) Prohibit the use of this series of products by children and other people who lack knowledge of
the safe use of lithium-ion batteries.
19) Do not disassemble, squeeze, puncture, high temperature shelving or baking the battery, to
avoid the battery was too high amplitude vibration, external impact, height drop and so on.
20) It is forbidden to charge the battery without a proper charge protection device (lithium-ion
battery protection circuit board, battery management system, etc.) or using a non-battery
manufacturer approved charging device (charger, DC power supply, etc.).
21) If there is a lot of dust, metal chips or other debris on the top cover and pole of the battery
pack, clean it with compressed air in time and avoid using water or wet objects.
22) When charging and discharging Try to avoid splashing water or other conductive objects on
the battery cover and pole, such as exposure to heavy rain.
23) Once inadvertently make some kind of conductor come into contact with the positive and
negative poles of a single battery or battery pack at the same time to cause a short circuit, be sure
to disconnect the circuit which causes the short circuit in the shortest time.
24) Once the battery has been destructively hit, a large amount of energy stored in the battery will
be released in an instant, the battery can be cooled using a dry powder fire extinguisher.
25) Evacuate persons in the danger area if the battery is cracked or ignited, and immediately
spray with water or soak a smoldering, smoldering battery in the water tank.
26) Risk of fire or smoke: LFP batteries can leak / evaporate or decompose and release
flammable electrolyte under the condition of 150 ℃ if they are improperly used or affected by the
environment. Hydrogen fluoride (HF) and phosphorus oxides may form during fire, and chemical
reactions between LIPF6 and water in the electrolyte will produce fluoride and carbon dioxide.
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

37
 necessary, please go to the hospital for treatment immediately. Otherwise it will hurt your
eyes.
30) Contact with skin: The electrolyte inside the battery may cause skin infections, inadvertent
contact, take off contaminated clothing and wash the infection with plenty of water and soap for at
least 15 minutes, do not rub the ointment.
31) Inhalation: When the battery is leaked or ruptured, the internal components of the battery may
cause mucus, edema and other respiratory tract problems, inadvertently inhaled, to fresh air and
ventilated contaminated area. If necessary, oxygen or artificial respiration.
32) Special Protection Tools: Use breathing apparatus to avoid inhalation of irritating gases. Wear
protective clothing or other devices to prevent body contact with the electrolyte.

38
 Battery specification
Item 1.6t~2.0t

Length（L） mm 1035

Width（W） mm 443

Height（H） 540

Allowable lightest kg 140

Allowable heaviest kg 590

Rated capacity Ah/5hr 271

Rated voltage V 80
Battery box dimension

39
Battery charging outlet.
Charging procedures： 7. Close each battery filling cap.
For this series forklift battery, charge by taking
Caution
the battery out. After replacing a fully charged  Charge in appointed and well ventilated
battery, the forklift can work continuously, thus place.
daily work efficiency is improved. Charging  Place No Flame signs when charging.

procedures are as follows: Before charging, first check if wire or
1 . Remove the battery. Battery removing outlet damaged. Check if battery
procedures refer to Battery Replacement part. connector loosens and tighten.
2 . Open each battery filling cap. 
Electrolyte temperature during charging
should not exceed 50 ℃ , or try to cool, if
the temperature does not drop, suspend
Warning charging, after the temperature drops,
 There will generate combustible
continue to charge.
and explosive gas when charging,
Normal charging
please open the cover and make – Batteries that have undergone initial
sure no covering on the battery, make
charging and been used for day-to-day
sure each battery filling cap is opened, work can undergo normal charging.
keep in good ventilated place and no The procedure for normal charging using
–
flame in the charging area. the constant current charging method is
3 . Insert the battery charging plug into the basically the same as that for initial
charger plug.
charging.
– The amount of charge given should be
Warning
 about 1.2 times the amount of the
Output voltage, current and
previous discharge. However, for new
application range of the charger must
match with the battery voltage and batteries, the first 5 charges should be

volume, otherwise it will influence battery about 1.5 times the amount of the

 volume and service life. Charging cable previous discharge.

polarity must keep the same with the – During any charge cycle, the electrolyte
charger output terminal polarity. temperature must not exceed 50 ℃ . If

4 . Start charging according to the charger necessary, adopt cooling measures or

manual. reduce the charge current. If the
5. After the battery is fully charged, finish temperature remains high, stop charging
charging according to the charger and allow the battery to cool down before
manual. resuming.
6. Take out battery charging plug from Use smart charging to carry out normal
–
charger plug, and then connect the truck charging. For new batteries, an equalizing

40
 charge should be carried out for the first 5 is resumed after the 1-hour interval.
charges, based on the smart charger Boost charge
manual. – When a single charge cannot meet the
demands of a full day's work, provide a
Equalizing charge
– With time, the voltage, density and boost charge during rest times.
capacity of a battery tend to become – A boost charge can be given when the
unbalanced. ambient temperature is low.
–
The voltage and specific gravity of some Storage charge
cells increase more slowly compared with – Before storing a battery, give it an
other cells when charging, and decrease equalizing charge.

at a faster rate when discharging. – Apply an equalizing charge every 15–30

– days during storage.

Equalizing charge should be applied
when any of the following situations – Charge special ordered batteries in
occur： accordance with the Battery User Manual.

a. The discharge voltage frequently falls

below the cut-off voltage; Battery replacement
b. The discharge current is frequently
1. Park the truck on the flat ground, and
too high;
apply hand brake handle.
c . The battery is not charged in a timely 2. 。 Shrink the mast backward in place,
manner after discharge is complete； aligning the reach device holes at the
d . The electrolyte is mixed with minor battery tray holes. Pull out the hinge pin
impurities; from hole 1, insert into hole 2, and then
e . The battery frequently gets connect the left/right battery to reach
insufficient charge, or hasn't been used for device with hinge pin.
a long time;
f . The battery plates have been taken out
for inspection or to clean out sediment.
Equalizing charge method：
– Firstly charge the battery normally, then
let it rest for 1 hour after charging is
complete.
–
Continue charging the battery using the
second-stage charge current specified for
normal charging until multiple bubbles 3 . Start the truck, push the reach device,
and the battery is pulled out.
appear, then stop charging for one hour.
4 . Shut down the forklift, and pull out the
– Repeat the above steps several times
battery socket.
until the voltage and density stop rising
5 . Remove the battery pressing plates and
and bubbles appear as soon as charging

41
 bolts on both sides.

9. Pull out the hinge pins on both sides of

the battery from N0.2 and insert to the
hole 1. Fix the battery on the truck frame.
6. Use proper lifting device to hoist the
battery or remove from the right side
(option).

Warning
7. Replace battery. Screw down the pressing Lift the battery by attaching hooks to all 4 lifting holes. Do not
Before pulling out the battery with reach device, make s
plate, fix the battery, align the reach
fter replacing the battery, align the battery tray holes with
device with battery tray hole, and insert efore replacing a battery, make sure that the voltage, capa
the lockpin(one for left and right).

8. Insert the battery socket, start the truck,

shrink the reach device to push the
battery move backward, aligning the
battery tray holes at the truck frame holes,
such as hole 1 alignment.

42
 the forklift specifications. and rubber gloves.
 Do not use replacement batteries with （2）Fill a squeeze bulb pipette with a certain
a different voltage, weight or amount of distilled water.
dimensions without the manufacturer's （2） Open all the vent or filler caps on the
permission. battery unit.
 Do not discharge the battery liquid （3） Inject distilled water into battery cells
waste at will, but dispose it according
using squeeze bulb pipette.
to local environment protection law.

Electrolyte level and specific gravity Battery with

Stop adding water when the red hydrometer
Warning float rises and a white line appears.

 Using a battery when the electrolyte

level is low may lead to
overheating

1. Checking electrolyte level

Battery without
Electrolyte is 15-20mm higher than
splashguard level.

Battery with
Measure electrolyte level by reading vent cap
hydrometer.

Battery without
Stop adding water when electrolyte is 15-20
mm higher than splashguard level.
（5）After topping up, tightly fasten the vent or battery caps.
（5） Use a damp cloth to wipe clean the surface of each battery cell.

2. Topping up distilled water Warning

（ 1 ） Wear protective eyewear, rubber boots
 When adding distilled water, do not
43 exceed the specified maximum
level.
 electrolyte leakage and damage
the
forklift when charging or
discharging the battery.
Use a squeeze ball pipette to draw off any
excess water.
3. Specific gravity reading
Specific gravity of the electrolyte varies
with temperature.
Specific gravity conversion
（ 1 ） Use a thermometer to measure the
Convert electrolyte density at the standard
temperature of the electrolyte. temperature of 30 oC based on the following
（ 2 ） Vertically insert the flexible tube of a
formula：
pipette-type density meter into the D30＝Dt＋0.0007（t-30）
electrolyte and squeeze the bulb. Wherein：
Electrolyte will enter the glass tube and
D 30 ——electrolyte density at 30℃
the float will rise up.
D t——measured electrolyte density at ℃
（3）Take the density reading.
t——electrolyte temperature during
density measurement.
Caution
All references to specific gravity in this manual
 Hold the density meter vertically refer to specific gravity at 30 ℃.
so
that the float does not touch the
sides of the glass tube.

Battery replacement
1 . Park the truck on the flat ground, and
apply hand brake handle. Remove the key and
pull out the battery plug.
2 . Screw out the knob 2, and take down the
panel1.
3. Unscrew nut 4, screw out bolt 3, and then
remove battery pressure plate 5. Slot 6 is
Specific gravity measurement used for the wheelbarrow alignment to the
Use a hydrometer to measure the specific battery.
gravity of electrolyte.

44
 1 3

1.Side plate 2.Knob 3.Truck frame

front of the wheelbarrow to prevent the its
movement. And then pull the battery into
the wheelbarrow,

1
2

1. 2.Wheelbarro 3.Ped

3 3
2 1

5. Upfold the left/right pedal in front of the

wheelbarrow. Pull out the wheelbarrow a
little, switch the baffle 3 straight up, block
the battery. And then pull the battery to
5 desired position.
1. Battery
tray 6 2. 3.Bo
2
3
4 5.Battery
4.N 6.Sl
1
Caution： 3
 After installing the battery, compress 1. 2. 3.Baffl 4.ped

it with battery pressure plate 5 through 4

bolt 3. Screw down nut 4 to prevent Caution：
slot. Step on the left and right pedals in
 When carrying battery with
bolt looseness.
wheelbarrow, block the battery with
baffle, otherwise it is easily slipping from

4. Switch the front wheelbarrow baffle

straight down, and then the arrow on the
baffle vertically aligned in the truck frame
 6. To replace the battery, installment is
opposite to the dismantlement.

45
 local environmental protection laws.
Caution：
.
 Before replacing a battery, make sure that
the voltage, capacity, weight and
dimensions of the new battery match the
forklift specifications.
 Do not use replacement batteries with a
different voltage, weight or dimensions
without the manufacturer's permission.
 The replaced battery waste cannot be
dumped at will, but dispose according to

Lithium battery charge

SLC-80200/ SLC-80100 Operation instructions for intelligent charger (CATL battery charger)
Start-up interface

Start-up interface

46
 Click on the icon： , Enter the help description interface.
Click on the icon： or , on-off alarm sound, to turn on the alarm sound state, to
turn off the alarm sound state.
The control operation requires password permission. The default password is: 123456 .
Click on the boot icon: toggle charging control to turn on or off.
Click on the purple part of the charging status information bar, enter into the single charging
module information display bar.
Click on the battery BMS battery bar to enter the detailed BMS information display bar.
Click on the mode switch, you can perform the normal mode booking mode switch.

Help interface

Click on the icon： , return to main interface.

Click on the reservation icon to set the time for booking mode. The default password is
123456.

Click on the icon ： , enter the password input interface, enter the correct

47
password into the factory parameter setting interface

Password entry interface

Enter the correct password in the password entry box. The default password is 888888.

Click on the icon： , return to help description interface.

Click on the icon：, enter the password modify interface.
Click on the icon ： , if the password is entered correctly, enter the parameter setting
interface, otherwise the password input error is prompted. Please enter it again.

Password modification interface

Enter in sequence according to the prompt: Enter the user's old password, enter the new
password for the first time and enter the new password for the second time.

Click on the icon： , if the user's old password is entered correctly, the first time the new
password is entered and the second time the new password is entered, the modification is

48
successful. Otherwise, the prompt modification fails. Please re-enter.
Click on the icon：
, Return to the password entry interface.

Parameter setting interface

Click on the icon： , return to the help description interface.

Parameter setting information: rated voltage, rated current and shunt range are related to
machine hardware, and must not be arbitrarily modified after the factory.
Consult the manufacturer if the above parameters need to be modified. The charging machine
number is easy for the user to distinguish, and the user can set it at will.
Debug interface for the factory to adjust the test, users can not operate at will.

Power module information display interface

Click on the icon： , switch module information backward.

Click on the icon：, return to the main interface.

Click on the icon： , switch module information forward.

Display single power module output voltage, output current, various operating conditions.

49
 Charging process explanation

The charging step：

1. Choose "turn on" charging control mode. The "CAN" and "485" indicator lights are bright
green.
2. DC charging gun and battery connection is normal.
3. "Residual capacity" is less than "allowed to charge the SOC limit" to start charging.
4. "Battery" indicator light is bright green (charging machine detected the battery voltage, this
light), "BMS" indicator light green.
5. The "working" light is bright green. When the "output voltage" is similar to the "battery
voltage", the charging motor outputs the relay to absorb and the charging machine officially begins
to charge the battery. At this point, "output current" and "output voltage" will be output according to
"current demand" and "voltage demand".
6. BMS charging complete, send charging termination command, charging motor end
charging.
7. During the charging process, charging motor failure ("overheated "and" abnormal "lights of
charging motor information are all charging motor failures), BMS charging or" charging allowed "in
a prohibited state, and artificial charging control in a" stop "state, all will terminate the charging.
* In appointment mode, the charging machine will only work when the appointment time is set.

50
User wiring instruction

Input AC Plug Output DC Plug

AC input air switch power supply. The input is an Yida plug and the output is a charging gun.
Warning: PE protection of the earth must be connected, otherwise it may threaten life
safety.

Operating instructions
1.Cautions
a. Before the charger is turned on, it should be checked whether the battery box wiring is
correct, whether there will be a short circuit or a positive and negative electrode connection. To
avoid overloading the charging machine and burning components or lines.
b. It can be put into use only after the charger has no abnormal, overheating and other
warning information.
c. For the safety of charging machines and equipment, it is forbidden to directly disconnect the
battery switch under the condition of output current, except in case of emergency.

51
Power check
Make sure that AC input zero wire and DC output positive and negative electrode wiring are
correct, and that there is no short circuit in input and output; The input voltage and frequency are
normal; At any time in the state of electricity.Offline online charging lines can not be connected at
the same time.

Power on
Check whether the AC fan wind direction is correct after the power is on.The touch screen
can be turned on normally, communication with the charging machine is normal.

Access to the battery

The battery voltage level and current level meet the requirements of the charging machine.
Battery polarity is not reversed. Battery's fine. No abnormalities.

Power off
After the charging current and voltage drop to 0, exit the battery.Turn off the AC input air
switch.

52
 6.Charging procedures：
1 . Stop the truck, turn off the key switch, and the
truck is disconnected.
Main input valve 2 . Pull up the four-wheel pedals on the charger tray,
pull the charger to a proper position, step down four
pedals to prevent movement.

Emergency stop
button

5 . Open the charging door, open the

rechargeable lithium battery cover. Check the
charging socket, make sure no water or debris
on each port, or metal terminal damaged or
influenced by rust or corrosion.

Display screen 6 . Insert the charging gun into the lithium

battery socket, the charger self checks and
communicate with the lithium battery, when the
entire system is fault-free, in about 15S, the inner
3. Close the charger main input valve, make relay is closed, start charging, and the charging
sure the emergency stop button bounce, the indicator illuminates, while the instrument will
charger turns on automatically, the indicator display charging voltage, charging current,
illuminates, and the display screen starts charging time and charging failure
automatically. information.
4. Remove the charging gun, press the button
lock before pulling it out. Check the
charging gun, make sure no water or debris
on each port, or metal terminal damaged or
influenced by rust or corrosion.

7 . The charger will automatically stop

charging after fully charged, output voltage and
output current on the meter is 0, press the pause
button, and then press charging gun lock and
pull the charging gun out. If it needs stop
charging without being fully charged, first
press the pause button, wait until the charge
current is reduced to 0A, and then press
charging gun lock and pull the charging gun out.
8 . Insert the charging gun to the charger
lay-down position, and pull down the
charger main input valve.
9 . Close the rechargeable lithium battery cover
and truck charging door.

53
11. Maintenance
11.1 Maintenance summary

- Establish and follow a comprehensive maintenance and service schedule.

- The forklift must be regularly checked and maintained to keep it in good working order.
- Inspection and maintenance are often easily overlooked. Early detection enables problems to

be settled in a timely manner.

- Use original Hangcha Group spare parts.

- Do not use different types of oil when changing or topping up oil.

- Waste oil and battery fluid must not be poured away indiscriminately, but recycled or

disposed of in accordance with local environmental laws and regulations.

- Untrained personnel must not attempt to carry out forklift repairs.

- Maintain current and complete records of all maintenance and servicing activities.

Ca uti on
· No open flames.

· Turn off the key switch and disconnect the battery plug before carrying out any servicing

or maintenance.

· Clean electrical parts with compressed air. Do not clean with water.

· Do not put your hands, feet or any part of your body between the mast and dashboard.

54
11.2 Periodic maintenance schedule
〇—check, correct, adjust
×—replace
Battery
Every 3 Every 6
Item
Service Tool
Daily Weekly Monthly
months months
required (8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)

Visual
Electrolyte level
inspection
〇 〇 〇 〇

Electrolyte
specific gravity
Hydrometer 〇 〇 〇 〇

Battery power 〇 〇 〇 〇 〇
Check for loose
connection 〇 〇 〇 〇 〇
terminals
Check for loose
Battery

connection 〇 〇 〇 〇 〇
cables
Clean the
battery surface
〇 〇 〇 〇

Check for tools

left on battery
〇 〇 〇 〇 〇
Check vent caps
are tight, vents 〇 〇 〇 〇
unobstructed
Keep away from
flames
〇 〇 〇 〇 〇

Controller
Every 3 Every 6
Service Daily Weekly Monthly
Item Tool months months
required (8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)
Check contact
wear of the 〇 〇
contactor
Check mechanical
movement of 〇 〇
contactors
Check pedal
microswitches are
〇 〇
Controller

functioning
properly
Check condition of
connections
between motor, 〇 〇
battery and power
unit
Check controller
faults to determine 〇
whether system is 2 years for
functioning first time
properly

55
Motor
Every 3 Every 6
Service Daily Weekly Monthly
Item Tool months months
required (8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)
Clear foreign
bodies on motor 〇 〇 〇
housing
Clean or replace
bearings
〇
Check wear
condition of carbon
brushes and 〇 or× 〇 or×
DCMotor

commutators,
check spring force
Wiring correct and
secure
〇 〇 〇
Brush away carbon
powder from
grooves between
commutator 〇 〇
segments and on
commutator
surface
Clear foreign
bodies on motor 〇 〇 〇
ACMotor

housing
Wiring correct and
secure
〇 〇 〇

Transmission system
Every 3 Every 6
Item
Service Tool
Daily Weekly Monthly
months months
required (8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)

Check for noise 〇 〇 〇 〇 〇

Transmission

Check for
leakage
〇 〇 〇 〇 〇

Change oil ×

Wheels (Front, Rear Wheels)

Every 3 Every 6
Daily Weekly Monthly
Item Service required Tool months months
(8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)
Check for
abrasion, cracks 〇 〇 〇 〇 〇
or damage
Check wheels
fasteners for 〇 〇 〇 〇 〇
looseness
Wheels

Check for wheel

bearing 〇 〇 〇
pretightening
Check for wheel
bearing lubricate
〇 〇 〇

Check for noise 〇 〇 〇 〇 〇

56
〇
Check for rope
winding
the wheels

Steering System
Every 3 Every 6
Daily Weekly Monthly
Item Service required Tool months months
(8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)
Adjust the steering
〇 〇 〇 〇 〇
Steerin wheel locking
g wheel Check steering
work 〇 〇 〇 〇 〇
condition
Gearwheel and
〇 〇 〇
Gear pinion lubrication
pair If pinion mounting
〇 〇 〇
bolt loosens
Hydraulic system
Every 3 Every 6
Daily Weekly Monthly
Item Service required Tool months months
(8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)
Check for oil level,
change oil
〇 〇 〇 〇 ×
Hydraulic
reservoir

Clean suction strainer 〇

Drain for foreign

matter
〇

If return automatically 〇 〇 〇 〇 〇
Fingertip

Operation condition 〇 〇 〇 〇 〇

Leakage 〇 〇 〇 〇 〇
Multiwayvalve

Operation of safety
valve and self-locking 〇 〇 〇
tilt valve
Oil
Measure safety valve
pressure 〇
pressure gauge
Leaks, looseness,
connectors

rupture, deformation, 〇 〇 〇
Line

damage
×
Replace pipes
1-2 years
Check hydraulic
Pump pump for oil leaks or 〇 〇 〇 〇 〇
noise
Check for oil leakage
〇 〇 〇
Oil or noise
motor
If work normally 〇 〇 〇
Priority
Operation condition 〇 〇 〇
valve

Braking system

57
 Every 3 Every 6
Daily Weekly Monthly
Item Service required Tool months months
(8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)

Operation condition 〇 〇 〇 〇 〇
Brakepedal

Operation condition of
〇 〇 〇 〇 〇
electromagnetic brake

Truck brake effect 〇 〇 〇 〇 〇

Operation condition of
Parking electromagnetic brake 〇 〇 〇 〇 〇
brake
button If brake is safe 〇 〇 〇 〇 〇
Damage, leakage,
〇 〇 〇
Pipelines

rupture
Connection, clamping
〇 〇 〇
parts, looseness
Operation condition of
〇 〇 〇 〇 〇
Electrom
agnetic

electromagnetic brake
brake

If electromagnetic
〇 〇 〇 〇 〇
brake is safe
Lifting system
Every 3 Every 6
Daily Weekly Monthly
Item Service required Tool
(8 hrs) (40 hrs) (166 hrs)
months months
(500 hrs) (1000hrs)
Check chain tension,
check for
deformation, damage
〇 〇 〇 〇 〇
and corrosion
Chainsprocket

Lubricate chain 〇 〇 〇

Riveting pins and

looseness
〇 〇 〇

Sprocket deformation
and damage
〇 〇 〇

Looseness of
sprocket bearings
〇 〇 〇
Piston rod and piston
rod threading, loose Testing
Reachcylinder,tiltingcylinder,

connections, hammer
〇 〇 〇 〇 〇
deformation, damage
liftingcylinder

Operation 〇 〇 〇 〇 〇

Leakage 〇 〇 〇 〇 〇
Wear and damage of
pins and cylinder
steel-backed
〇 〇 〇
bearings
Check forks for
damage, wear or 〇 〇 〇
deformation
Fork

Check for stopper

pins for damage or 〇 〇
wear

58
 Check fork base and
hook welding for
defective cracks
〇 〇 〇
or wear
Cracking and damage
of welding on inner
mast, outer mast and
〇 〇 〇
crossbars
Wear, cracking and
damage of welding on
tilt cylinder brackets
〇 〇 〇
and mast
Wear, cracking or
damage of welding on 〇 〇 〇
inner and outer masts
Wear, cracking and
Mastandfork

damage of welding on 〇 〇 〇
fork carriage

Loose roller bearings 〇 〇 〇

Wear and damage of
mast support bearing
bushes
Check lift cylinder
bottom bolts, piston
rod head bolts, Test
U-bolts, and piston hammer
〇 〇 〇
head guide bolts for
looseness
Check rollers, roller
pins and welded parts 〇 〇 〇
for cracks or damage
Others
Every 3 Every 6
Service Daily Weekly Monthly
Item Tool months months
required (8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)
Check
Testing
Overhead mounting is 〇 〇 〇 〇 〇
secure hammer
guard and
Check for
load deformation,
〇 〇 〇 〇 〇
backrest cracking,
damage
Operation and
Turn signal
mounting
〇 〇 〇 〇 〇

Operation and
Horn mounting
〇 〇 〇 〇 〇

Light & Operation and

mounting
〇 〇 〇 〇 〇
Lamps
Operation and
Instrument mounting
〇 〇 〇 〇 〇

Wire damage
or looseness
〇 〇 〇 〇
wire Looseness of
electric circuit 〇 〇 〇
joint

59
11.3 Replace the key safe parts termly

Some parts should be checked termly to detect the damage, in order to fully improve the safety,
users should replace the parts termly according to the following table.

If the part is abnormal before the replacing time is due, replace it immediately
Key safe part’s description Service life (year)

Brake hose or rigid pipe 1～2

Lifting system hydraulic hoses 1～2

Steering, lifting chain 2～4

Hydraulic system high-pressure hoses 2

Brake fluid cup 2～4

Brake cylinder cover and dust cover 1

Hydraulic system inner seals and rubber parts 2

60
11.4 Bolt tightening torque table
Unit :Nm
Grade
Bolt 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 bolts 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.

61
11.5 Forklift used oil

No. Description Mark, code Volume（L） Remark

L－HM32 Add to the

1 Hydraulic oil (Cold environment: L－ corresponding Oil tank
HV32) scale mark
Add until the
oil overflows Reduction
2 Gear oil GL-5 85 W/90
from the oil gearbox
filler plug

Industrial vaseline 2# Battery terminal

General purpose lithium

Lubricating grease lubricating grease for
automobile

Replace hydraulic oil in the tank：

Oil drainage：There is one drain plug under the oil tank, unscrew the drain plug, and discharge the
old oil into the container. After being completely discharged, screw down.
Add oil： Screw out the breather plug above the oil tank, add hydraulic oil with the same model
until oil is between the dipstick scale marks.

62
 Replace gear oil in the reduction gearbox

Drain oil ： Place a container under drain plug,

screw out the drain plug, and the oil flows into

the container. After oil being fully drained, screw

down the drain plug.

Add oil ： Screw out the oil filler plug, oil flows

into the reduction gearbox with the help of

funner and hose until it overflows. And then

2
screw down the oil filler plug and clean the
spilled oil with cloth.


Caution ：
Waste battery and waste oil should be disposed according to local environmental protection requirement, but no

Apply lubricating grease：

– Apply lubricating grease on the mast channel steel and roller inner channel steel;

–
Apply lubricating grease on the truck frame pillar and reach device roller inner channel steel;
– Apply lubricating grease on the plane of action of steering gearwheel and pinion;

– Apply lubricating grease on bearing or turning part.

63
 12. Forklift hoist and transport
Forklift trucks are generally used for loading, unloading and short-distance transportation. They

are not designed to be a long-distance mode of transport. A forklift that needs to be transported
over a long distance should be transported in a ship, train or a truck.
Warning
 Front and rear wheel of this series truck is installed with electromagnetic brake, and rear
wheel brake is normally closed. It’s forbidden to drag when hoisting or transporting this series truck.

Hoist the truck

Procedures：

1 . Move the truck reach device backward to the end, lower the mast and shut down the forklift.

2 . Wire rope passes through grooves of two front pillars, and gets stuck in the grooves to avoid
wire rope slipping during hoisting.

3 . Another wire rope passes under the rear end of the forklift, and get through inner end of the
bolt to avoid wire rope slipping during hoisting.

4. Slowly hoist the forklift off the ground, and make sure the wire ropes are tied firmly.

Caution ：
Before hoisting the forklift, first move the mast backward in place, lower the mast in place, and
then shut down the forklift. It is suggested to dismantle two forks before hoisting. If the outer mast is too high, dis
The steel wire must own enough strength. After getting through the front truck pillar, the wire
rope must get stuck in the groove. When the rope gets under the rear end of the truck, get through the inner en
Front and rear wheel of this series truck is installed with electromagnetic brake. Make sure the
rear wheel is off the ground during hoisting. No towing, or the electromagnetic brake maybe damaged.
Never walk under a forklift when it is being lifted.

64
 Transport the
truck
Forklift for long-
distance
transportation,
needs take
advantage of
means of
transportation
as

semi-trailer,
trailer or lorry.
Tie up the truck
body when the
1.Groove 2.Bolt
forklift is on the
transport vehicle, block the wheel if necessary.

Mast height for this series truck has many choices, if the outer mast is too high, dismantle the

mast assembly to transport. After reaching the destination, reinstall the mast. Refer to Mast
Dismantlement and Installment for detailed procedures.

 aution ：
C
According to Provisions on the Administration of Highway Management for Over Limit
Transport the defective truck
Transport Vehicles by Ministry of Communications, overall height of loaded truck for
heavy/medium truck forklift
Brake of this series and semi-trailer is calculated
adopts electromagnetic fromwhich
brake, the isground, with
normally 4M type.
closed high When
limit; container
the truck with

forklift has travelling fault, the electromagnetic brake will lock the motor shaft of the driving wheel,

65
so the fault forklift cannot be dragged directly on the ground, otherwise it may damage the

electromagnetic brake. Generally the defective truck is transported by the means of

transportation.

Warning
 This series truck is installed with electromagnetic brake, rear wheel brake is
normally
closed, so the truck cannot be dragged, otherwise it may damage the

electromagnetic brake.


66
13. Main technical parameters list
CQD12/14/16/18/20-AC4
CQD12-AC4 CQD14-AC4 CQD16-AC4 CQD18-AC4 CQD20-AC4
CQD12-AD2 CQD14-AD2 CQD16-AD2 CQD18-AD2 CQD20-AD2
CQD12-AC4-I CQD14-AC4-I CQD16-AC4-I CQD18-AC4-I CQD20-AC4-I
CQD12-AD2-I CQD14-AD2-I CQD16-AD2-I CQD18-AD2-I CQD20-AD2-I
No. Item Unit
CQD12-AC5 CQD14-AC5 CQD16-AC5 CQD18-AC5 CQD20-AC5
CQD12-AD6 CQD14-AD6 CQD16-AD6 CQD18-AD6 CQD20-AD6
CQD12-AC5-I CQD14-AC5-I CQD16-AC5-I CQD18-AC5-I CQD20-AC5-I
CQD12-AD6-I CQD14-AD6-I CQD16-AD6-I CQD18-AD6-I CQD20-AD6-I

1 Rated load capacity ㎏ 1200 1400 1600 1800 2000

2 Load center distance ㎜ 600 600 600 600 600

3 Lifting height ㎜ 3000 3000 3000 3000 3000

4 Free lift height ㎜ 340 340 340 340 340

5 Max. lift speed (laden) km/h 280 280 280 280 280

6 Tilt of fork (forward/backward) (°) 2/4 2/4 2/4 2/4 2/4

7 Max. travel speed(laden) km/h 10.2 10.2 10.2 10.2 10.2

8 Max. Gradeability ( laden) % 10 10 10 10 10

9 Min. turning radius ㎜ 1735 1735 1735 1735 1804

67
10 Min. ground clearance ㎜ 75 75 75 75 75

11 Braking distance m 2.5 2.5 2.5 2.5 2.5

Length(fork excluded) ㎜ 1903 1903 1903 1922 1983

Dimension

12 Width ㎜ 1270 1270 1270 1286 1286

Height ㎜ 2200 2200 2200 2200 2200

13 Service weight（Including battery ） ㎏ 3110 3110 3300 3310 3320

14 Battery Voltage/Capacity V/Ah 48/400 48/400 48/500 48/500 48/500

Drive kw 6.5 6.5 6.5 6.5 6.5

Motorpower

15 Lift kw 12.8 12.8 12.8 12.8 14.5

Steer kw 0.67 0.67 0.67 0.67 0.67

Front wheel/Quantity 285×100/2 285×100/2 285×100/2 343×108/2 343×108/2

Wheel

16
Rear wheel/Quantity 343×114/1 343×114/1 343×114/1 343×135/1 343×135/1

68
 No. Description
1 Product nameplate：Basic forklift parameter
2 Character label：Manufacturer character
3 Hoisting label：Hoist position indicator.
4 Series label：Product series and tonnage label
5 Danger label：Be careful when lifting the mast
6 Danger label：No climbing
7 Danger label：Loading part is not allowed to carry people. Never stay under the
loading part.

14. Nameplates and warning labels

Stick different nameplates and warning labels at different positions of the truck.
许可证号：

型号 规格

整机编号 自重
额 定 起重量
允许最大蓄电池重量
允许最小蓄电池重量

最 大 起升高 载荷中心 最大起升高度起重量

无
装 有属具时，最大起升高度起重量参见属具标牌或载荷曲线标牌

警 告

警 告

蓄电池平衡重式 叉车

1
中 国 浙江 临 安 经济 开 发区 东 环 路

6
号 客 服电 话 ：

2 5

4
3

69
Operation procedure label

Slowly! P

WARNING!
WARNING !

70
15. The use, install and safety rules of attachment
HANGCHA will choose attachment that in accordance with International standard ISO2328 Forklift
pothook fork and installation size of carriage, such as sideshifters, fork positioner, rotator,
push/pull and clamp etc.

sideshifter fork positioner rotator push/pull coil boom

bar arm clamp paper roll clamp block clamps load stabilizer turnaload
Attachment install
–
Untempered technology license of our company, any refit at safety and capability to

attachment is strictly prohibited.

–
Actual rating load capacity should be the least of rating load capacity, the load capacity of

attachment, combined load capacity of truck. Generally speaking, the combined load capacity

of truck is the least. Attachment load capacity just a count value of attachment pressure.
–
Installation goes to in reason, credibility, safety to avoid the attachment glide around carriage
in using.
–
After hang attachment, embed the rise catch block to the gap of top beam, let the offset of

centre line of attachment and carriage is less than 50mm.Otherwise, it will affect the
landscape orientation stability of forklift.
–
To these attachment with rotating function, such as paper roll clamp, bale clamp,

muti-purpose clamp, drum clamp, it needs to weld chock block in the joint of carriage beam
and attachment to prevent move from side to side in the operation.
–
Install the attachment of below catch orientation, it need to adjust the clearance between
below catch and beam of carriage.

Attachment use
–
Know well the content of nameplate on attachment, read the instruction manual before usage.

(Especially the manual from attachment company) Before operate the attachment, the people
should be trained and obtain the qualification.
–
It should be understand the basic capability and operate methods of attachment. Especially
71
 the admit load, lift height, size of cargo and adapt range of attachment.

– Operate the multi-functional attachment, such as with side-shifter, clamp or rotator, it is not
allowed that two action at one time. Operate one functional then do another one.

– Prohibit the cargo at a high position when truck with attachment moves. If the size of cargo is

too big, prohibit the truck move on. Transport the cargo, make sure that the distance of
bottom of cargo and ground is less than 300mm and mast incline back.

– The weight of cargo couldn’t exceed the limited value of combination carrying capacity of

forklift and attachment. It is not allowed that partial load at high position. It is a short time work

for attachment with side shifter. Partial load is around 100mm (Above 5 ton (including 5 ton),
the side-shifter movable within 300mm.

– In the range of the projection forth 2m of the lower of attachment and cargo, prohibit standing
to avoid the suddenness except the driver position under overhead.

– It is not allowed that an emergency brake in moving. Run slowly with load.

– Prohibit outside force when attachment working;

– It couldn’t be use at malfeasance situation and overstep normal work range.

– When the attachment has trouble, prohibit using without check.

Check and maintenance
–
Check the clearance of carriage beam and below catch of attachment if meet the attachment

manual.
–
Check the hook is right on the flute of fork carriage.
–
Use the auto general lithium-grease per 500 hours to bearing surface.
–
If the tighten firmware become flexible.
–
Check the tie-in of hydraulic pressure loop, if tube attaint. Prohibit use after repair.
–
Check the drive of attachment or if the rotating elements fray or block, change in time.
–
Check if each element and attachment working pressure is normal as well as attachment

works normally under load. If not, check the hydraulic pressure loop, find out the broken part,
change sealing element or whole loop element.

72
 16. 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

73
 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 Stacker
Model CQD16-AC5-I、CQD18-AC5-I、CQD20-AC5-I
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 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

74
– Part Two: Structure, principle and maintenance
1. Drive system
Drive system is composed of drive motor, reduction gearbox, electromagnetic brake, steering

motor, steering gear, tyre, fan and wire etc. Power transmission route: drive motor → reduction
gearbox → tyre; tyre steering route: steering motor →pinion → gearwheel → tyre.
 4 No. Designation

1 Mounting plate
3
2 Bolt
2 5
3 Drive motor
1
Electromagnetic
4
brake
2
5 Fan

Reduction
10 6
7 6 gearbox
Oil filler plug of
7 reduction
9 gearbox
Drain plug of
8 reduction 75
8 gearbox

9 Tyre

10 Steering motor
Inner reduction gearbox structure refers to the following drawing:
No. Designation
1 1 Brake
10 2 Motor
2
3 Screw
3 11 4 Nut
12
5 5 Screw
4 6 Mounting plate
7 Screw
6 8 Turntable bearing
7 9 Steering gearwheel
10 Steering motor
8
13 11 Screw
14 12 Washer
9 15
13 Steering pinion
14 Washer
15 Screw
16 Wheel
17 17 Assembly
18 Spring washer
19 Wheel nut
19 18 16

4 No. Designation No. Designation

1 5 2 7
1 Drive gear 10 Plug screw
3
8 2 Gear 11 Nameplate
6 9 Protection
10 3 Hex nut 12
cover
17
11 16 Breather
4 13 Plug screw
plug
5 Cap 14 O-ring
14 15
6 Case body 15 Case cover
12 9 7 Cover 16 Pin
13
8 Screw 17 Screw
9 Seal ring

76
 15 No. Designation No. Designation
14
1 Bearing 9 Gear set
1
13 2 Base plate 10 Snap ring
2
12 3 Stud 11 Bearing
4 Gear shaft 12 Gasket
5 Shaft seal 13 Gear shaft
10 11 6 Bearing 14 Bearing
8
7 9 7 Cover 15 Base plate
6
3 4 5 8 Base plate

1.1 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 braking torque in the power-off position
by pressure spring, and electromagnetic effect releases the brake.

1.Mounting screw

2.Stator component
6

5
3.Braking friction plate

4
4.Axle sleeve
3

5.Friction disk
2

6. Dust cover
1

Working principle
Shaft(9) connects spline housing(4)through flat key; spline housing(4) connects friction disk

assembly(3) through spline. When the stator (11) is off power, spring (10) generated force works

on the armature(8), friction disk assembly(3) drove by the shaft(9) grips between armature(8) and

friction disk(5), thus generates braking torque. For this moment, there will be a gap “Z” between

armature(8) and brake friction plate(3). When need to release the brake, stator(11) connects the

DC, then the generated magnetic field draws the armature(8) move to the stator(11), spring(10) is

compressed when armature(8) moves, at this time, friction disk assembly(3) is loosened, brake is
77
released.

1. Mounting screw
6
3. Braking friction plate

4. Axle sleeve
1
5. Friction disk
7

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

6.Stator

Z. Air gap
Z

78
Install the brake
–
Put the flat key(12) in the key groove of motor shaft(9), press 13
4 12
the shaft sleeve(4) on the shaft(9), and fix with inner snap
9
spring(13).

– Put friction disk(5) on the motor end face.

– Cover the braking friction plate(3) above the shaft sleeve.

– Assemble stator component(2) and three mounting

screws(1). Note: remove three rubber pads from the stator

component before assembling. 14

Z 15

6
– Screw down there mounting screws(1) with torque

wrench(14), and check braking air gap “Z” with feeler

gauge(15).

79
– Put dust cover（6）.

– Connect brake wire.

Warning
 No wire surface damage to avoid circuit damage.

 Do not process product locating surface or hole voluntarily so as not to affect magnet loop.

 Do not force too much when pressing fitting on the motor shaft, do not damage the
friction
surface, remove burrs on the mounting hole and surface, install shaft sleeve on the

shaft, and fix it with axial snap spring.


Measure the brake connected DC voltage, and compare the voltage with the one

stipulated on the nameplate. 10% deviation is allowable.



U=x V DC±10%

OIL

Adjust brake air gap

Rated air gap ”Z” will be larger for wear. Make sure the brake get enough brake torque, readjust

air gap before the air gap reaches the largest air gap value. Air gap can be adjusted repeatedly,

when the thickness of friction braking plate reaches the allowable minimum thickness (refer to
specification table), replace the friction disk plate.

When the air gap exceeds maximum air gas value, the brake may be unable to release, friction

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

severe accident. So check and re-adjust the air gap periodically, and cut off the truck general
power.

80
Specifications
Rated Rated Rated air Max. air Min. rotor Tightening torque of
torque power gap gap thickness mounting screw

16 N.m 30 W 0.2 mm 0.5 mm 8.1mm 9.5 N.m

When the brake is off power, adjust three hollow screws(7), adjust the air gap between armature

and friction brake plate to rated value “Z” with the help of feeler gauge, and ensure that air gap of
each direction is the same. Procedures are as follows:

– Screw off three mounting screws(1).

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

– Screw down three mounting screws(1).

– Use feeler gauge to check if air gap ”Z” meets requirement. Readjust until ”Z” reaches the
rated range.
1

7
- Z

In general working condition, the first air gap adjustment should proceed after brake working for
1500 ～ 2000hours, frequency of air gap adjustment is once per 6 months. In severe working

condition, like frequently brake and repeatedly sudden brake etc., the first adjustment can be
shortened and adjust the interval.
Maintenance
–
If work in high temperature environment for long time, please prevent rust, it may influence

use if there is rust on the suction surface.

–
Do not touch the friction surface with hand, no oil stain, otherwise it cannot reach the
maximum torque.
–
General use environment temperature is -10℃～+40℃.
–
Please check periodically, and the check item : if the switch motion is normal; if there is noise;

if there is abnormal heating; if any impurity, oil stain mixed into friction part or rotating part; if
clearance of friction part is proper, exciting voltage normal.

81
 Fault Probable cause Corrective action
Common
Power is obstructed Connect fault and

Too low exciting voltage Check voltage and adjust.

Brake does not work Improper air gap Adjust air gap

Stator coil breaks Replace stator

Oil dirt mixed in Clean oil dirt

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

Oil dirt mixed in Clean oil dirt

Unstable operation in previous
Breaking-in for a while
use

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 Reduce rotational inertia or

dynamic unbalance value dynamic unbalance value
troubleshooting

Dismantle and install the drive system

1 . Park the forklift on the stable ground, shut down the forklift, press the red emergency button, and pull out the
battery socket.
2 . Jack up the rear end of the forklift, support the frame with whole block or iron, make sure the block or iron is hard
enough to support the forklift and keep stably.

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 4 No. Designation
No. Designation
1 Block
3 1 Mounting plate 3 . Pull out
2 Drive wheel fingertip plug to
2 3 4 5 prevent wire
3 Fingertip
2 armrest
Bolt break when
taking down the
1 4 Seat cover.
3 Drive motor
6 5 Cover 4 . Dismantle
2
8 5 cover. Unscrew
6 4
Cover fixing Electromagnetic brake
bolt
7
10 10 cover fixing
7 Cover fixing bolt
6 5 Fan bolt, raise the
9 7 Base plate rubber
8
pad cover a little
6 Reduction gearbox
Base plate fixing
9 vertically, first
9 bolt Oil filler plug of reduction
1 2 1 7 pull out the
10 Base plate gearbox
Drain plug of reduction seat OPS(option)
8 8
gearbox plug and fan
plug, and then remove the cover.
5 . Dismantle the base plate rubber pad and front floor. Before removing the base plate, first pull out the safety
pedal, foot brake pedal and accelerator pedal plugs, in case of wire break.
6 . Dismantle all wires and connectors of drive system assembly. Dismantle the drive motor and steering motor
connected wire, pull out the plugs of electromagnetic brake and fan etc.
7. Dismantle drive system assembly. Unscrew mounting plate and truck frame connected bolts, and hoist the
drive system assembly stably.

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 9 Tyre

10 Steering motor

8. Drain reduction gearbox oil. Place a container under the reduction gearbox, and unscrew the drain plug to drain
Caution：
the oil. And then screw down the oil drain plug.
 Before laying aside the drive system assembly, first drain the reduction gearbox oil in case
of the oil leakage in the motor.

Caution
The waste oil needs to be dealt with according to local environment requirement, do not dump at will.
Replace the reduction gearbox oil every six months.

9 . Dismantle the steering motor. Unscrew three bolts on the mounting plate, erect the steering motor and take it
down stably.
1 0 . Dismantle the electromagnetic brake: Dismantle the outer snap ring of the electromagnetic brake,
unscrew bolt, and then erect the brake and take it down stably.
11. Dismantle the steering motor: Unscrew motor fixing bolt, and then erect the steering motor and take it down
stably.
12. Dismantle the reduction gearbox: Dismantle mounting plate, pivotal bearing and gearwheel in sequence, and
then dismantle reduction gearbox.
13. Dismantle the driving wheel: Unscrew wheel nut, pull out the wheel horizontally and then dismantle.
14. Install the driving system assembly, and the sequence is as follows：
1 ) Assemble the driving wheel;
2 ) Assemble the reduction gearbox, big gear, pivotal bearing and bearing seat etc., add gear oil in the reduction
gearbox until oil overflows from the oil filler plug;
3 ) Install to the truck frame;
4 ) Install gears on the driving motor shaft and then install the driving motor in the reduction gearbox; 5) Install
pinions on the motor shaft and then install the driving motor in the driving seat;
6 ) Install the electromagnetic brake and test the air gap of the brake.
7 ) Connect the electric circuit. Correctly connect motor wire and plugs.
8 ) Connect plugs of safety pedal, foot brake pedal and accelerator pedal, install front floor and rubber pad.
9 ) Connect fan plug, seat sensor and fingertip plugs. And then fix the cover.
1 0 ) Jack up the rear end of the forklift, and take out the block or iron.
11 ) Insert the battery plug and start the forklift.

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 No. Designation
1 Wheel
2. Front
wheel
2
Electromagnetic assembly
brake
Front wheel
3 Screw assembly is
composed of
4 Bearing wheel and
5 Circlip for hole
6 End cap
7 Lock washer
8 Screw
9 Screw
10 Screw
11 Washer
12 Front axle
13 Truck front pillar
electromagnetic brake etc.
The front wheel adopts polyurethane, which is strong and durable.
Electromagnetic brake works with power on, but stops braking with power off. During travelling, the more the
foot brake pedal is depressed, the stronger the front wheel braking force is. Installation structure of front
wheel assembly refers to the following drawing.

Disassembly and installment of front wheel

1 . Park the forklift on the stable ground, shut down the forklift
2 . Jack up the front end of the frame and support with block or iron, make sure the block or iron is hard enough
to support the front end of the forklift.
3 . Dismantle the cover plate of front wheel.
4 . Unscrew screw 8, dismantle end cap 6, and dismantle snap ring 5.
5. Unscrew screw 9, and knock out tyre assembly.
6. Pull out the electromagnetic brake plug. Unscrew screw 3, and then dismantle the electromagnetic brake. 7.
Unscrew screw 10, and take out front axle.
8. To install, reverse the order of disassembly. When installing bearing, smear lubricating grease. When
installing screw 3, 9 and 10, smear Loctite 270 glue. Torque of screw 9 is 25N.m.

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 Condition Cause and Analysis Correction

Thread damage Replace tyre

Unstable wheel running N Designatio
Bearing wear Replace bearing
9 Scre
Electromagnetic brake failed to Check and repair
stop the wheel rotation
1 Bushin electromagnetic brake
Wheel does not rotate Bearing damage and
1 seizure
Spacer Replace bearing
1
Front axle distortion Sprin Replace
Electromagnetic brake Electromagnetic brake
Repair brake or replace
malfunctions malfunction or no braking force


Caution ：
Front wheel brake adjusts the space automatically, torque of screw 9 is 25N.m, please refer to the above drawing

Common failures and troubleshooting measures

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 Condition Cause and Analysis No. Correction
Designation
Steering wheel cannot Nuts on the steering wheel are Adjust the tightness of nuts on 3.
be turned or too loose screwed too tight or loose. theSteering
steering wheel.
1
Steering motor damage or failure wheel
Inspect
Steering electronic control system
No steering failure or line failure
3 2 Inspect
Housing
action Gears of reduction gearbox failure or
Inspect or replace
wear 3 Guide rail
Pivotal bearing4 wear Replace
1 2
Dry engagement of big gear wheel and4 Smear
Knob lubricating grease or
pinion or gear damage replace gear
Noise Pivotal bearing wear Replace
Main reduction gearbox insufficient Add lubricating grease or
gear lubrication or gear damage replace gear
Turn the steering Check the wiring or debug the
wheel, the instrument Wiring fault or controller fault
controller
angle does not display
steering angle Instrument damage Replace
Steering device
This series forklift is electric powering steering, which can realize 180°or 360°turn on the ground by turning
the steering wheel. Steering device is mainly composed of steering wheel, housing and guide rail, as shown
in the drawing below.
Steering wheel position is adjustable. Adjusting steps: turn the knob 4 in counterclockwise, release housing
and move it to a proper position, and then tighten the knob 4 in clockwise.

Fault diagnoses and corrections

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 4. Hydraulic system
Hydraulic system is mainly composed of oil tank assembly, mutiway valve, cylinder and tube. Step on the
safety pedal with left foot, operate the fingertip with right hand, and the cylinder proceeds the corresponding
movement. Hydraulic schematic diagram is as follows.

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 Fault Probable reason Corrective action
Oil pressure is too low Check and turn up the safety valve value
Oil intermingle in the
Replace the seal ring on the piston rod
inner cylinder cavity Fault
Cylinder extends Oil leakage Check the connection and oil tube
powerless Oil intermingle or
damage in the inner Replace the seal ring or replace multiway valve
multiway valve cavity
Oil pump leakage Replace the seal ring, replace damaged part
Oil lacks and oil pump
Add the hydraulic oil to the dipstick scale
cannot absorb oil.
Filter blockage Replace the hydraulic oil and clean filter.
No pressure oil in oil Oil leakage Check the oil line
system
Oil pump malfunction Repair the oil pump or replace
Damage in the inner
Repair or replace
multiway valve cavity
Oil pump gear damage Replace the gear
Oil pump bearing
Abnormal noise Replace
damage
Air in the oil pump Check the reason for the bubble and eliminate.
Do not step on the Step on the safety pedal with left foot, operate
safety pedal the fingertip with right hand.
Operate fingertip but Line fault Check if the line is correctly connected.
cylinder does not Controller software
Debugging
work failure
Check if the oil line connects correctly or leaks,
Oil line breakdown
check oil pump, multiway valve and oil cylinder
Mast one-way governor
Replace
valve
Oil leaks in lifting
Mast lowers Replace the seal ring
cylinder piston
automatically
Multiway valve damage Repair or replace
Oil leak from the
Replace the connector seal ring
connector
diagnoses and corrections

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 5. Mast system
The lifting system is mast, reach device, load bracket, fork carriage, forks, lifting cylinder, tilting cylinder,
forward cylinder and pipeline etc. There are three types for the fitted mast: duplex wide view mast, duplex full
free lift mast and triplex full free lift mast.
There are many mast choices for this series forklift, mast structure and pipeline connection may be different
for different mast heights. Due to the continuous updating and improvement of the masts, there may be minor
discrepancies between your forklift mast and this manual.

8
9

5
4

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 Fault Probable cause Corrective action
Tilting cylinder and seal ring abraded Replace piston seal ring or
Fork carriage excessively Trouble
tilting cylinder. shooting
tilts
automatically Fingertip does not reset automatically in place Adjust or replace and
corrective
action
Mast reaches, Piston jamming or piston rod bends Replace the damage parts.
Mast
lifts and tilts disassembly and
sluggishly. Too much dirtoris accumulated in the cylinder. Clear installation
1 . Disassemble
Improper adjustment between rollers and Adjust clearance between roller
channel steel and channel steel the fork. Lower the
Fork carriage Dirt in the mast channel steel or damage Remove dirt or repair mast 15~20cm off
is lifted or
lowered the ground,
unsmoothly Insufficient mast channel steel lubrication Apply grease on contact
surfaces of sliding parts unscrew the bolts
Reach device
moves in the middle of
unsmoothly Mast deflection or fork carriage bent Repair or replace
the fork carriage,
Channel deflection or reach device bend Repair or replace pull up the fork
Fork carriage is Improper adjustment of lifting chains Adjust lifting chains on both stopper and rotate
lifted unevenly sides to the same tightness it 90°, push the
Rollers deformation or damage Replace forks to the
middle of the fork
Lifting roller Improperly adjustment of lifting roller. Adjust.
cannot rotate carriage and aim
Rollers get stuck by dirt Clean and lubricate the rollers. at the gap. Tilt the
fork carriage
Too much Insufficient lubrication. Lubricate. forward, slowly
noise on the Side rollers on fork carriage adjust improperly. It
mast strikes the mast channel steel, when the Adjust the rollers and side back up the truck,
extended mast lowering. rolling adjusting gaskets meanwhile the
Oil line pressure is too low Adjust safety valve value mast lowers and
the forks fall off.
Oil intermingle in the inner cylinder cavity Replace cylinder seal ring 2 . Move the mast
forward to the end
Insufficient Check, repair or replace seal and lower it.
lifting power or Oil line leaks or connector leaks ring
unable to lift pg. 129
Fingertip line fault Repair

Overloaded Load in the regulated range

Outer mast tilts Outer mast is not vertical, but tilts Adjust connecting rod and bolt
11 — DIAGNOSTICSANDTROUBLESHOOTING
 No. Designation/Remark
3 . Press down parking brake
1 Bolt button and shut down the
forklift.
2 Pedestal cover 4 . Dismantle the hydraulic
3 Eccentric bushing block connected multiway
valve rubber pipe, and plug the
4 Reach device
coupling to prevent oil outflow.
5 Mast 5. Dismantle mast connecting
wires to prevent wire breakage
when removing the mast.
6 . Rope or wire rope hangs to the lifting device through the inner mast beam, fasten firmly to avoid dropping. Notice
that the lifting rope cannot extrude the oil pipe to avoid damage.
7 . Dismantle the bottom connection of outer mast and reach device. Dismantle mast and reach device, left and
right connecting bolts, as well as intermediate connecting rod.
8. Dismantle the upper connection of the outer mast and reach device. Unscrew the pedestal cover bolts, and
then hoist the mast slowly with the lifting device. Knock out the eccentric bushing, to prevent from being lost or
damage during transport or laydown. Never stand around or under the mast when the mast is hoisted or
transported.
9 . Dismantle the reach device. 1. First dismantle two front blocks; 2. Dismantle forward cylinder connecting oil
pipe, and plug the connector. Dismantle reach device connecting forward cylinder end. 3. Dismantle multiway
valve connecting oil return pipe and pressure pipe. Pull out the multiway valve and controller connecting wire plug
so as not to break the wire when removing the reach device. 4. Tie the steel wire or rope to the reach device beam,
pull out horizontally and hoist.
1 0 . To install, reverse the order of disassembly. Smear lubricating grease to the channel steels when
installing. Smear lubricating grease to the rotary parts. After installment, adjust the clearance between rollers and
steel channels, and adjust the outer mast verticality. Correctly connect each line and each oil pipe connection.

Caution：
 According to Provisions on the Administration of Highway Management for Over
Limit Transport Vehicles by Ministry of Communications, overall height of loaded
truck for heavy/medium truck and semi-trailer is calculated from the ground, with 4M
high limit; container truck with 4.2M high limit. If the outer mast is too high, dismantle it
11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129
to transport. Reassemble by professionals after reaching the destination. Non-
professionals are not allowed to dismantle or assemble the mast.
 It's prohibited to stand under or near the mast when disassembling and assembling the
mast, as it is very high and heavy.
1.Plunger 2.LBH Dust 3. Check 4.IDI seal 5. Guide 6. Cylinder 7.O-ring
lever ring ring ring sleeve
For different high masts, mast, oil line and circuit of this manual body
may not be exactly the same as the forklift you ow
8.Sealing 9.Plug screw 10. 11.Valve 12. 13. Nipple
gasket Support sleeve Check component
ring ring
Inner structure of lifting cylinder
5 6 7 8 9
13

1 2 3
4 10 11 12

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

Inner structure of forward cylinder
7 8 14 15
4 9 10 13 11 12 13 16
5 6
1 2 3 2 3
 rod of2. Circlip
1. Piston group 2.Dust for
ringhole 3.Bearing
3.O-ring 4.Guide 4.U-ring
5.A1 dust ring 6.B3 sealsleeve
5.Guide ring
piston rod sleeve Inner
6.O-ring
7.O-ring 7.GLYD
8.FR guide ring
ring 8.Support10.Piston
9.Cylinder ring 9.Cylinder
11.O-ring tube 12.KR-ring structure of
body tilting
cylinder
13.FR guide 14.Washer 15.Nut 16.Pin
ring
7 8

2 34
5 6 9

Caution
 Forward cylinder, lifting cylinder and tiling cylinder relate to the mast height. For different high
masts, their cylinders maybe different.

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 6. Electrical system
6.1Motor
AC motor
AC motor does not have commutator and brush. No maintenance. But it needs regular inspection and dusty
clearing.

Motor maintenance
1 . Motor must be maintained well so as to guarantee safety work and extend service life.
2 . Motor installation and each fastener should be reliable.
3. Power cable should be correctly and firmly connected, no protrusion, no oil stain on the insulation part, and
keep dry.
4 . Idle motion should be quick.
5 . If there is any abnormal phenomenon, stop immediately, such as overheating or abnormal noise. Operate until
malfunction is corrected.
6 . Do not disassemble the motor arbitrarily, follow the rules of CAUTION OF MOTOR DISASSEMBLING. 7.
Clean the surface of motor regularly, replace the grease of the motor bearing annually(working
temperature of grease is -40℃~+200℃).
8 . Washing the motor case with high pressure liquid is strictly prohibited, in case of case deformation.
9 . To protect the shaft extension, do not remove the motor by putting ropes on motor shift, during the
disassembling and assembling process.
Caution of motor disassembling：
1. Be careful of the outer coder, no strike and protect the connectors of both signal wire. Do not knock
against coder gear when disassembling and inspecting the coder. Clear the gear before assembling.
2 . Clear rust and other stain fully before assembling.
3 . No any part damages during the assembling.
4. Wire connection should be correct and secure. No cutting-edge protrusion, no stain on insulation, and keep
dry.
5. The motor rotor can rotate easily by hands.
2.

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 DIAGNOSTICS AND TROUBLESHOOTING

1232E-1234E-1236E-1238E-1232SE-1234SE-1236SE-1238SE controller

These controllers detect a wide variety of faults or error conditions. Faults can be detected by the operating system or by
the VCL code. This chapter describes the faults detected by the operating system
Faults detected by VCL code (faults 51 –67 in Table 6) cannot be de fined here as they will vary from application to application.
Refer to the appropriate OEM documentation for information on these faults.

Diagnostics information can be obtained in either of two ways: (1) by reading the display on a 1313 handheld or 1314 PC
programmer or (2) by observing the fault codes issued by the Status LEDs. See Table 5 for a summary of LED display formats.
The 1313 /1314 programmer will display all faults that are currently set as well as a history of the faults that have been set
since the history log was last cleared. The 1313/1314 displays the faults by name.
The pair of LEDs built into the controller (one red, one yellow) produce flash codes displaying all the currently set faults in a
repeating cycle. Each code consists of two digits. The red LED flashes once to indicate that the first digit of the code will
follow; the yellow LED then flashes the appropriate number of times for the first digit. The red LED flashes twice to indicate
that the second digit of the code will follow; the yellow LED flashes the appropriate number of times for the second digit.

Example:

B+ Undervoltage Cutback (code 23).

In the Fault menu of the 1313/1314 programmer, the words B+ Undervoltage Cutback will be displayed; the real-time
battery voltage is displayed in the Monitor menu (“Capacitor Voltage ”).

The controller ’s two LEDs will display this repeating pattern:

Yellow
Red
( first digit)
(2)
(second
(3) digit)

The numerical codes used by the yellow LED are listed in the troubleshooting chart (Table 6), which also lists possible fault
causes and describes the conditions that set and clear each fault.

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 Display Status
Neither LED illuminated Controller is not powered on; or vehicle has dead battery; or severe damage.
Yellow LED flashing Controller is operating normally. Summary of
LED
Yellowand redLEDs both on solid Display
Controller is in Flash program mode. Formats
Red LED on solid Internal hardware fault detected by the Supervisor or Primary microprocessor.
Missing The two
or corrupt software. Interrupting a software download may cause corruption of LEDs have
the software.Cycle KSI to clear.Reload software or replace controller if four different
necessary. display
modes,
Red LED and yellow LED Controller has detected a fault. 2-digit code flashed by yellow LED identi fies indicating the
flashing alternately the speci fic fault; one or two flashes by red LED indicate whether first or type of
second code digit will follow. information
they are
providing.
Table 5 Types of LED Display

TROUBLESHOOTING

The troubleshooting chart, Table 6, provides the following information on all the controller faults:
• fault code
• fault name as displayed on the programmer’s LCD
• the effect of the fault
• possible causes of the fault
• fault set conditions
• fault clear conditions.

W henever a fault is encountered and no wiring or vehicle fault can be found, shut o ff KSI and turn it back on to see if the fault
clears. If it does not, shut o ff KSI and remove the 35-pin connector. Check the connector for corrosion or damage, clean it
if necessary, and re-insert it.

11 — DIAGNOSTICSANDTROUBLESHOOTING pg. 129

 System_Action Bit Action
No de fined System_Action Effect of fault as noted in Table 6

Bit0 = ShutdownMotor Disable the motor. The

fault
Bit1 = ShutdownMainContactor Shut down the main contactor (only if Main Enable = On)
Bit2 = ShutdownEMBrake Shut down the EM brake (only if EM Brake Disable Upon Fault = On).
Bit3 = ShutdownThrottle Set the Throttle_Command = 0%.
Bit4 = ShutdownInterlock Set the Interlock_State = Off.
Bit5 = ShutdownDriverl Shut down Driver1.
Bit6 = ShutdownDriver2 Shut down Driver2.
Bit7 = ShutdownDriver3 Shut down Driver3.
Bit8 = ShutdownDriver4 Shut down Driver4.
Bit9 = ShutdownPD Shut down Proportional Driver
Bit10 = FullBrake Set the Brake_Command = 100%.
Bit11 = [reserved] N/A (for 1232 –1238E/SE, and 1239E controllers)
Bit12 = TrimDisable Disable Dual Drive trim calculation.
For Dual Drive system, one controller has a severe fault but the main
Bit13 = SevereDual contactor must stay closed so the other controller can continue to
operate.
Bit14 = ShutdownSteer Steer angle = 0° (DD applicable).
For Dual Drive system, set the max speed to
Bit15 = LOSDual Dual_LOS_Max_Speed parameter for operation in Limited
Operating as
actions (e ffect of fault) in Table 6 use the same bit-structure Strategy.
the User_Fault_Action_xx listed in the OEM-defined User
Faults on page 113. The variable System_Action (available in WinVCL Monitor or TACT) returns the decimal number
corresponding to the active fault action bit(s). The Dual Drive fault actions, Bits 12–15, are listed in the supplemental Dual
Drive Operation manual.

Example:
HPD/Sequencing Fault, Flash Code 47. Effect of fault = Shutdown
Throttle.
System_Action = 8 (equates to Bit3 set: 0000 0000 0000 1000)
Table 6 TROUBLESHOOTING CHART
PROGRAMMER LCD DISPLAY
CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
12 Controller 1. External short of phase U,V,or Set: Phase current exceeded the
Overcurrent W motor connections. current measurement limit.
ShutdownMotor; 2. Motor parameters are mis-tuned. Clear: Cycle KSI.
ShutdownMainContacto 3. Controller defective.
r; ShutdownEMBrake;
ShutdownThrottle; 4. Speed encoder noise problems.
FullBrake.
13 Current Sensor Fault 1. Leakage to vehicle frame from Set: Controller current sensors have
ShutdownMotor; phase U, V,or W (short in motor invalid offset reading.
ShutdownMainContacto stator).
Clear: Cycle KSI.
r; ShutdownEMBrake; 2. Controller defective.
ShutdownThrottle;
FullBrake.
14 Precharge Failed 1. See Monitor menu » Set: The precharge failed to charge
ShutdownMotor; Battery: Capacitor Voltage. the capacitor bank.
ShutdownMainContacto 2. External load on capacitor bank Clear: Cycle Interlock input or use
r; ShutdownEMBrake; (B+ connection terminal) that VCL function
ShutdownThrottle; prevents the capacitor bank from Enable_Precharge().
FullBrake. charging.
15 Controller Severe 1. See Monitor menu » Set: Heatsink temperature below -40°C.
Undertemp Controller: Temperature. Clear: Bring heatsink temperature above
ShutdownMotor; 2. Controller is operating in -40°C, and cycle interlock or KSI.
ShutdownMainContactor; an extreme environment.
ShutdownEMBrake;
ShutdownThrottle;
FullBrake.
16 Controller Severe 1. See Monitor menu » Set: Heatsink temperature above +95°C.
Overtemp Controller: Temperature. Clear: Bring heatsink temperature below
ShutdownMotor; 2. Controller is operating in +95°C, and cycle interlock or KSI.
ShutdownMainContactor; an extreme environment.
ShutdownEMBrake; 3. Excessive load on vehicle.
ShutdownThrottle;
FullBrake. 4. Improper mounting of controller.
17 Severe B+ Undervoltage 1. Battery parameters are misadjusted. Set: Capacitor bank voltage dropped below
No DRIVE torque. 2. Non-controller system drain on the Severe Undervoltage limit ( see page 25)
battery. with FET bridge enabled.
3. Battery resistance too high. Clear: Bring capacitor voltage above
4. Battery disconnected while driving. Severe Undervoltage limit.
5. See Monitor menu » Battery:
Capacitor Voltage.
6. Blown B+ fuse or main contactor did
not close.
17 Severe KSI Undervoltage 1. See Monitor menu » Battery: Set: When below Brownout Voltage for
No action. Keyswitch Voltage. 2 seconds (see Table D-1).
2. Non-controller system drain on Clear: Bring KSI voltage above
battery/ KSI circuit wiring. Brownout Voltage.
3. KSI disconnected while driving.
4. Blown KSI fuse.
18 Severe B+ Overvoltage 1. See Monitor menu » Battery: Set: Capacitor bank voltage exceeded the
ShutdownMotor; Capacitor Voltage. Severe Overvoltage limit (see page 25 )
ShutdownMainContactor; 2. Battery parameters are misadjusted. with FET bridge enabled.
ShutdownEMBrake; 3. Battery resistance too high Clear: Bring capacitor voltage below
ShutdownThrottle; for given regen current. Severe Overvoltage limit, and then
FullBrake. cycle KSI.
4. Battery disconnected while
regen braking.
Set:
27External
Digital
Digital
1. Output
Out load
7 7 (pin 20)
Open/Short
impedance oncurrent
Digital exceeded
Digital
OutputOutput 71will
7 DRIVER Amp.
driver
not(pin
turn20)
on. is too low.
Clear: Remedy the overcurrent cause and use the VCL function Set_DigOut() to turn the driver on again.

PROGRAMMER LCD DISPLAY

CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
18 Severe KSI Overvoltage 1. Incorrect (to high) Set: KSI voltage exceeded Severe
ShutdownMotor; battery-voltage applied to KSI Overvoltage limiit
ShutdownMainContactor; (pin 1) Clear: Bring KSI voltage below the
ShutdownEMBrake; 2. See Monitor menu » Severe Overvoltage limit
ShutdownThrottle; Battery: Keyswitch
FullBrake. (see page 25 , Severe Overvoltage)
Voltage.
Note: Prevents the Main Contactor
closure if KSI is greater than the
22 Controller Overtemp Severe Overvoltage limit.
1. See Monitor menu » Set: Heatsink temperature exceeded 85°C.
Cutback Controller: Temperature. Clear: Bring heatsink temperature below
Reduced DRIVE and brake 2. Controller is performance-limited at
torque. 85°C.
this temperature.
3. Controller is operating in an
extreme environment.
4. Excessive load on vehicle.
5. Improper mounting of controller.
23 B+ Undervoltage Cutback 1. Normal operation. Fault indicates Set: Capacitor bank voltage dropped
Reduced DRIVE torque. the batteries need recharging. below the Undervoltage limit ( see page 25
Controller is performance limited at ) with
this voltage. the FET bridge enabled.
2. Battery parameters are misadjusted. Clear: Bring capacitor voltage above
3. Non-controller system drain on the Undervoltage limit.
battery.
4. Battery resistance too high.
5. Battery disconnected while driving.
6. See Monitor menu » Battery:
Capacitor Voltage.
7. Blown B+ fuse or main contactor did
not close.
24 B+ Overvoltage Cutback 1. Normal operation. Fault shows that Set: Capacitor bank voltage exceeded the
Reduced brake torque. Note: regen braking currents elevated the Overvoltage limit (see page 25 ) with the
This fault is declared only battery voltage during regen braking. FET bridge enabled.
when the controller is Controller is performance limited at
Clear: Bring capacitor voltage below
running in regen. this voltage.
the Overvoltage limit.
2. Battery parameters are misadjusted.
3. Battery resistance too high for
given regen current.
4. Battery disconnected while
regen braking.
5. See Monitor menu »
Battery: Capacitor Voltage.
25 +5V Supply Failure 1. External load impedance on the Set: +5V supply (pin 26) outside the
None, unless a fault action +5V supply (pin 26) is too low. 5 V±10% range.
is programmed in VCL. 2. See Monitor menu » outputs: 5 Clear: Bring voltage within range.
Volts and Ext Supply Current.

26 Digital Out 6 Open/Short 1. External load impedance on Set: Digital Output 6 (pin 19)
Digital Output 6 DRIVERwill Digital Output 6 driver (pin 19) current exceeded 1 Amp.
not turn on. is too low. Clear: Remedy the overcurrent cause and
use the VCL function Set_DigOut() to turn
the driver on again.
 PROGRAMMER LCD DISPLAY
CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT limited motor control.
28 Motor Temp Hot Cutback 1. Motor temperature is at or Set: Motor temperature is at or above
Reduced DRIVE torque. above the programmed the Temperature Hot parameter
Temperature Hot setting, and the setting.
current is being cut back. Clear: Bring the motor temperature within
2. Motor Temperature Control range.
36 Sin/Cos Sensor 1. Sin/Cos sensor failure. Set: Greater than Sin_Cos_Fault_Threshold
Menu parameters are
Fault 2. Bad crimps or faulty wiring. % difference from expected value between two
mis-tuned.
ShutdownEMBrake; phases seen 5 times within one second.
3. See Monitor menu3.»See
Motor disabled.
Monitor menu » Motor:
Motor:
Motor
Temperature and » Inputs: RPM. Clear: Cycle KSI, or VCL reset, or Entry into
Analog2. LOS mode if enabled, (or entry into an
4. If the application doesn ’t use a ACIM auto- characterization).
motor thermistor,
TempCompensation and
29 Motor Temp Sensor Fault 1. TempCutback
Motor thermistor should
is notbe Set: Motor thermistor input (pin 8) is at
MaxSpeed reduced (LOS, connected properly. the voltage rail (0 V or 10 V).
Limited Operating Strategy), 2. If the application doesn ’t use Clear: Bring the motor thermistor input
and motor temperature a motor thermistor, Motor voltage within range.
cutback Temp
disabled. Sensor Enable should be
programmed Off.
3. See Monitor menu » Motor:
31 Coil1 Driver Open/Short 1. Temperature
Open or short andon»driver
Inputs:
load. Set: Driver 1 (pin 6) is either open or shorted.
Shutdo WNDRIVER1. 2. Dirty connector pins. This fault can be set only when Main
Enable = Off.
3. Bad crimps or faulty wiring.
Clear: Correct open or short, and cycle
31 Main Open/Short 1. Open or short on driver load.
driver.
Set: Main contactor driver (pin 6) is either
ShutdownMotor; 2. Dirty connector pins. open or shorted. This fault can be set only
ShutdownMainContacto 3. Bad crimps or faulty wiring. when Main Enable = On.
r; ShutdownEMBrake; Clear: Correct open or short, and cycle
ShutdownThrottle; driver
FullBrake. Bad crimps
32 Coil2 Driver Open/Short 1. Open or short on driver load. Set: Driver 2 (pin 5) is either open or
Shutdo WNDRIVER2. 2. Dirty connector pins. shorted. This fault can be set only when
EM Brake Type = 0.
3. Bad crimps or faulty wiring.
Clear: Correct open or short, and cycle
32 EMBrake 1. Open or short on driver load.
driver.
Set: Electromagnetic brake driver (pin 5) is
Open/Short 2. Dirty connector pins. either open or shorted. This fault can be set
ShutdownEMBrake; only when EM Brake Type >0.
3. Bad crimps or faulty wiring.
ShutdownThrottle; Clear: Correct open or short, and cycle
FullBrake. driver.
33 Coil3 Driver Open/Short 1. Open or short on driver load. Set: Driver 3 (pin 4) is either open or
Shutdo WNDRIVER3. 2. Dirty connector pins. shorted. Clear: Correct open or short, and
3. Bad crimps or faulty wiring. cycle driver.
34 Coil4 Driver Open/Short 1. Open or short on driver load. Set: Driver 4 (pin 3) is either open or
Shutdo WNDRIVER4. 2. Dirty connector pins. shorted. Clear: Correct open or short, and
3. Bad crimps or faulty wiring. cycle driver.
35 PD Open/Short 1. Open or short on driver load. Set: Proportional driver (pin 2) is either
ShutdownPD. 2. Dirty connector pins. open or shorted.
3. Bad crimps or faulty wiring. Clear: Correct open or short, and cycle
driver.
36 Encoder Fault 1. Motor encoder failure. Set: Motor encoder phase failure detected.
ShutdownEMBrake; 2. Bad crimps or faulty wiring. Clear: Either cycle KSI, or if parameter LOS
Motor disabled. 3. See Monitor menu » Motor: Motor Upon Encoder Fault= On and Interlock has
RPM. been cycled, then the Encoder Fault is cleared
and
Set:
46 Controller
EEPROMFailure
1. Failure operating
to write system tried
to EEPROM to write
memory. Thistocan
EEPROM memory
be caused and failed.
by EEPROM memory writes initiated by VCL, by the CAN
Clear:
bus, byDownload
adjustingtheparameters
ShutdownMotor; correct software (OS)programmer,
with the and matching parameter
or by default
loading new settingsinto
software intothe
thecontroller.
controller and cycle KSI.
ShutdownMainContacto
r; ShutdownEMBrake;
ShutdownThrottle;
PROGRAMMER
ShutdownInterlock; Shutdo WND LCD DISPLAY
RIVER 1; Shutdo WNDRIVER2; Shutdo WNDRIVER3; Shutdo WNDRIVER4; ShutdownPD;
CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
FullBrake. EFFECT OF FAULT
37 Motor Open 1. Motor phase is open. Set: Motor phase U, V, or W detected
ShutdownMotor; 2. Bad crimps or faulty wiring. open. Clear: Cycle KSI.
ShutdownMainContacto
r; ShutdownEMBrake;
ShutdownThrottle;
FullBrake.
38 Main Contactor 1. Main contactor tips are welded Set: Just prior to the main contactor closing,
Welded closed. the capacitor bank voltage (B+ connection
ShutdownMotor; 2. Motor phase U or V is disconnected terminal) was loaded for a short time and
ShutdownMainContactor or open. the voltage did not discharge.
; ShutdownEMBrake; 3. An alternate voltage path (such as Clear: Cycle KSI
ShutdownThrottle; an external precharge resistor) is
FullBrake. providing a current to the
capacitor
39 Main Contactor Did Not 1. Main contactor did not close. Set: With the main contactor
Close ShutdownMotor; 2. Main contactor tips are oxidized, commanded closed, the capacitor bank
ShutdownMainContactor; burned, or not making good voltage (B+
ShutdownEMBrake; contact.* connection terminal) did not charge to
ShutdownThrottle; 3. External load on capacitor bank B+. Clear: Cycle KSI.
FullBrake.
(B+ connection terminal) that *New contactors may need to be cycled
prevents capacitor bank from electrically & mechanically to remove
charging. any non-conductive material on the tips.
4. Blown B+ fuse. Use reduced voltage (e.g., 12V) to
41 Throttle Wiper High 1. See Monitor menu » Inputs: prevent tip damage
Set: Throttle through
pot wiper (pin 16)excessive
voltage is
ShutdownThrottle. Throttle Pot. higher than the high fault threshold (can
2. Throttle pot wiper voltage too high. be changed with the VCL function
Setup_Pot_Faults()).
Clear: Bring throttle pot wiper voltage below
the fault threshold.
42 Throttle Wiper Low 1. See Monitor menu » Inputs: Set: Throttle pot wiper (pin 16) voltage is
ShutdownThrottle. Throttle Pot. lower than the low fault threshold (can be
2. Throttle pot wiper voltage too low. changed with the VCL function
Setup_Pot_Faults()).
Clear: Bring throttle pot wiper voltage above
43 Pot2 Wiper High 1. See Monitor menu » Inputs: Set: Pot2 wiper (pin 17) voltage is higher
FullBrake. Pot2 Raw. than the high fault threshold (can be
2. Pot2 wiper voltage too high. changed with the VCL function
Setup_Pot_Faults()).
Clear: Bring Pot2 wiper voltage below the
44 Pot2 Wiper Low 1. See Monitor menu » Inputs: Set: Pot2 wiper (pin 17) voltage is lower
FullBrake. Pot2 Raw. than the low fault threshold (can be
2. Pot2 wiper voltage too low. changed with the VCL function
Setup_Pot_Faults()).
Clear: Bring Pot2 wiper voltage above the
45 Pot Low 1. See Monitor menu » Outputs: Set: Pot low (pin 18) current exceeds 10
OverCurrent Pot Low. mA. Clear: Clear pot low overcurrent condition
ShutdownThrottle; 2. Combined pot resistance
FullBrake. and
connected to pot low is too low.
cycle KSI.
71 OS General 1. Internal controller fault. Set: Internal controller fault detected.
ShutdownMotor; Clear: Cycle KSI.
ShutdownMainContacto
r; ShutdownEMBrake;
ShutdownThrottle;
PROGRAMMER LCD DISPLAY
ShutdownInterlock;
CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT
Shutdo OF FAULT
47 WN DRIVER1;Shutdo Fault
HPD/Sequencing 1. KSI, interlock, direction, and Set: HPD (High Pedal Disable) or
WN DRIVER2;Shutdo
ShutdownThrottle. throttle inputs applied in sequencing fault caused by incorrect
WNDRIVER3;Shutdo incorrect sequence. sequence of KSI, interlock, direction, and
WNDRIVER4; 2. Faulty wiring, crimps, or switches throttle inputs.
ShutdownPD; at KSI, interlock, direction, or Clear: Reapply inputs in correct sequence.
72 PDO Timeout 1. Time between
throttle inputs.CAN PDO Set: Time between CAN PDO
ShutdownThrottle; messages received exceeded messages received exceeded the
3. See Monitor menu » Inputs.
CAN NMT State set the PDO Timeout Period.
47 Emer Rev HPD
to Pre-operational. 4. PDO
Emergency Reverse operation
Timeout Period. Set:At the conclusion of Emergency
ShutdownThrottle; has concluded, but the throttle, Clear: Cycle
Reverse, theKSI
faultorwas
receive CAN various
set because
ShutdownEMBrake. forward and reverse inputs, and NMT
inputsmessage.
were not returned to neutral.
interlock have not been returned Clear: If EMR_Interlock = On, clear the
to neutral. interlock, throttle, and direction inputs. If
EMR_Interlock = Off, clear the throttle
and direction inputs.
49 Parameter Change 1. This is a safety fault causedby a Set: Adjustment of a parameter setting
Fault ShutdownMotor; change in certainparameter settings that requires cycling of KSI.
ShutdownMainContactor so that the vehicle will not operate
Clear: Cycle KSI.
; ShutdownEMBrake; until KSI is cycled. For example,if a
ShutdownThrottle; user changestheThrottle Type this
FullBrake. fault will appear and require
cyclingKSI beforethe vehiclecan
51-67 OEM Faults 1. operate.
These faults can be de fined by the Set: See OEM documentation.
(See OEM documentation.) OEM and are implemented in the
Clear: See OEM documentation.
application-speci fic VCL code. See
OEM documentation.
68 VCL Run Time Error 1. VCL code encountered a runtime Set: Runtime VCL code error condition.
ShutdownMotor; VCL error. Clear: Edit VCL application software to fix
ShutdownMainContacto 2. See Monitor menu » Controller: VCL
r; ShutdownEMBrake; this
Error Module and VCL Error.This
ShutdownThrottle; error condition; flash the new compiled
error can then be compared to the
ShutdownInterlock; software and matching parameter defaults;
runtime VCL module ID and error
Shutdo WNDRIVER1; cycle KSI.
code
Shutdo WNDRIVER2; de finitions found in the specific
Shutdo WNDRIVER3; OS system information file.
Shutdo
WNDRIVER4;
ShutdownPD;
69 External Supply Out of 1. External load on the 5V and 12V Set: The external supply current (combined
Range None, unless a fault supplies draws either too much or current used by the 5V supply [pin 26] and
action is programmed in too little current. 12V supply [pin 25]) is either greater than
VCL. 2. Fault Checking Menu parameters the upper current
Ext Supply Max and Ext Supply threshold or lower than the lower current
Min are mis-tuned. threshold. The two thresholds are de fined
3. See Monitor menu » Outputs: by the External Supply Max and External
Ext Supply Current. Supply Min parameter settings (page 54 ).
Clear: Bring the external supply current
within range.
 PROGRAMMER LCD DISPLAY
CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
73 Stall Detected 1. Stalled motor. Set: No motor encoder movement detected.
ShutdownEMBrake; 2. Motor encoder failure. Clear: Either cycle KSI, or if parameter LOS
Motor disabled; 3. Bad crimps or faulty wiring. Upon Encoder Fault = On and Interlock has
Control Mode changed to been cycled, then the Stall Detected fault is
4. Problems with power supply
LOS (Limited Operating cleared and Encoder LOS fault (code 93) is
Strategy). for the motor encoder.
5. See Monitor menu » Motor: set, allowing limited motor control.
Motor RPM.
74 Fault On Other 1. Dual Drive fault: see Dual
Traction Controller Drive manual.

75 Dual Severe Fault 1. Dual Drive fault: see Dual Drive

manual.

77 Supervisor Fault 1. The Supervisor has detected a Set: Mismatched redundant readings;
ShutdownMotor; mismatch in redundant readings. damaged Supervisor; illegal switch inputs.
ShutdownMainContacto 2. Internal damage to Clear: Check for noise or voltage drift in
r; ShutdownEMBrake; Supervisor all switch inputs; check connections;
ShutdownThrottle; microprocessor. cycle KSI.
ShutdownInterlock; 3. Switch inputs allowed to be
Shutdo within upper and lower thresholds
WNDRIVER1;Shutdo
for over 100 milliseconds. (for
WNDRIVER2;Shutdo
recurring errors, check the
WNDRIVER3;Shutdo
switches for moisture).
WNDRIVER4;
ShutdownPD;
78 Supervisor Incompatible 1. The main OS is not compatible Set: Incompatible software.
ShutdownMotor; with the Supervisor OS.
Clear: Load properly matched OS code or
ShutdownMainContactor; update the Supervisor code; cycle KSI.
ShutdownEMBrake;
ShutdownThrottle;
ShutdownInterlock;
Shutdo
WNDRIVER1;Shutdo
WNDRIVER2;Shutdo
WNDRIVER3;Shutdo
WNDRIVER4;
ShutdownPD;
82 Bad Calibrations 1. Internal controller fault. Set: Internal controller fault detection.
ShutdownMotor; Clear: Cycle KSI.
ShutdownMainContacto
r; ShutdownEMBrake;
ShutdownThrottle;
FullBrake.
83 Driver Supply 1. Internal controller fault in the Set: Internal controller fault detection.
ShutdownMotor; voltage supply for the driver Clear: Cycle KSI.
ShutdownMainContacto circuits.
r; ShutdownEMBrake;
ShutdownThrottle;
FullBrake.
 PROGRAMMER LCD DISPLAY
CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
87 Motor Characterization 1. Motor characterization failed Set: Motor characterization failed during
Fault ShutdownMotor; during characterization process. the motor characterization process.
ShutdownMainContactor; See Monitor menu » Controller: Normally caused by turning off
ShutdownEMBrake; Motor Characterization Error for Motor_Characterization_Test_Enable before
ShutdownThrottle; cause: running test. Needs controller reset.
FullBrake. 0 = sequencing error. Normally Clear: Correct fault; cycle KSI, or VCL reset.
caused by turning off Motor
Characterization Test Enable
before running the test.
1 = encoder signal seen but step
size not auto-detected; set up
Encoder Steps manually
2 = motor temp sensor fault
3 = motor temp hot cutback fault
4 = controller overtemp cutback
fault 5 = controller undertemp
cutback fault 6 = undervoltage
cutback fault
7 = severe overvoltage fault
8 = encoder signal not seen, or one
or both channels missing
9 = motor parameters out
of characterization
range
20 = Sin/Cos sensor not
found 21 = phasing not
detected
22 = Sin/Cos sensor
characterization failure
23 = started characterization
procedure while motor rotating.
88 Encoder Pulse Count 1. Encoder Steps parameter does Set: Detected wrong setting of the
Fault ShutdownMotor; not match the actual motor Encoder Steps parameter.
ShutdownMainContactor; encoder. Clear: Ensure the Encoder Steps
ShutdownEMBrake; parameter matches the actual encoder;
ShutdownThrottle; cycle KSI.
ShutdownInterlock;
Shutdo
WNDRIVER1;
Shutdo WNDRIVER2;
Shutdo WNDRIVER3;
Shutdo
WNDRIVER4;
89 Motor Type Fault 2. The Motor_Type parameter value Set: Motor_Type parameter is set to an
ShutdownMotor; is out of range. illegal value.
ShutdownMainContacto Clear: Set Motor_Type to correct value
r; ShutdownEMBrake; and cycle KSI.
ShutdownThrottle;
FullBrake.
Inmotion controller common fault and corrections

PROGRAMMER LCD DISPLAY

CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
91 VCL/OS Mismatch 1. The VCL software in the Set: VCL and OS software do not match; when
ShutdownMotor; controller does not match the KSI cycles, a check is made to verify that
ShutdownMainContacto OS software in the controller. they match and a fault is issued when they
r; ShutdownEMBrake; do not.
ShutdownThrottle; Clear: Download the correct VCL and OS
ShutdownInterlock; software into the controller.
Shutdo
WNDRIVER1;Shutdo
WNDRIVER2;Shutdo
WNDRIVER3;Shutdo
WNDRIVER4;
ShutdownPD;
92 EM Brake Failed to 1. Vehicle movement sensed after the Set: After the EM Brake was commanded to
Set EM Brake has been commanded set and time has elapsed to allow the brake
ShutdownEMBrake; to set. to fully engage, vehicle movement has
ShutdownThrottle. 2. EM Brake will not hold the motor been sensed.
Position Hold is engaged from rotating. Clear: 1.Activate the Throttle (EM Brake type
when Interlock = On. 2).
2. Activate the Interlock (EM Brake type 1).
93 Encoder LOS (Limited 1. Limited Operating Strategy (LOS) Set: Encoder Fault (code 36) or Stall
Operating Strategy) control mode has been activated, Detected (code
Enter LOS control mode. as a result of either an Encoder 73) was activated, if parameter LOS Upon
Fault (Code 36) or a Stall Encoder Fault = On and Interlock has
Detected fault (Code 73). been cycled, then the Encoder LOS (code
2. Motor encoder failure. 93) control mode is activated, allowing
limited motor control.
3. Bad crimps or faulty wiring.
Clear: Cycle KSI or,if LOS mode was
4. Vehicle is stalled.
activated by the Stall Detected fault, clear by
ensuring encoder senses proper operation,
Motor RPM = 0, and Throttle Command =
94 Emer Rev 1. Emergency Reverse was activated 0.
Set: Emergency Reverse was activated and
Timeout and concluded because the ran until the EMR Timeout timer
ShutdownEMBrake; EMR Timeout timer has expired.
ShutdownThrottle expired. Clear: Turn the emergency reverse input
. 2. The emergency reverse input is Off.
98 Illegal Model Number 1. Model_Number variable contains Set: Illegal Model_Number variable; when
ShutdownMotor; illegal value. KSI cycles, a check is made to con firm a
ShutdownMainContacto 2. Software and hardware do not legal Model_ Number, and a fault is issued if
r; ShutdownEMBrake; match. 3. Controller defective. one is not found.
ShutdownThrottle; Clear: Download appropriate software for
FullBrake. your controller model.
99 Parameter Mismatch 1. Dual drive enabled on only Set: When the Dual Drive software is
ShutdownMotor; one controller. enabled, the controller must be set to
ShutdownMainContacto 2. Incorrect position feedback type either Speed Mode
r; ShutdownEMBrake; chosen for motor technology in Express or Speed Mode; otherwise this fault
ShutdownThrottle; use. is set.
FullBrake. 3. Dual drive is enabled in torque Motor Techology=0 must be paired with
mode. Feedback Type=1, and Motor
Technology=1 must be paired with
Feedback Type=2; otherwise this fault is
set.
Clear:Adjust parameters to appropriate
values and cycle KSI.
No Fault code Hexadecimal Display Fault analysis

ERROR Accelerator pedal switch The accelerator pedal switch is closed

1 20 0×14 activated at startup before the steering calibration is completed.

Please release the accelerator pedal

 ERROR Direction switch activated at The direction switch is closed before the

2 21 0×15 statup steering calibration is completed. Please

disconnect direction switch

ERROR Front and rear direction switch 1. Direction switch fault

3 22 0×16
activated simultaneously 2. Harness fault, direction signal shorted

ERROR Accelerator pedal analog value 1.Accelerator pedal failure or analog value

is out of range needs to be recalibrated

4 23 0×17
2. Harness fault, accelerator output signal

line disconnect

ERROR Accelerator pedal analog value 1. Accelerator pedal analog fault

5 24 0×18 failure 2. Harness fault, accelerator pedal signal

line fault.

ERROR Driver CAN communication fault Please check the CAN line or controller, the
6 31 0×1F
meter is disconnected

7 32 0×20 ERROR Low battery voltage Need to charge

8 34 0×22 ERROR Traction driver internal fault Restart key switch

ERROR Tilt switch activated at startup The tilt switch is closed before the steering

9 36 0×24 calibration is completed. Please disconnect

tilt switch

ERROR Side shift switch activated at The side shift switch is closed before the

10 37 0×25 startup steering calibration is completed. Please

disconnect side shift switch

ERROR Attachment switch activated at The attachment switch is closed before the

11 38 0×26 startup steering calibration is completed. Please

disconnect attachment switch

ERROR Lift switch activated at startup The lift switch is closed before the steering

12 39 0×27 calibration is completed. Please disconnect

lift switch
 ERROR
WARNING Traction Lifttemperature
motor analog value
is is 1.
outTraction
of rangemotor1.temperature
Lift speed sensor fault or lift analog value
is too high
21 85 0×55
high 2. Traction motorneeds to be fault
thermistor recalibrated
13 41 0×29
ERROR Traction motor temperature 1. Traction motor2.thermistor
Harness fault
fault, lift speed sensor output

22 86 0×56 sensor error 2. Harness fault,signal line

traction disconnect
motor temperature

ERROR Front and rear shiftsensor

analogcable
valuedisconnect
1. Front and rear shift finger switch fault or

is out
ERROR Traction of range
motor speed sensor 1. Traction motoranalog
speedvalue needs
sensor fault to be recalibrated
14 42 0×2A
23 87 0×57 error 2. Harness
2. Harness fault, traction fault,
motorfront and rear shift finger
speed
switch output signal line disconnect.
sensor cable disconnect

ERROR Front and rear tilt analog value is 1. Front and rear tilt finger switch fault or

out of range analog value needs to be recalibrated

15 43 0×2B
2. Harness fault, front and rear shift finger

switch output signal line disconnect

ERROR Left and right shift analog value 1. Left and right shift finger switch fault or

is out of range analog value needs to be recalibrated

16 44 0×2C
2. Harness fault, left and right shift finger

switch output signal line disconnect

WARNING Traction driver temperature is Alarm for low temperature of controller

17 81 0×51
low

WARNING Traction driver temperature is Alarm for over-high temperature of

18 82 0×52
high controller

ERROR Traction driver temperature Controller temperature sensor error

19 83 0×53
sensor error

WARNING Traction motor temperature is 1. Traction motor temperature is too low

20 84 0×54
low 2. Traction motor thermistor fault
 WARNING Traction driver voltage is high 1. Battery voltage is high

24 88 0×58 2. The ramp is too steep and the

regenerative braking is too strong

WARNING Traction driver voltage is low 1. Battery voltage is low

25 89 0×59 2. Need to charge or check the power

harness

26 90 0×5A Reserved

WARNING Traction driver limited Low battery power, vehicle speed is limited,
27 91 0×5B
mode lifting locked.

ERROR Traction driver output error 1. Check the output harness for short circuit

28 97 0×61 and open circuit

2. Drive coil open or shorted

29 98 0×62 Reserved

ERROR Traction motor driver short circuit 1. Check power harness

30 101 0×65 2. Contact the not closed controller is

enabled.

ERROR Traction driver temperature is Traction driver temperature is too high,

31 102 0×66
high need to be cooled

ERROR Traction motor temperature is 1. Traction motor temperature is too high,

32 103 0×67 high need to be cooled.

2. Traction motor temperature sensor fault

ERROR Traction driver overcurrent 1. Vehicle overload or mechanical jam

33 104 0×68
2. Motor encoder fault

ERROR Traction driver precharge 1. Replace the precharge resistor

34 105 0×69 timeout 2. Battery voltage is low

3. Wire harness broken

35 110 0×6E ERROR Traction driver voltage is low Battery voltage is low

36 111 0×6F ERROR Traction driver voltage is high Battery voltage is high

ERROR Traction driver internal power Check motor encoder and temperature
37 114 0×72
fault sensor cable

38 121 0×79 WARNING Pump driver temperature is Alarm for low temperature of controller
low

39 122 0×7A WARNING Pump driver temperature is Alarm for over-high temperature of
high controller
40 123 0×7B ERROR Pump driver temperature sensor Controller temperature sensor error
error

41 124 0×7C WARNING Pump motor temperature is 1. Pump motor temperature is too low

low 2. Pump motor thermistor fault

enable
 WARNING Pump motor temperature is 1. Pump motor temperature is over high
42 125 0×7D
high 2. Pump motor thermistor fault

ERROR Pump motor temperature sensor 1. Pump motor thermistor fault

43 126 0×7E fault 2. Harness fault, pump motor temperature

sensor cablebreak

ERROR Pump driver speed sensor fault 1. Pump motor speed sensor fault

44 127 0×7F 2. Harness fault, pump motor speed sensor

cable disconnect

45 128 0×80 WARNING Pump driver voltage is high Battery voltage is high

1. Battery voltage is low 2. Need to

46 129 0×81 WARNING Pump driver voltage is low
charge or check the power harness

47 130 0×82 Reserved

48 132 0×84 Reserved

49 134 0×86 ERROR Pump driver internal error Restart key switch

1.Check the output harness for short circuit

50 137 0×89 ERROR Pump driver output port fault and open circuit

2. Drive coil open or shorted

WARNING Pump driver overcurrent or 1. Check the power harness

51 138 0×8A
short circuit 2. Contact the not closed controller is

52 141 0×8D ERROR Pump driver short circuit

Alarm for over-high temperature of pump

53 142 0×8E ERROR Pump driver temperature is high
driver

Alarm for over-high temperature of pump

54 143 0×8F ERROR Pump motor temperature is high
motor

Check motor encoder and temperature

55 144 0×90 ERROR Pump driver internal power fault
sensor cable

1. Replace the precharge resistor

56 145 0×91 ERROR Pump driver precharge timeout 2. Battery voltage is low

3. Wire harness broken

ERROR Steering wheel encoder fault 1. Steering encoder fault

67 209 0×D1
2. Steering encoder cable fault

ERROR Steering driver speed sensor 1. Steering motor speed sensor fault

68 210 0×D2 fault 2. Harness fault, steering motor speed

sensor cable disconnect

ERROR Steering motor temperature 1. Steering motor thermistor fault

69 211 0×D3 sensor fault 2. Harness fault, steering motor

temperature sensor cable disconnect

 57 150 0×96 ERROR Pump driver voltage is low Battery voltage is low

58 151 0×97 ERROR Pump driver voltage is high Battery voltage is high

1. Check the power harness

59 201 0×C9 ERROR Steering driver short circuit 2. Contact the not closed controller is

enabled.

ERROR Steering driver temperature is Steering driver temperature is too high

60 202 0×CA
high

ERROR Steering motor temperature is Steering motor temperature is too high that
61 203 0×CB
high cut the output, and need to be cooled

ERROR Steering driver internal power Check motor encoder and temperature
62 204 0×CC
supply fault sensor cable

ERROR Steering driver precharge 1. Battery voltage is low

63 205 0×CD
timeout 2. Wire harness broken

64 206 0×CE ERROR Steering driver voltage is low Battery voltage is low

65 207 0×CF ERROR Steering driver voltage is high Battery voltage is high

ERROR Speed life count overtime Communication fault between the traction
66 208 0×D0
driver and the main control

ERROR Steering driver temperature Steering driver temperature is too high that
70 212 0×D4
sensor fault cut the output or too low that fails.

ERROR Steering contactor fault 1. Steering contactor fault

71 213 0×D5
2. Steering contactor cable fault

ERROR Steering driver valve control 1.Check the output harness for short circuit

72 214 0×D6 relay fault and open circuit

2. Drive coil open or shorted

73 215 0×D7 Reserved

74 216 0×D8 Reserved

ERROR Steering driver output fault 1.Check the output harness for short circuit

75 217 0×D9 and open circuit

2. Drive coil open or shorted

WARNING Steering motor temperature is 1. Steering motor temperature is too low.

76 218 0×DA
low 2. Steering motor thermistor fault

WARNING Steering motor temperature is 1. Steering motor temperature is over high

77 219 0×DB
high 2. Steering motor thermistor fault

WARNING Steering driver temperature is Alarm for low temperature of controller

78 220 0×DC
low

WARNING Steering driver temperature is Alarm for over-high temperature of

79 221 0×DD
high controller

80 222 0×DE WARNING Steering driver voltage is high Battery voltage is high

1. Battery voltage is low

81 223 0×DF WARNING Steering driver voltage is low
2. Charge or check power harness

82 231 0×E7 ERROR Traction driver CAN timeout Check CAN communication cable

83 232 0×E8 ERROR Pump driver CAN timeout Check CAN communication cable

84 233 0×E9 ERROR Steering driver CAN timeout Check CAN communication cable

85 234 0×EA ERROR Steering driver internal error Check CAN communication cable

86 157 0×9D BMS over-temperature protection Lithium battery over-temperature protection

87 158 0×9E BMS cells overdischarge Lithium battery cells overdischarge

88 159 0×9F BMS over voltage protection Lithium battery low voltage protection

89 163 0×A3 BMS overcurrent Lithium battery overcurrent

90 164 0×A4 Charging protection Lithium battery charging protection

91 156 0×9C Temperature protection Lithium battery temperature protection

F2A F4A F6A DIAGNOSTICS AND TROUBLESHOOTING
The Troubleshooting Chart, Table 24, describes the feult flash codes. The faults list is in the
numerical flash code order. The faults name, VCL name and CAN Object Index are listed,
induding the fault types. Possible causes, the set and clear conditions and the fault actions are
listed. Fault actions are «what the controller will do" when the fault is active. Table 23 lists the
fault actions and their associated 'bits' when using the System_Action variable (0x4E00 0x00).
Table 22 is a quick index to the faults by flash codes. Faults, after the set condition(s) have
been resolved, are usually cleared by cycling the keyswitch (On- Off^On), yet can be handled
using the applicable VCL Reset function, or the CAN NMT Reset function. These are
collectively referred to as Reset Controller.

THE DIAGNOSTICS PROCESS

Obtain diagnostics information in either of three ways: (l)by observing the fault codes flashed
by the controllers status indicator, (2) by reading the indicated fault (■• ； ) in the Curtis
Integrated Toolkit™ Programmer tool, or (3) the CAN Emergency Messages.
The status indicator is a translucent window on the cover, which blinks red and yellow LEDs.
Its illumination indicates the following information:
Off: Controller is not powered on, or is severely damaged.
Slow yellow blinking: Controller is operating normally;
Solid yellow or orange: Controller is in flash program mode, or corrupted software is
preventing the unit from completing the startup sequence (boot process).
Red/yellow flashing pattern: Fault code, review the fault table.
Solid red: Internal hardware fault detected by the supervisor or primary microprocessor, or
the controller has no software loaded.
Fast flashing red: Non-production/experimental/custom device profile software.
The Troubleshooting Chart Index, Table 22, indicates both the controllers LED flash
sequences and the CANbus Emergency Message hexadecimal Error Code values. The fault
flash pattern is decimal. For example, the Driver 1 Fault is assigned the flash code 10-1,
which illuminates in a sequence of 10 red LED flashes (xlO) followed by 1 yellow LED flash (xl)
before repeating. The hexadecimal code is OxAl, which will be the Error Code value in the
CAN Emergency message, explained below.
 TROUBLESHOOTING CHART INDEX
Table 22 Troubleshooting Chart Index
Flash Code Fault Name CAN Index Page

1-2 0x12 Controller Overcurrent 0x2510

1-3 0x13 Current Sensor 0x2832 205

1-4 0x14 Precharge Failed 0x2223

1-5 0x15 Controller Severe Undertemperature 0x2141

1-6 0x16 Controller Severe Overtemperature 0x2142 206

1-7 0x17 Severe B+ Undervoltage 0x2120

1-7 0x17 Severe KSI Undervoltage 0x2122

1-8 0x18 Severe B+ Overvoltage 0x2130 207

1-8 0x18 Severe KSI Overvoltage 0x2132

1-9 0x19 Speed Limit Supervision 0x2133

1-10 0x1 A Motor Not Stopped 0x2134 208

1-11 0x1 B Critical OS General 0x2109

1-12 0x1 C OS General 2 0x210A

1-14 0x1 E Motor Short 0x210E

209
1-13 0x1 D Reset Rejected 0x2110

2-2 0x22 Controller Overtemperature Cutback 0x2140

2-3 0x23 Undervoltage Cutback 0x2121

2-4 0x24 Overvoltage Cutback 0x2131

210
2-5 0x25 Ext 5V Simply Failure 0x2531

2-6 0x26 Ext 12V Su 叩 ly Failure 0x2532

2-8 0x28 Motor Temp Hot Cutback 0x2151

2-9 0x29 Motor Temp Sensor 0x2150 211

3-1 0x31 Main Driver 0x2222

3-2 0x32 EM Brake Driver 0x2320

212
3-3 0x33 Pump Driver 0x2420

3-4 0x34 Load Hold Driver 0x2430 213

3-5 0x35 Lower Driver 0x2440

3-6 0x36 IM Motor Feedback 0x2230 214

3-6 0x36 Sin Cos Motor Feedback 0x2232

3-7 0x37 Motor Open 0x2240

215
3-8 0x38 Main Contactor Welded 0x2220
 Table 22 Troubleshooting Chart Index, confd
Flash Code Fault Name CAN Index Page

3-9 0x39 Main Contactor Did Not Close 0x2221 215

3-10 0x3A Motor Setup Needed 0x2103

4-2 0x42 Throttle Input 0x2210 216

4-4 0x44 Brake Input 0x2310

4-6 0x46 NV Memory Failure 0x2830

4-7 0x47 HPD Sequencing 0x2211

217
4-7 0x47 Emer Rev HPD 0x2331

4-9 0x49 Parameter Change 0x2813

4-10 0x4A EMR Switch Redundancy 0x2817

5-1 0x51 User 1 Fault thru User 32 Fault 0x2710

5-2 0x52 User 2 Fault 0x2711

5-3 0x53 User 3 Fault 0x2712

5-4 0x54 User 4 Fault 0x2713

5-5 0x55 User 5 Fault 0x2720

5-6 0x56 User 6 Fault 0x2721

5-7 0x57 User 7 Fault 0x2722

5-8 0x58 User 8 Fault 0x2723

5-9 0x59 User 9 Fault 0x2730 218

6-1 0x61 User 10 Fault 0x2731

6-2 0x62 User 11 Fault 0x2732

6-3 0x63 User 12 Fault 0x2733

6-4 0x64 User 13 Fault 0x2740

6-5 0x65 User 14 Fault 0x2741

6-6 0x66 User 15 Fault 0x2742

6-7 0x67 User 16 Fault 0x2743

5-10 0x5A User 17 Fault 0x2750

5-11 0x5B User 18 Fault 0x2751

5-12 0x5C User 19 Fault 0x2752

5-13 0x5D User 20 Fault 0x2753

5-14 0x5E User 21 Fault 0x2760 219

5-15 0x5F User 22 Fault 0x2761

6-10 0x6A User 23 Fault 0x2762

 Table 22 Troubleshooting Chart Index, confd
Flash Code Fault Name CAN Index Page

6-11 0x6B User 24 Fault 0x2763

6-12 0x6C User 25 Fault 0x2770

6-13 0x6D User 26 Fault 0x2771

6-14 0x6E User 27 Fault 0x2772

6-15 0x6F User 28 Fault 0x2773

219
7-10 0x7A User 29 Fault 0x2780

7-11 0x7B User 30 Fault 0x2781

7-12 0x7C User 31 Fault 0x2782

7-13 0x7D User 32 Fault 0x2783

6-8 0x68 VCL Run Time Error 0x2820

7-1 0x71 OS General 0x2831

7-2 0x72 PDO Timeout 0x2541 220

7-3 0x73 Stall Detected 0x2231

7-7 0x77 Supervision 0x2840

7-9 0x79 Supervision Input Check 0x2841 22

8-2 0x82 PDO Mapping Error 0x2542

8-3 0x83 Internal Hardware 0x2835

8-4 0x84 Motor Braking Impaired 0x211A 222

8-7 0x87 Motor Characterization 0x2850

8-8 0x88 Encoder Pulse Error 0x2234

8-9 0x89 Parameter Out of Range 0x2811 224

9-1 0x91 Bad Firmware 0x2815

9-2 0x92 EM Brake Failed to Set 0x2321

9-3 0x93 Encoder LOS 0x2233

22
9-4 0x94 Emer Rev Timeout 0x2330

9-6 0x96 Pump BDI 0x2450

9-9 0x99 Parameter Mismatch 0x2812 226

9-10 0x9A Interlock Braking Supervision 0x2332

9-11 0x9B EMR Supervision 0x2333 227

10-1 0xA1 Driver 1 Fault 0x2160

10-2 0xA2 Driver 2 Fault 0x2161

228
10-3 0xA3 Driver 3 Fault 0x2162
10-4 0xA4 Driver 4 Fault 0x2163 229
 Table 22 Troubleshooting Chart Index, confd
Flash Code Fault Name CAN Index Page

10-5 0xA5 Driver 5 Fault 0x2164 230

10-6 0xA6 Driver 6 Fault 0x2165 231

10-7 0xA7 Driver 7 Fault 0x2166

232
10-8 0xA8 Driver Assignment 0x2632

10-9 0xA9 Coil Simply 0x2169

11-1 0xB1 Analog 1 Out Of Range 0x2620

11-2 0xB2 Analog 2 Out Of Range 0x2621

11-3 0xB3 Analog 3 Out Of Range 0x2622

11-4 0xB4 Analog 4 Out Of Range 0x2623

233
11-5 0xB5 Analog 5 Out Of Range 0x2624

11-6 0xB6 Analog 6 Out Of Range 0x2625

11-7 0xB7 Analog 7 Out Of Range 0x2626

11-8 0xB8 Analog 8 Out Of Range 0x2627

11-9 0xB9 Analog 9 Out of Range 0x2628

11-11 OxBB Analog 14 Out Of Range 0x262A

11-13 OxBD Analog 18 Out of range 0x262B

11-14 OxBE Analog 19 Out of range 0X262C

11-12 OxBC Analog Assignment 0x2631

12-1 0xC1 Branding Error 0x2860

234
12-2 0xC2 BMS Cutback 0x2861

12-5 0xC5 PWM Input 10 Out of Range 0x2629

12-7 0xC7 Analog 31 Out of Range 0x2106

12-8 0xC8 Invalid CAN Port 0x2107

12-9 0xC9 VCL Watchdog 0x2108

12-11 OxCB Primary State Error 0x2113

235
12-12 OxCC PWM Input 29 Out of Range 0x21 OD

12-13 OxCD PWM Input 28 Out of Range 0x21 OC

13-1 0xD1 Lift Input 0x2104 236

13-2 0xD2 Phase PWM Mismatch 0x2101

13-3 0xD3 Hardware Compatibility 0x2870

13-4 0xD4 Lower Input 0x2105 237

13-6 0xD6 Hazardous Movement 0x211C

13-13 OxDD IMU Failure 0x2114 238
 FAULT ACTIONS
The fault actions (effect of fault) in Table 23 use the action code bits individually or when
combined as listed in the fault action column in Table 24. The variable System^ction
(0x4E00), which is available in the CIT Programmer List Vie^w (I), or TACT, returns the
decimal number corresponding to the active fault action bit(s). The example illustrates how to
determine and plan for faults in both single and dual motor applications.

Table 23 Fault Actions

Action Code
Fault Action 1 Hex Bit(s) Description

NO_ACTION 0x00000000

ShutdownMotor 0x00000001 1 Disables the motor.

Shut down the Main contactor.
ShutdownMainContactor 0x00000002 2 Opens the main by de-energizing the main
contactor driver, only if Main Enable = On.
Shut down the EM Brake.
ShutdownEMBrake 0x00000004 3 Sets the EM Brake by de-energizing the driver, only
if the parameter Set EM Brake On Fault = On.

ShutdownThrottle 0x00000008 4 Set the Throttle_Command = 0%.

Shutdowninterlock 0x00000010 5 Set the lnterlock_State = Off.

ShutdownDriverl 0x00000020 6 Shut Down Driverl (e.g., turn off the driver's PWM).

ShutdownDriver2 0x00000040 7 Shut Down Driver2 (e.g., turn off the driver's PWM).

ShutdownDriver3 0x00000080 8 Shut Down Drivers (e.g., turn off the driver's PWM).

ShutdownDriver4 0x00000100 9 Shut Down Driver4 (e.g., turn off the driver's PWM).

ShutdownPD 0x00000200 10 Shut down Proportional Driver (legacy namd).

FullBrake 0x00000400 11 Set the Brake_Command = 100%.

ShutdownPump 0x00000800 12 Disables the pump.

TrimDisable 0x00001000 13 Disable Dual Drive trim calculation.

For a Dual Drive system, one controller has a
SevereDual 0x00002000 14 severe fault but the main contactor must stay closed
so the other controller can continue to operate.

ShutdownSteer 0x00004000 15 Steer angle = 0° (Dual Drive applicable).

For a Dual Drive system, it uses the max speed set
LOSDual 0x00008000 16
by the Dual LOS Max Speed parameter.

ShutdownDriver5 0x00010000 17 Shut Down Driver 5 (eg, turn off the driver's PWM).
Shut Down Driver 6 (as applicable to the controller;
ShutdownDriver6 0x00020000 18
e.g.,turn off the driver's PWM).

ShutdownDriver7 0x00040000 19 Shut Down Driver 7 (as a|jplicable to the controller;

e.g.jturn off the driver's PWM).
Shuts down (turns off) the Coil Supply (return)
ShutdownCoilSupply 0x00080000 20 voltage. (Note, based upon the controller model, this
will also shut down the low-side drivers).

Shutdownvehicle 0X01000C0F 25,12,11,4,3,2,1 Evokes all Fault Actions as per the indicated bits.
 Table 23 Fault Actions, contd

Action Code
Fault Action 1 Hex Bit(s) Description

ShutdownDualSteer 0x00100000 21 Sets the Steer Angle to zero.

RequestTractionStop 0x00200000 22 Regen braking.

When operating the single motor as a pump; see the
ShutdownLower 0x00400000 23
Hydraulic»Lower Settings menu.
When operating the single motor as a pump. See
ShutdownLift 0x00800000 24
the Hydraulic»Lift Settings menu.

ShutdownSteeringSafetyOutput 0x01000000 25 Not applicable to traction motor controllers.

ShutdownAII 0x7rrrrrrr sets all bits (1-31) = 2 Applies all the fault actions.

Fault Action Examples, where the System^Action variable applies to the

specific motor. 2

Stall_Detected, Flash Code 0x73. [7-3]

Fault Single Motor 二 ShutdownEMBrake + ShutdownThrottle

3

+ ShutdownMotor.
System^Acti Single Motor = 0x4h + 0x8h + Oxlh = OxDh = 13d = bits:
on 0000 1101.
Dual Drive (this motor) = SevereDual + ShutdownThrottle 3
+ ShutdownMotor.
Dual Drive (other motor) = SevereDual + LOSDual + TrimDisable.
Systemy^cti Dual Drive (this motor) = 8009h = 32,777d = bits: 1000 0000
0000 1001.
Dual Drive (other motor) 二 BOOOh = 45,056d = bits: 1011
0000 0000 0000.

1
Not all fault actions are applicable to all controllers.
2 Reference the dual drive supplement manual for further dual drive details and its
application.
3
Note that for the Stall_Detected, the ShutdownThrottle was removed since FOS 4.4.
 TROUBLESHOOTING CHART
Table 24 Fault Code Troubleshooting Chart

The text of Table 24 is available in the System Information (Sys Info) file.

Note that the indicated CAN Index is useful to search within Sys Info and the List View in CIT Programmer.
-The fault's "active” status (the icon in CIT Programmer) is sub-index of 01.
-The fault's "type ” has the sub-index of 06.
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
1-2 Controller Overcurrent 5. External short of phase U, SeZ: Phase current Shutdownvehicle:
0x12 Controller Overcurrent V, or W motor exceeded the current
0x2510 connections. ShutdownMotor
measurement limit ShutdownMainCont
Fault Type(s): 6. Speed encoder noise Clear: Reset Controller. actor
3. = Controller problems. ShutdownEMBrake
Overcurrent 7. Motor parameters are ShutdownThrottle
Phase U mistuned. FullBrake
4. = Controller 8. Controller defective. ShutdownPump
Overcurrent
Dual Drive
PhaseW This Motor:
5. = Controller Shutdownvehicle
Overcurrent Other Motor:
Phase V Shutdownvehicle
1-3 6. Current=lrmsSensor>120% 7. Leakage to vehicle frame Set: Controller current ShutdownMehicle
0x13 Current Current_Sensor from phase U, V, or W sensors have invalid (except Diimu):
0x2832 (short in motor stator). offset reading. Clear:
Fault Type(s): 1 ShutdownMotor
8. Controller defective. Reset Controller. ShutdownMainCont
actor
ShutdownEMBrake
ShutdownThrottle
FullBrake
Dual Drive
This Motor:
Same
Other Motor:
Same
1-4 Precharge Failed 5. An external load on the Set; The precharge Shutdownvehicle:
0x14 Precharge_Failed capacitor bank (B+ failed to charge the
0x2223 connection terminal) that ShutdownMotor
capacitor bank. Clear ShutdownMainCont
Fault Type(s): prevents the capacitor Cycle Interlock or Reset
5. = Abort bank from charging. actor
Controller. ShutdownEMBrake
6. = Energy Limit 6. See Programmer»System
Exceeded Monitor ShutdownThrottle
7. = Time Limit menu»Controller»Capacit FullBrake
Exceeded or Voltage. ShutdownPump
Dual Drive
This Motor:
Shutdownvehicle
Other Motor:
Shutdownvehicle
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
1-5 Controller is operating in
Controller Severe Undertemp 3. Set: Heatsink Shutdownvehicle:
0x15 Controller_Severe_Und an extreme environment. temperature
ertemp 0x2141 4. See Programmer»System
ShutdownMotor
below-40°C(-40°F). ShutdownMainCont
Fault Type(s):1 Monitor C/ear: Bring the heatsink actor
menu»Controller»Controll temperature above ShutdownEMBrake
er Temperature. -40°C (-40°F) and then ShutdownThrottle
Reset Controller. FullBrake
ShutdownPump
Dual Drive
This Motor:
ShutdownMotor
SevereDual
Other Motor:
SevereDual
LOSDual
TrimDisable
1-6 Controller Severe Overtemp 6. Controller is operating in Set Heatsink Shutdownvehicle:
0x16 Controller_Severe_ an extreme environment. temperature above
Overtemp 0x2142 ShutdownMotor
7. Excessive load on vehicle. +95°C. ShutdownMainCont
Fault Type(s): 1 8. Improper mounting of C/ear: Bring heatsink actor
controller. temperature below ShutdownEMBrake
+95°C, and then Reset ShutdownThrottle
9. See Programmer»System Controller.
Monitor menu»Controller» FullBrake
Controller Temperature. ShutdownPump
Dual Drive
This Motor:
Shutdownvehicle
Other Motor:
Shutdownvehicle
1-7 Severe B+ Undervoltage 6. Non-controller system Set When Main is closed No drive torque.
0x17 Severe_B_Plus_Underv drain on battery. and the FET Bridge is
Fault Action:
oltage 0x2120 7. Battery resistance too enabled, either the
Fault Type(s): high. undervoltage drive ShutdownPump
8. = Undervoltage 8. Battery disconnected while current cut back = 0% ShutdownMotor
cutback driving. for 64 ms or the Dual Drive
(0x343B = 0%) or 9. Blown B+ fuse or main Brownout Voltage is This Motor:
capacitor voltage contactor did not close. reached. TrimDisable
below safe limits for 10. Battery parameters are C/ear: Undervoltage ShutdownPump
64ms. misadjusted. drive current cut back > ShutdownMotor
9. = Commanded voltage 11. See Programmer»Monitor 0% for 100 ms and
could menu» capacitor voltage > Other Motor:
not be achieved due Controller»Capacitor brownout voltage. TrimDisable
to low capacitor Voltage.
 Table 24 Fault Code Troubleshooting Chart, cont'd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
1-7 Severe KSI Undervoltage 5. Non-controller system Set The KSI voltage ShutdownAII:
0x17 Severe_KSI_Undervolta drain on battery/keyswitch dropped into the
ge 0x2122 circuit wiring. Brownout Voltage ShutdownMotor
Fault Type(s): regions. ShutdownMainCont
6. Resistance in low power
3. = Brownout is (KSI) circuit is too high. C/ear Bring KSI voltage actor
disabled due 7. KSI disconnected while above Brownout ShutdownEMBrake
to invalid product ShutdownThrottle
driving. Voltage. Shutdowninterlock
data configuration. 8. Blown fuse.
4. = Keyswitch_Voltage 9. See Programmer»System
ShutdownDriverl
below brownout ShutdownDriver2
Monitor menu» ShutdownDriver3
threshold at bootup. Battery»Keyswitch
5. = Keyswitch_Voltage
ShutdownDriver4
Voltage. ShutdownDriver5
below 10. See the Voltage Limits ShutdownDriver6
low brownout in Chapter 3. ShutdownDriver7
threshold for 5 ms. ShutdownPD
6. = Keyswitch_Voltage
FullBrake
below ShutdownPump
high brownout ShutdownCoilSuppl
threshold for 64 ms. y Shutdownvehicle
ShutdownLower
ShutdownLift
Dual Drive
Same, both motors
1-8 Severe B+ Overvoltage 4. Battery parameters are Set: Capacitor bank Shutdownvehicle:
0x18 Severe_B_Plus_ misadjusted. voltage exceeded the
Overvoltage 0x2130 5. Battery resistance too high Severe Overvoltage limit
ShutdownMotor
Fault Type(s): 1 for given regen current with the FET bridge ShutdownMainCont
6. Battery disconnected while enabled.
actor
regen braking. Clear: Bring capacitor ShutdownEMBrake
7. See Programmer»System voltage below Severe
ShutdownThrottle
Monitor menu » Overvoltage limit, and FullBrake
Controller» Capacitor then Reset Controller. ShutdownPump
Voltage. Dual Drive
8. See the Voltage Limits in
This Motor:
Chapter 3. ShutdownMotor
SevereDual
Other Motor:
SevereDual
LOSDual
TrimDisable
1-8 Severe KSI Overvoltage 4. Battery-voltage applied to Sef;KSI voltage Shutdownvehicle:
0x18 Severe_KSI_ KSI (pin 1) exceeds the exceeded the Severe
Overvoltage 0x213 》 Severe Overvoltage limit. Overvoltage limit. ShutdownMotor
Fault Type(s): 1 5. See Programmer»Monitor C/ear Bring KSI voltage
ShutdownMainCont
menu》 Battery»Keyswitch below the Severe actor
Voltage. Overvoltage limit, and ShutdownEMBrake
6. See the Voltage Limits in then Reset Controller.
ShutdownThrottle
Chapter 3. FullBrake
ShutdownPump
Dual Drive
This Motor:
ShutdownMotor
SevereDual
Other Motor:
SevereDual
LOSDual
TrimDisable
 Table 24 Fault Code Troubleshooting Chart, cont'd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
1-9 Speed Limit Supervision 4. Motor speed detected that Set Motor rpm has Shutdowninterlock
0x19 Speed_Limit_Supervisi exceeds the limit set by exceeded the Max ShutdownEMBrake
on 0x2133 the Max Speed Speed Limit setting for
Fault Type(s): 1 Supervision parameter. the Max Speed Time Dual Drive
5. Misadjusted Max Speed Limit setting's duration. This Motor:
Supervision parameters. Clear: Reset Controller. Shutdowninterlock
6. See: ShutdownEMBrake
Programmer»Application Other Motor:
Setup»Max Speed Shutdowninterlock
Supervision menu. ShutdownEMBrake
1-10 Motor Not Stuped Set： Motor Not Stepped Shutdownvehicle:
0x1 A Motor_Not_Stopped ped parameters. is a safety function
ShutdownMotor
0x2134 implemented in the
Fault Type(s): 5. ShutdownMainCont
Programmer»Application Primary actor
4. = The motor moved Setup * Motor Not on a category
more architecture per ISO ShutdownEMBrake
revolutions than the Stopped ShutdownThrottle
6. Internal Controller fault or 13849. The purpose FullBrake
parameter, this function is to
Motor_Not_ conflict allowing the motor ShutdownPump
hazardous
Stopped_Position_Er to rotate when in the st 叩 when the AC motor is Dual Drive
ror setting. ped state. stepped and expected to This Motor:
5. = The motor moved stay sto 叩 ed (i.e., no Shutdownvehicle
faster throttle command).
than the parameter, There are three main Other Motor:
Motor_ checks done when the Shutdownvehicle
Not_Stopped_Speed motor is in the stepped
_Error (RPM)for 160 state, each of which can
ms. be independently
6. = The three-phase enabled and each of
drive which has a unique fault
has applied an type.
electrical frequency Clear: Reset Controller.
greater than the
1-11 CriticalMotor_Not_StoppedOSGeneral 4. (<100) Internal Fault Set Program execution ShutdownAII:
0x1 B Critical_OS_General 4. (>100) CIT version is too within the controller
ShutdownMotor
0x210 。 encountered a serious
Fault Type(s): old to fully ShutdownMainCont
problem and could not
(<100) Internal Fault. support the FOS recover. actor
Contact Curtis support. version. Clear: ShutdownEMBrake
(<100) Internal Fault. ShutdownThrottle
(>100) Update CIT Shutdowninterlock
(>100) An ill-formed or ShutdownDriverl
corrupted version,
re-package the ShutdownDriver2
application ShutdownDriver3
package was project, and
re-flash the ShutdownDriver4
loaded into ShutdownDriver5
controller. application
package. ShutdownDriver6
ShutdownDriver7
ShutdownPD
FullBrake
ShutdownPump
ShutdownCoilSuppl
y Shutdownvehicle
ShutdownLower
ShutdownLift
Dual Drive
Same, both motors
 Table 24 Fault Code Troubleshooting Chart, cont'd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
1-12 OS General 2 4. (<100) Internal Fault Set Program execution NO ACTION
0x1 C 0S_General_2 5. (>100) CIT version is too within the controller (controller is not
0x210A encountered a serious
Fault Type(s): old to fully operable)
problem and could not
(<100) Internal Fault. support the FOS recover.
Contact Curtis support. version. Dual Drive
Clear:
(<100) Internal Fault. Same, both motors
(>100) An ill-formed or (>100) Update CIT
corrupted 叩 version,
plication package re-package the
was loaded into project, and
controller. re-flash the a 叩
1-13 Reset Rejected This occurs if a controller is Set A reset was called at Shutdowninterlock
lication
0x1 Reset_Rejected 0x2110 commanded to reset while a time unsafe for the ShutdownThrottle
Fault Type(s): 1 controlling aPMAC motor controller. C/ear Cycle
D Dual Drive
that is not stationary. KSI.
Examples of resets include Same, both motors
sending an NMT reset or
calling reset_ controllerO in
VCL.
Note, the controller will NOT
reset when safe unless the
NMT is resent or
reset_controllerO is called
again. If legacy brownout is
set to off, the user may see
this fault if the controller is
turned off and on again at an
unsafe time, but in this
instance the controller will
1-14 Motor Short Check Motor Type and SetThe motor was NO ACTION
0x1 E Motor_Short 0x210E Parameters. See the PMAC shorted to avoid (controller is not
Fault Type(s): 1 dangerous voltage
considerations. Indicates operable)
whether the fault is presently levels. Clear ： Reset
active or not. controller. Dual Drive
2-2 Controller Overtemp Cutback 4. Controller is operating in Set Controller's heatsink Same,Reducedboth motors
0x22 Controler_Overtemp_C an extreme environment. temperature exceeded torque.
utback 0x2140 5. Excessive load on vehicle. 85°C. C/ear Bring Reduced
Fault Type(s): 6. Improper mounting of heatsink temperature regen-braking
4. = Controller heatsink controller which is below 85°C. torque.
high preventing controller
temperature cooling. Fault Action:
(affecting AC 7. Controller is None, unless a fault
phases) performance-limited at this action is
5. = Controller heatsink temperature. programmed in
high 8. See Programmer»System VCL.
temperature Monitor
(affecting pump menu»Controller»Temper Dual Drive
phase) ature. This Motor:
6. = Capacitor bank high TrimDisable
temperature Other Motor:
7. = AC phase FET high TrimDisable
temperature
8. = Pump phase FET
high
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis POSSIBLE CAUSES SET/CLEAR CONDITIONS FAULT ACTIONS
CODE Integrated Toolkit™)
2-3 UndervoKage Cutback 3. Batteries need recharging. Set Capacitor bank Reduced drive
0x23 Undervoltage_Cutback Controller is performance voltage dropped below torque.
0x2121 limited at this voltage. the Undervoltage Reduced regen
Fault Typefs): 1 4. Battery parameters are Cutoack limit with the braking torque.
misadjusted. FET bridge enabled.
5. Non-controller Clear: Bring the Fault Action:
system-drain on battery. capacitor voltage above None, unless a fault
6. Battery resistance too the controller's action is
high. Undervoltage programmed in
7. Battery disconnected while Cutbacklmt VCL.
driving.
8. Blown B+ fuse or main Dual Drive
contactor did not close.
9. See Programmer»System
This Motor:
Monitor menu»Controller» TrimDisable
Cutbacks» Undervoltage Other Motor:
Cutback. TrimDisable
10. See Programmer»System
2-4 Overvoltage Cutback 4. Normal operation. Fault Set The controller's Reduced brake
0x24 Overvoltage_ Cutback shows that regen braking capacitor bank voltage torque. Note: This
0x2131 currents elevated the exceeded the fault is declared only
Fault Type(s): 1 battery voltage during Overvoltage Cutback when the controller
regen braking. Controller limit with the FET bridge is running in regen.
is performance limited at enabled.
this voltage. Clear: Bring controller's Fault Action:
5. Battery parameters are capacitor voltage below
misadjusted. the Overvoltage Cutback None, unless a fault
6. Battery resistance too high limit.
action is
for given regen current programmed in
7. Battery disconnected while
VCL.
regen braking. Dual Drive
8. See Programmer»System
Monitor menu»Controller» This Motor:
Cutbacks» Overvoltage TrimDisable
Cutback. Other Motor:
9. See Programmer»System TrimDisabl
2-5 Ext 5V Supply Failure 3. External load Set Triggered by the Disables the 5V
0x25 Ext_5V_Supply_Failure on the +5V simply is too Fault Type indicated. Simply.
0x2531 low (i.e., a short circuit). Clear: Reset Controller,
Fault Type(s): 4. See the System Monitor » or Reset using the VCL Fault Action:
5. = The 5V supply is Outputs menu: variable Ext_5V_ None, unless a fault
outside 5V External_5V_Supply, Output_Enable. action is
±10%. Ext_5V_Current. programmed in
VCL.
6. = The current is
outside the
limits defined by:
-Ext_5V_Supply_Min.
2-6 Ext 12V Supply Failure 3. External load impedance Set Triggered by the Disables the 12V Su
0x26 Ext_ on the +12V simply is too Fault Type indicated. 叩 ly.
12V_Supply_Failure low (i.e., a short circuit). Clear: Reset Controller.
0x2532 4. See Programmer»System Or Reset using the VCL Fault Action:
Fault Type(s): Monitor menu»Outputs: variable Ext_ None, unless a fault
3. = The 12V simply is External_ 12V_Supply, 12V_0utput_Enable. action is
outside Ext_12V_Current. programmed in
12V ±15%. VCL.
4. = The current is
outside the
limits defined by:
-Ext_12V_Supply_Mi
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
2-8 Motor Temp Hot Cutback 3. Motor temperature is at or Set: Motor temperature Reduced Drive
0x28 Motor_ 7emp_Hot_ above the programmed is at or above the Torque.
Cutback Temperature Hot Temperature Hot
0x2151 setting—resulting in a parameter setting. If
Fault Type(s):1 reduction of controller C/ear: Bring the motor MotorBrakingTherm
drive current. temperature within al CutBack_Enable
4. The motor temperature range. = On, then Regen
and sensor control Braking Torque is
parameters are reduced.
misadjusted.
5. See Programmer»AC Fault Action:
Motor Setup None, unless a fault
»Temperature Sensor. action is
programmed in
VCL.
Dual Drive
2-9 Motor Temp Sensor 3. Motor thermistor is not Set: Motor thermistor Motor
This temperature
0x29 Motor_ 7emp_Sensor connected properly. input (pin 9) is at the cutback disabled.
0x2150 4. Sensor polarity (between voltage rail.
Fault Type(s): 1 Pin 8 and Pin 18) is Clear: Bring the motor Fault Action:
incorrect. thermistor input voltage None, unless a fault
5. The motor temperature within range. action is
and sensor parameters programmed in
are misadjusted. VCL.
6. See Programmer»System
Monitor menu»AC Dual Drive
Motor»Temperature. This Motor:
LOSDual
Other Motor:
3-1 MAIN DRIVER 3. Open or short on driver Set: Main Contactor Shutdownvehicle:
0x31 Main_Driver_Fault load. driver is either open or
0x2222 4. Dirty connector pins at shorted. ShutdownMotor
Fault Type(s): controller or contactor coil. This fault can be set ShutdownMainCont
4. = Driver current 5. Bad connector crimps or only when Main Enable actor
exceeded faulty wiring. ShutdownEMBrake
hardware limits. = On. Clear: ShutdownThrottle
6. Driver overcurrent, as set Restore/repair
5. = Driver current by the Driver x FullBrake
exceeded any external wiring or ShutdownPump
Overcurrent parameter. device-coil to their
configured 7. See
over-current limits. correct state, then Reset Dual Drive
Programmer»Controller Controller.
6. = Driver commanded Setup»Outputs» Driver x » This Motor:
PWM Driver x Overcurrent. Shutdownvehicle
active, using Other Motor:
diagnostic pulses. Shutdownvehicle
Voltage measured
high, should be low.
Typically caused by
driver failure, or
driver pin short to
high.
7. = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
low, should be high.
Either open circuit, or
driver pin short to
ground.
8. = Driver commanded
PWM
is 0, and voltage
measured low
(should be high).
 Table 24 Fault Code Troubleshooting Chart, cont'd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
3-2 EM Brake Driver Fauh 6. Open or short on driver Set Electromagnetic ShutdownEMBrake
0x32 EM_Brake_Driver_fault load. brake driver (pin 4) is ShutdownThrottle
0x2320 7. Dirty connector pins at either open or shorted. FullBrake
Fault Type(s): controller or contactor coil. This fault can be set
4. = Driver current 8. Bad connector crimps or only when EM Brake Dual Drive
exceeded faulty wiring. Type This Motor: Same
hardware limits. 9. Driver overcurrent, as set >0. Other Motor:
5. = Driver current by the Driver x Same
exceeded Overcurrent parameter. C/ear Restore/repair any
configured 10. See external wiring or
over-current limits. Programmer»Controller device-coil to their
6. = Driver commanded Setup»Outputs»Driver x» correct state, then Reset
PWM Driver x Overcurrent. Controller.
active, using
diagnostic pulses.
Voltage measured
high, should be low.
Typically caused by
driver failure, or driver
pin short to high.
7. = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
low, should be high.
Either open circuit, or
driver pin short to
ground.
8. = Driver commanded
PWM is
0, and voltage
measured low (should 3. Open or short on driver Set The assigned
3-3 Pump Driver Shutdownpump
0x33 Pump_Driver_fault load. pumpcontactor driver is
0x2420 4. Dirty connector pins at either open or shorted,
Fault Type(s): controller or contactor coil. or exceeded its Dual Drive
4. = Driver current 5. Bad connector crimps or overcurrent setting. This Motor:
exceeded faulty wiring. Shutdownpump
hardware limits. 6. Driver overcurrent, as set Note: This fault
5. = Driver current typically associated with Other Motor:
by the Driver Shutdownpump
exceeded Overcurrent parameter. non-pump
configured operating a DC pump
7. See
over-current limits. Controller Setup»Outputs via a Driver, yet can apply
6. = Driver commanded » Driver x» DriverX controllers with
PWM Overcurren
active, using pump (e.g., the
diagnostic pulses. F2-T/F2-C) is also so
Voltage measured configured.
high, should be low. C/ear Correct the open
Typically caused by or short, and then Reset
driver failure, or driver Controller.
pin short to high.
7. = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
low, should be high.
Either open circuit, or
driver pin short to
ground.
8. = Driver commanded
PWM is
0, and voltage
measured low (should
 Table 24 Fault Code Troubleshooting Chart, cont'd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
3-4 Load Hold Driver Fault 3. Open or short on driver Set The assigned load NO ACTION
0x34 Load_Hold_Driver_Fault load. hold driver is either open
0x2430 4. Dirty connector pins at or shorted, or exceeded Dual Drive
Fault Type(s): controller or contactor coil. its overcurrent setting. Same, both motors
5. = Driver current 5. Bad connector crimps or C/ear Correct the open
exceeded faulty wiring. or short, and then Reset
hardware limits. 6. Driver overcurrent, as set Controller.
6. = Driver current by the Driver x
exceeded Overcurrent parameter.
configured 7. See Programmer»
over-current limits. Controller Setup »
7. = Driver commanded Outputs»DriverX » DriverX
PWM Overcurrent.
active, using
diagnostic pulses.
Voltage measured
high, should be low.
Typically caused by
driver failure, or driver
pin short to high.
8. = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
low, should be high.
Either open circuit, or
driver pin short to
ground.
9. = Driver commanded
PWM is
0, and voltage
measured low (should
 Table 24 Fault Code Troubleshooting Chart, cont'd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
3-5 Lower Driver Fault 4. Open or short on driver Set The assigned lower ShutdownPD
0x35 Lower_Driver_Fault load. driver is either 叩 en or
0x2440 5. Dirty connector pins at shorted, or exceeded its Dual Drive
Fault Type(s): controller or contactor coil. overcurrent setting. This Motor: Same
4. = Driver current 6. Bad connector crimps or Clear: Correct the open Other Motor: Same
exceeded faulty wiring. or short, and then Reset
hardware limits. 7. Driver overcurrent, as set Controller.
5. = Driver current by the Driver x
exceeded Overcurrent parameter.
configured 8. See Programmer»
over-current limits. Controller Setup»Outputs»
6. 二 Driver commanded Driver x » Driver x
PWM Overcurrent.
active, using
diagnostic pulses. Note:
Voltage measured See Driven* Fault
high, should be low. * Driver 1 is the PD Driver,
Typically caused by therefore the Lower Driver
driver failure, or fault cascades to the Driver
driver pin short to 1 fault (see flash code 10-
high. 1).
7. = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
low, should be high.
Either open circuit, or
driver pin short to
ground.
8. = Driver commanded
PWM
is 0, and voltage
measured low
3-6 IM (should
MOTOR be
FEEDBACK 1. Motor encoder failure. Set: Motor ShutdownEMBrake
0x36 IM_Motor_Feedback 2. Bad crimps or faulty wiring. position/speed sensor ShutdownMotor
0x2230 3. See Programmer»System fault.
Fault Type(s): Dual Drive
1. Controller saw a fast Monitor menu »AC Motor: Clear: Either Reset This Motor:
Motor RPM. Controller, or if SevereDual
transition to zero parameter LOS Upon ShutdownMotor
speed. 4. See Programmer»AC Encoder Fault = On and
Motor Setup » Quadrature Interlock has been Other Motor:
2. Encoder su 叩 ly SevereDual
failed. Encoder» Encoder Fault cycled, then the Encoder
Setup. LOSDual
3. Sine or Cosine input Fault is cleared and TrimDisable
differs from expected. Encoder LOS fault (flash
4. Controller saw sensor code 9-3) is set, allowing
failure at speed. limited motor control.
5. Unrealistic motor
acceleration seen.
6. Resolver loss of
signal.
7. Resolver degradation
of signal.
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
3-6 PM Motor Feedback 1. Motor encoder failure. Set Motor Shutdownvehicle:
0x36 PM_Motor_Feedback 2. Bad crimps or faulty position/speed Sin/ Cos
0x2232 wiring. sensor fault. ShutdownMotor
Fault Typefs): 3. See Programmer»System Clear: Reset Controller. ShutdownMainCont
1. Controller saw a fast Monitor menu» Hardware actor
transition to zero Inputs: Analog ShutdownEMBrake
speed. 3 and 4. ShutdownThrottle
2. Encoder supply failed. FullBrake
3. Sine or Cosine input ShutdownPump
differs from expected. Dual Drive
4. Controller saw sensor Same, both motors
failure at speed.
5. Unrealistic motor
acceleration seen.
6. Resolver loss of
signal.
7. Resolver degradation
of signal.
0x36 8.MotorResolverOpen loss of 1. Motor phase is open. Set: Motor phase U, V,or Shutdownvehicle:
Motor_Open 0x2240 2. Bad crimps or faulty W detected open.
Fault Type(s): 1 Clear: Reset Controller. ShutdownMotor
wiring. ShutdownMainCont
actor
ShutdownEMBrake
ShutdownThrottle
FullBrake
ShutdownPump
Dual Drive
This Motor:
ShutdownMotor
SevereDual
Other Motor:
SevereDual
LOSDual
ThmDisable
3-8 Main Contactor Welded 1. Main contactor tips are Set Just prior to the Shutdownvehicle:
0x38 Main_ Contactor_ welded closed. main contactor closing,
Welded 0x2220 2. Motor phase U or Vis the ShutdownMotor
Fault Type(s): 1 disconnected or open. capacitor bank voltage ShutdownMainCont
3. An alternate voltage path (B+ connection terminal) actor
(such as an external was loaded (via the ShutdownEMBrake
circuit to B+) is providing a motor) for a short time ShutdownThrottle
current to the capacitor and the voltage did not FullBrake
bank (B+ connection discharge, indicating a ShutdownPump
terminal). direct-contact to the Dual Drive
battery (i.e., Main tips Same, both motors
are welded closed).
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
3-9 Main Contactor Did Not Close Type 1: Set With the main Shutdownvehicle:
0x39 Main_Contactor_Did_N 1. Main contactor did not contactor commanded
ot_Close 0x2221 close. closed, the capacitor ShutdownMotor
Fault Type(s): 2. Main contactor tips are bank voltage (B+ ShutdownMainCont
1 = Main did not close oxidized, burned, or not connection terminal) did actor
when commanded. making good contact. not charge to B+. ShutdownEMBrake
2 = Main disconnected 3. An external load on the Clear: Reset Controller. ShutdownThrottle
during 叩 eration. capacitor bank (B+ FullBrake
3 = Battery disconnected connection terminal) is ShutdownPump
with preventing the capacitor Dual Drive
main enable off. bank from charging. Same, both motors
4. Blown B+ fuse.
5. Main Contactor
parameters mistuned;
• Main Pull-in Voltage,
• Main Holding Voltage.
Type 2:
1. Main contactor opened
during op eration (while
commanded closed).
2. Driver wiring to contactor's
coil (e.g., pin wiring)
removed during operation.
3. Contactor/coil defective.
Type 3:
Battery not connected to B+
when main enable is off and
interlock applied.
3-10 Motor Set 叩 Needed Motor setup is required. Set: Default for both Fault Action:
0x3A Motor_Setup_Needed Please refer to fault type. ACIM and PMAC
0x2103 Bit1: The current regulator motors. None.
needs to be configured. Clear: Run the Yet, the motor will
Fault Type(s): Bit2:The slip gain test needs appropriate motor not operate until the
Hex# to be run. commissioning motor configuration
Bit1 -4 Bit3: The base speed test sequences. and/or
Binary 0000 => bits 4 needs to be run. commissioning tests
3 21 Bit4: The automated test are complete.
needs to be run (full
4-2 Throttle Input 1. motorvoltage exceeded
Throttle Set Throttle voltage ShutdownThrottle
0x42 Throttlejnput the Analog Low or Analog exceeded the Analog
0x2210 High parameters for the Low or Analog High Dual Drive
analog input defined for parameters for the This Motor:
Fault Type(s):* the throttle input. analog input defined for ShutdownThrottle
1 = Outside the Low or 2. See the throttle input. Clear: Other Motor:
High parameter. Programmer»Controller Bring throttle input
Setup»Inputs»Analog 1 No Action
Throttle voltage voltage within the Min
exceeded the Analog Type. and Max thresholds.
Low or Analog High 3. See Reset Controller.
parameters for the Programmer»Controller
analog input defined Setup»Inputs»Configure.
for the throttle i 叩 ut
2 = Input 1 fault
diagnostics may
be either out of range
if it is configured as a
voltage input, or may
include potentiometer
faults if configured as
a 2/3- wire pot.
 Table 24 Fault Code Troubleshooting Chart, conVd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
4-4 Brake Input Brakejnput Triggered by the respective Set: See Throttle Input. FullBrake
0x44 0x2310 fault diagnostic associated Note: An Input 1 fault
with the brake input source diagnostics may be out Dual Drive
Fault Type(s): 1* Same, both motors.
(assigned analogX input). of range if it is
configured as a voltage Any additional fault
input or may include action that is
potentiometer faults if programmed in VCL
configured as a 2/3-wire (see AnalogX).
pot. Clear: Bring Brake
Input voltage within the
4-6 NV Memory Failure 1. Failure to read or write to Min and Max thresholds. ShutdownAII:
Set Controller
0x46 NV_Memory_Failure nonvolatile (NV) memory. system tried to read or
0x2830 2. Internal controller fault. write to EEPROM ShutdownMotor
Fault Type(s): memory and failed. ShutdownMainCont
1 = Invalid checksum. Clear: Download the actor
2 = NV write failed. 3 correct software and ShutdownEMBrake
= NV read failed. 4 = matching parameter ShutdownThrottle
NV write did not default settings into the Shutdowninterlock
complete controller and Reset ShutdownDriverl
during power down. Controller. ShutdownDriver2
ShutdownDriver3
ShutdownDriver4
ShutdownDriver5
ShutdownDriver6
ShutdownDriver7
ShutdownPD
FullBrake
ShutdownPump
ShutdownCoilSuppl
y Shutdownvehicle
ShutdownLower
ShutdownLift
Dual Drive
Same, both motors
4-7 HPD Sequencing 1. Incorrect sequence in Set: HPD (High Pedal ShutdownThrottle
0x47 Hpd_Sequencing application of Keyswitch, Disable) or SRO (Static
0x2211 Interlock, Direction, or Return to Off) Dual Drive
Fault Type(s): Throttle. sequencing fault caused Same, both motors
Type 1 through 9 - HPD 2. Faulty wiring, crimps, or by incorrect sequence of
depends on switches at KSI, Interlock, KSI, interlock, direction,
HPD_SRO_Type Direction, or Throttle. and throttle inputs.
Type 10 - Interlock 3. Moisture in above-noted Clear ： Re 叩 ply inputs in
AntiTiedown digital input switches correct sequence.
causing invalid (real)
On/Off state.
4. Verify input switch status.
See Programmer»System
Monitor menu»Hardware
Inputs» Switch Status.
5. Verify Throttle. See
4-7 EMER Rev HPD EmergencyProgrammer»ReverseSystem Set At the conclusion of ShutdownThrottle
0x47 Emer_Rev_Hpd 0x2331 operation has concluded, but Emergency Reverse, the ShutdownEMBrake
Fault Type(s): 1 the throttle, forward and fault was set because
reverse, and interlock inputs various inputs were not Dual Drive
have not been returned to returned to neutral. Same, both motors
neutral. Clear: If EMRJnterlock =
On, clear the interlock,
throttle, and direction
inputs.
If EMRJnterlock = Off,
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
4-9 Parameter Change While the Interlock was On, a Set Adjustment of a Shutdownvehicle:
0x49 Parameter_Change safetybased parameter was parameter setting that
0x2813 changed. Parameters with requires cycling of KSI. ShutdownMotor
Fault Type(s): this property are marked Clear: Reset Controller. ShutdownMainCont
Reports the CAN Object with a [PCF] (Parameter actor
ID of parameter. Change ShutdownEMBrake
Fault) in the Parameter ShutdownThrottle
menu FullBrake
listings. ShutdownPump
Dual Drive
Same, both motors
4-10 EMR Switch Redundancy 1. Either or both Emergency Set The Emergency Shutdowninterlock
0x4A Emr_Switch_Redundan Reverse input switches Reverse Switch NO ShutdownEMBrake
cy 0x2817 are inoperative, resulting input does not agree
Fault Type(s):1 in an invalid state. with the Emergency Dual Drive
Reverse Switch NC Same, both motors
NO NC input. They are o 叩
On Off valid osites: NO and NC.
Off On valid Clear: Correct the two
switch states. Reset
On On invalid Controller.
Off Off invalid
2. Ingress of dirt or moisture
in switch(es).
5-1 USER 1 FAULT 1. These faults (and fault Set: See User/OEM See User/OEM
0x51 User_{ 1,2... 32}_Fault actions) can be defined by documentation. documentation.
0x2710 the User/ OEM and are Clear: See User/OEM
Fault Type(s): OEM implemented in the documentation.
Definable. application-specific VCL
software.
5-2 USER 2 FAULT See User 1 fault (above) Set See User/OEM See User/OEM
0x52 0x2711 documentation. documentation.
Clear: See User/OEM
USER 3 FAULT documentation.
5-3
0x53 0x2712
5-4 USER 4 FAULT
0x54 0x2713
5-5 USER 5 FAULT
0x55 0x2720
5-6 USER 6 FAULT
0x56 0x2721
5-7 USER 7 FAULT
0x57 0x2722
5-8 USER 8 FAULT
0x58 0x2723
5-9 USER 9 FAULT
0x59 0x2730
6-1 USER 10 FAULT
0x61 0x2731
6-2 USER 11 FAULT
0x62 0x2732
6-3 USER 12 FAULT
0x63 0x2733
6-4 USER 13 FAULT
0x64 0x2740
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
6-5 USER 14 FAULT See User 1 fault (above) Set: See User/OEM See User/OEM
0x65 0X2741 documentation. Clear: documentation.
USER 15 FAULT See User/OEM
6-6 documentation.
0x66 0X2742
6-7 USER 16 FAULT
0x67 0X2743
5-10 USER 17 FAULT
0x5A 0X2750
5-11 USER 18 FAULT
0x5B 0X2751
5-12 USER 19 FAULT
0x5C 0x2752
5-13 USER 20 FAULT
0x5D 0x2753
5-14 USER 21 FAULT
0x5E 0x2760
5-15 USER 22 FAULT
0x5F 0x2761
6-10 USER 23 FAULT
0x6A 0x2762
6-11 USER 24 FAULT
0x6B 0x2763
6-12 USER 25 FAULT
0x6C 0x2770
6-13 USER 26 FAULT
0x6D 0x2771
6-14 USER 27 FAULT
0x6E 0x2772
6-15 USER 28 FAULT
0x6F 0x2773
7-10 USER 29 FAULT
0x7A 0x2780
7-11 USER 30 FAULT
0x7B 0x2781
7-12 USER 31 FAULT
0x7C 0x2782
7-13 USER 32 FAULT
0x7D 0x2783
 Table 24 Fault Code Troubleshooting Chart, cont'd
FLASH FAULT NAME (Curtis SET/CLEAR
POSS 旧 LE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
6-8 VCL Run Time Error 1. Runtime errors are defined Set VCL Run Time Error ShutdownAII:
0x68 VCL_Run_ Time_Error using the VCL Error detected. Clear: Edit the
0x2820 Module and VCL Error. VCL application software ShutdownMotor
Fault Type(s):1 See the System to fix this error condition; ShutdownMainCont
Information flash the new compiled actor
• Curtis software and matching ShutdownEMBrake
Toolkit™» VCL Studio» ShutdownThrotUe
parameter Shutdowninterlock
Help» Reset Controller.
Information. ShutdownDriverl
2. Using driver control ShutdownDriver2
commands in VCL can ShutdownDriver3
lead to VCL runtime errors ShutdownDriver4
if the VCL command and ShutdownDriver5
the driver assignment do ShutdownDriver6
not match. ShutdownDriver7
ShutdownPD
FullBrake
ShutdownPump
ShutdownCoilSuppl
y Shutdownvehicle
ShutdownLower
ShutdownLift
Dual Drive
Same, both motors
7-1 OS General Physical damage from Set Internal controller ShutdownAII:
0x71 OS_General 0x2831 external sources/events. fault detected.
Fault Type(s):1 Clear: Reset Controller. ShutdownMotor
ShutdownMainCont
actor
ShutdownEMBrake
ShutdownThrottle
Shutdowninterlock
ShutdownDriverl
ShutdownDriver2
ShutdownDriver3
ShutdownDriver4
ShutdownDriver5
ShutdownDriver6
ShutdownDriver7
ShutdownPD
FullBrake
ShutdownPump
ShutdownCoilSuppl
y Shutdownvehicle
ShutdownLower
ShutdownLift
Dual Drive
Same, both motors
7-2 PD0 Timeout 1. The time between CAN Sef:Time between CAN Shutdowninterlock
0x72 PDO_Timeout 0x2541 PDO messages received PDO messages
Fault Type(s):1 exceeded the PDO received exceeded the Dual Drive
Timeout Period as defined PDO Timeout Period. Same, both motors
by the Event Timer C/ear: Receive CAN
parameter. NMT message, or Reset
2. Adjust PDO Settings. See Controller.
Programmer»Application
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
7-3 Stall Detected 1. Stalled motor. Set: No motor encoder ShutdownEMBrake
0x73 Stall_Detected 0x2231 2. Motor encoder failure. movement detected. ShutdownMotor
Fault Type(s): 1 3. Bad crimps or faulty Clear ： Either Reset
wiring. 4. Problems with Controller, or if Control Mode
power parameter LOS Upon changed to LOS
supply for the motor Encoder Fault = On and (Limited Operating
encoder. Interlock has been Strategy).
5. See Programmer »System cycled, then the Stall
Monitor menu»AC Motor» Detected fault is cleared Dual Drive
Motor RPM. and the Encoder LOS This Motor:
fault (flash code 9-3) is SevereDual
set, allowing limited ShutdownMotor
motor control. Other Motor:
SevereDual
LOSDual
TrimDisable
7-7 Supervision Internal controller fault. Set Internal controller ShutdownAII:
0x77 Supervision failure. Clear: Reset
0x2840 ShutdownMotor
Controller. ShutdownMainCont
Fault Type(s):
1-4 = Primary Init Error actor
ShutdownEMBrake
10 = Primary Task ShutdownThrottle
Queue Check Shutdowninterlock
12= Primary ALU Check ShutdownDriverl
13 = Primary Message ShutdownDriver2
Watchdog 100-103 = ShutdownDriver3
ShutdownDriver4
Supervisor Init Error ShutdownDriverS
104-108 = Supervisor ShutdownDriver6
Write Error ShutdownDriver7
109 = Supervisor ShutdownPD
Task FullBrake
Queue Check ShutdownPump
110= Supervisor ALU ShutdownCoilSuppl
y Shutdownvehicle
Check ShutdownLower
111= Supervisor ShutdownLift
Message
Watchdog Dual Drive
113-118 = Supervisor
Set Damaged Controller. Same, both motors
7-9 Supervision Input Internal controller fault. ShutdownAI
0x79 Supervision_lnput_Che Clear: Reset Controller.
ck 0x2841 ShutdownMotor
Fault Type(s): 1 ShutdownMainCont
actor
ShutdownEMBrake
ShutdownThrottle
Shutdowninterlock
ShutdownDriverl
ShutdownDriver2
ShutdownDriver3
ShutdownDriver4
ShutdownDriverS
ShutdownDriver6
ShutdownDriver7
ShutdownPD
FullBrake
ShutdownPump
ShutdownCoilSuppl
y Shutdownvehicle
ShutdownLower
ShutdownLift
Dual Drive
Same, both motors
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
8-2 PDO Mapping Error 1. The PDO Map has too Set Incorrect PDO map PDO message
0x82 PDO_Mapping_Error many data bytes assigned detected. Clear: Reset disabled.
0x2542 or has objects mapped
Fault Type(s): 1 that are not compatible. Controller. Fault Action:
2. Adjust PDO Settings. See None, unless a fault
Programmer»Application action is
Setup» CAN Interface» programmed inVCL.
PDO Setups.
Dual Drive
8-3 Internal Hardware Internal controller fault Set Internal controller Shutdownvehicle：
0x83 IntemaLHardware detected. fault detected.
0x2835 Clear: Reset Controller. ShutdownMotor
Fault Type(s): ShutdownMainCont
Curtis hardware code. actor
ShutdownEMBrake
ShutdownThrottle
FullBrake
ShutdownPump
Dual Drive
Same, both motors
8-4 Motor Braking Impaired 1. Battery overcharged, Set: Overallcutback Shutdowninterlock:
0x84 Motor_BrakingJmpaired excessive motor or 0x32D9 fell below
0x211 A controller heating, or Motor_Braking_
Fault Type(s): 1 misadjusted parameters. lmpaired_ Threshold for Dual Drive
2. Motor braking was Motor_ This Motor:
impaired beyond a safe Brakingjmpaired_ Time Shutdowninterlock
threshold. during regen (braking). Other Motor:
Clear: Reset interlock. Shutdowninterlock
8-7 Motor characterization failed Set: Motor
Motor Characterization Error Shutdownvehicle:
0x87 Motor_ Characterization during characterization characterization failed
0x2850 process. The fault type during the motor ShutdownMotor
Fault Type(s): indicates the cause. characterization ShutdownMainCont
1 Failure to determine process. actor
encoder pulses. Must Type 84: Clear: Reset Controller. ShutdownEMBrake
be set manually. ShutdownThrottle
During commissioning, if the FullBrake
72Temp sensor fault Type 84 fault occurs, check
73 Motor hot. ShutdownPump
that the Sin/Cos signal
74 Controller voltages at their maximums Dual Drive
temperature cutback. and minimums have Same, both motors
76 Undervoltage differences less than 78mV.
cutback. (i.e., that ISinmax A Cosmaxl
77 Overvoltage cutback. < 78mV and the ISinmin A
78 Encoder not reading Cosminl < 78mV). If the
properly. differences are greater than
79 Current Regulator 78mV (e.g., 100mV), it will
Tuning out of range. trigger the Type 84 fault and
80 Current Regulator abort the motor
Tuning out of range. characterization routine.
81 Encoder signal seen
but step size not
auto-detected, it must Types are also listed in
be set manually. Chapter 6, Table 21.
82 Aborted
commissioning.
83 Sensor signal too
noisy for
characterization.
84 Motor not rotating,
Sin/Cos sensor
voltages out of spec,
or Multiturn Sensor
setting incorrect.
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis
POSSIBLE CAUSES SET/CLEAR CONDITIONS FAULT ACTIONS
CODE Integrated Toolkit™)
8-7 86 Sin/Cos sensor
0x87 missing or sensor
voltage out of range.
87 PMAC Motor Type
must be set before
commissioning.
88 PMAC motor fell to
zero speed, check
your system for
excessive friction or
loading, retry with a
higher test speed, or
consult CCA.

91 PMAC motor not

rotating or motor type
incorrect.
92 PMAC Motor not
accelerating. Low
acceleration.
93 Started motor
characterization while
motor was spinning.
94-98 PMAC lag
compensation out of
range.
99 PMAC Motor not
accelerating. Low
acceleration.
102 PMAC motor
temp sensor.
103 PMAC motor
temp hot cutback.
104 PMAC controller
temp cutback.
106 PMAC
undervoltage cutback.
107 PMAC
overvoltage cutback.
108 Commissioning
stepped by user.
500 The Hall
patterns do not
match the pattern
table during refining
process.
501 Hall patterns
and angles are not
consistent during
rebuilding of sectors
in reverse direction.
502 The rebuilt
angle in reverse
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
8-8 Encoder Pulse Error 1. Encoder Steps parameter Set Detected wrong Shutdownvehicle:
0x88 Encoder_Pulse_Error does not match the actual setting of the Encoder ShutdownMotor
0x2234 motor encoder. Steps parameter. Clear: ShutdownMainCont
Fault Typefs): 1 2. Verify parameter settings: Ensure the Encoder actor
AC Motor Setup» Steps parameter ShutdownEMBrake
Quadrature Encoder matches the actual ShutdownThrottle
»Encoder Steps. encoder. FullBrake
Reset Controller. ShutdownPump
Dual Drive
Same, both motors
8-9 Parameter Out of Range1. Parameter value detected Set Parameter detected Shutdownvehicle：
0x89 Parameter__Out_Of_R outside of the limits. outside of limits.
ange 0x2811 2. Use CIT Clear: Bring parameter ShutdownMotor
Fault Type(s): orthe1313HHPtoview the within its limits. ShutdownMainCont
Reports the CAN Object parameter's range and actor
ID of parameter. adjust the parameter's ShutdownEMBrake
value. ShutdownThrottle
FullBrake
ShutdownPump
Dual Drive
Same, both motors
9-1 Bad Firmware The firmware in the controller Set The loaded software ShutdownAII:
0x91 Bad_Firmware 0x2815 is incorrect. is not compatible with
Fault Type(s): 1 1. The CRC of the application the controller hardware. ShutdownMotor
or OS does not match. Clear: Load the ShutdownMainCont
2. The application was built matching software. actor
with an incompatible OS Verify that the controller ShutdownEMBrake
version. model matches the cdev ShutdownThrottle
version for the project Shutdowninterlock
and the VCL Studio ShutdownDriverl
application. ShutdownDriver2
ShutdownDriver3
ShutdownDriver4
ShutdownDriver5
ShutdownDriver€
ShutdownDriver7
ShutdownPD
FullBrake
ShutdownPump
ShutdownCoilSuppl
y Shutdownvehicle
ShutdownLower
ShutdownLift
Dual Drive
Same, both motors
9-2 1. Vehicle movement sensed
EM Brake Failed To Set Set After the EM Brake Position Hold is
0x92 EM_Brake_F^iled_to_S after the EM Brake has was commanded to set engaged when
et 0x2321 been commanded to set. and time has elapsed to Interlock = On.
Fault Type(s): 1 2. EM Brake will not hold the allow the brake to fully
motor from rotating. engage, vehicle Fault Action:
movement has been None, unless a fault
sensed. action is
Clear: programmed in VCL
1. Activate the Throttle
(EM Brake type 2). Dual Drive
2. Activate the Interlock Same, both motors
(EM Brake type 1).
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis
POSSIBLE CAUSES SET/CLEAR CONDITIONS FAULT ACTIONS
CODE Integrated Toolkit™)
9-3 Encoder LOS 1. Limited Operating Strategy Set Either the Encoder LOS Mode
0x93 Encoder_LOS 0x2233 (LOS) control mode has Fault (flash code 3-6) or
Fault Type(s): 1 been activated as a result Stall Detected (flash Fault Action:
of either an Encoder Fault code 7-3) was detected. None, unless a fault
(flash code 3-6) ora Stall If the parameter LOS action is
Detected fault (flash code Upon Encoder Fault = programmed in
7-3). On and the Interlock has VCL.
2. Motor encoder failure. been cycled, then the
Dual Drive
3. Bad crimps or faulty wiring. Encoder LOS (flash
code 9-3) control mode Same, both motors
4. Vehicle has stalled. is activated, allowing
limited motor control
(limp home mode).
C/ear: Cycle KSI or, if
LOS Mode was
activated by the Stall
Detected fault, clear by
9-4 Emer Rev Timeout 1. Emergency Reverse was ensuring Set:
the encoder
ShutdownThrottle
0x94 Emer_Rev_Tlmeout activated and concluded Reverse was activated
0x2330 ShutdownEMBrake
because the EMR Timeout and ran until the EMR
Fault Type(s): 1 timer expired. Timeout timer expired. Dual Drive
2. The emergency reverse C/ear:Turn the Same, both motors
input is stuck On. emergency reverse input
9-6 Pump BDI 1. The BDI is below the Set: Pump No Fault Action.
0x96 Pump_BDI Lift_BDI_ Lockout se^ng. when BDI Percentage Ybt, the pump is
0x2450 2. BDI parameters are below Lift lockout deactivated.
Fault Type(s): 1 mistuned. setting.
C/ear: Charge Battery; Dual Drive
Cycle KSI. Same, both motors
 Table 24 Fault Code Troubleshooting Chart, cont'd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
9-9 Parameter Mismatch 1. A parameter with the [PCF] Set: ShutdownAII:
Parameter_Mismatch label was changed. Two or more parameter
0x9 0x2812 2. Incorrect position feedback settings conflict and ShutdownMotor
type chosen for motor cannot both be honored. ShutdownMainCont
technology in use. C/ear Adjust parameters actor
3. Dual drive is enabled in to a 叩 ropriate values and ShutdownEMBrake
torque mode. then Reset Controller. ShutdownThrottle
4. Dual drive enabled on only Cycle KSI. Shutdowninterlock
one controller. ShutdownDriverl
ShutdownDriver2
ShutdownDriver3
Fault Type(s)： ShutdownDriver4
0) Dual Drive is setup incorrectly. Speed Mode or Speed Mode Express must be used, ShutdownDriver5
EM Brake Type must be 2, Dual_Drive_Mode_7ype must be 1. Dual DC Motor ShutdownDriver6
Technology does not su 叩 ort AC dual drive. ShutdownDriver7
4) EM Brake Control Mode is invalid. ShutdownPD
5) Interlock Brake Control Mode is invalid. FullBrake
6) PMAC Short Circuit Current if PMAC_Short_Circuit_ Current set above ShutdownPump
Base_Current_Umit in a non-test mode. ShutdownCoilSuppl
7) In a differential steer system, fault actions are misconfigured. y Shutdownvehicle
8) Dual motor type must be Differential. ShutdownLower
9) PMAC EMF Restriction - In a PMAC application configured for restricted mode ShutdownLift
operation, the back EMF per speed value is not configured.
10) PMAC Release - A restricted and test mode for PMAC is being used in released Dual Drive
software. Same, both motors
11) Torque preload is configured to be saved across key-cycles, but EM Brake preload
torque is not set.
12) Invalid Torque Estimate - Configured torque estimation type is incompatible with
the selected ''Direct Torque” control mode.
13) Command M 叩 Stop - [STEERING] CommandMapLeftStop or
CommandMapRightStop equals zero.
14) [STEERING] Improper sequence of the redundant Command Analog map points.
15) Analog Feedback M 叩 s - [STEERING] Primary or Secondary Analog Feedback
maps do not have continuous slope.
16) Sawtooth Command - [STEERING] For Sin/Cos or Sawtooth Command device
selection, the primary and secondary types do not match.
17) Sawtooth Feedback - [STEERING] For Sin/Cos or Sawtooth Feedback device
selection, the primary and secondary types do not match.
18) Feedback Type - [STEERING] Autocenter is declared as Never and the feedback
device type is a relative position device type.
19) Interlock braking supervision must be enabled in PMAC if interlock braking is on.
20) The selected motor type has not been fully characterized and should only be used
for development.
21) R_sys6\6 not commission properly, contact CCA support.
22) Product Data Code not found in database.
23) Incompatible Motor Technology and Control Mode.
24) Invalid Feedback Type for selected Motor Technology.
25) External supply max current set above hardware limit.
26) Metric off in servo mode.
27) EM brake enabled in servo mode.
28) Travel control supervision not supported in selected control mode.
29 HPD enabled in servo mode.
30) Dual drive enabled in servo mode.
31) Emergency reverse enabled in servo mode.
32) Selected control mode is incompatible with controller model.
33) Selected Feedback Type is incompatible with controller model.
34) Emergency Reverse not supported for Motor Technology.
35) Selected encoder power source is not enabled.
36) Interlock Braking selected in torque mode.
100) Parameter Integrity.
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
9-10 Interlock Braking Supervision 1. For 1, ramp rate/time set Set The interlock brake ShutdownMotor
0x9A lnterlock_Braking_Supe too conservatively (needs supervision function, ShutdownEMBrake
rvision 0x2332 to be set for worst case when enabled, monitors ShutdownMainCont
Fault Type(s): braking (full load) to the vehicle speed during actor
1 = MotorSpeed did not prevent false trip). interlock braking to
ramp down fast 2. The vehicle could have a ensure the vehicle is Dual Drive
enough to meet full battery due to which decelerating and stops Same, both motors
configuration (set by regen is limited and within the stopping
lnterlock_Brake_ cannot decelerate fast distance.
Supervision_Ramp_ enough. Clear: Reset Controller.
Deiay and 3. For 2, check EM Brake<
lnterlock_Brake_ for failures/wear.
SuperivsionjRampjR
at^.
2 = Vehicle brought to
stop,
but then EM brake (if
configured) failed to
set.
3 = Vehicle brought to
stop,
9-11 EMRbutthenSupervisiontraversed a 1. During an EMR event, the Set During an EMR ShutdownMotor
0x9B Emc_Supervision motor speed exceeded the event, the motor speed ShutdownEMBrake
0x2333 limit set by the Emergency exceeded the limit set by ShutdownMainCont
Fault Type(s):1 Reverse Supervision the Emergency Reverse actor
parameters. Supervision parameters.
2. See Programmer»A 叩 Clear: Reset Controller. Dual Drive
lication Setup»Emergency Same, both motors
10-1 Driver 1 Fault Reverse»
1. Open or short on driver Set Driver 1 is either ShutdownDriverl
0xA1 Driver_1_Fault load. open or shorted, or
0x2160 2. Dirty connector pins at Driver 1 exceeded its Dual Drive
Fault Type(s): controller or contactor coil. overcurrent setting. This Motor:
1 = Driver current 3. Bad connector crimps or Clear: Correct the open ShutdownDriverl
exceeded faulty wiring. or short, and then Reset
hardware limits. Other Motor:
4. Driver overcurrent, as set Controller. No Action
2 = Driver current by the Driver 1
exceeded Overcurrent parameter.
configured 5. See
over-current limits. Programmer»Controller
3 = Driver commanded Setup»Outputs》Driver 1 »
PWM Driver 1 Overcurrent.
active, using
diagnostic pulses.
Voltage measured
high, should be low.
Typically caused by
driver failure, or
driver pin short to
high.
4 = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
low, should be high.
Either open circuit, or
driver pin short to
ground.
5 = Driver commanded
PWM
is 0, and voltage
measured low
(should be high).
Either open circuit, or
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis
POSSIBLE CAUSES SET/CLEAR CONDITIONS FAULT ACTIONS
CODE Integrated Toolkit™)
10-2 Driver 2 Fault 1. Open or short on driver Set: Driver 2 is either ShutdownDriver2
0xA2 Driver_2_Fault load. open or shorted, or
0x2161 2. Dirty connector pins at Driver 2 exceeded its Dual Drive
Fault Type(s): controller or contactor coil. overcurrent setting. This Motor:
1 = Driver current 3. Bad connector crimps or Clear: Correct the open ShutdownDriver2
exceeded faulty wiring. or short, and then Reset
hardware limits. Other Motor:
4. Driver overcurrent, as set Controller. No Action
2 = Driver current by the Driver 2
exceeded Overcurrent parameter.
configured 5. See
over-current limits. Programmer»Controller
3 = Driver commanded Setup»Outputs》Driver
PWM 2»Driver 2 Overcurrent.
active, using
diagnostic pulses.
Voltage measured
high, should be low.
Typically caused by
driver failure, or driver
pin short to high.
4 = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
low, should be high.
Either open circuit, or
driver pin short to
ground.
5 = Driver commanded
PWM is
0, and voltage
measured low (should 1. Open or short on driver Set: Driver 3 is either
10-3 Driver 3 ShutdownDriver3
0xA3 Driver_3_Fault load. open or shorted, or
0x2162 2. Dirty connector pins at Driver 3 exceeded its Dual Drive
Fault Type(s): controller or contactor coil. overcurrent setting. This Motor:
1 = Driver current 3. Bad connector crimps or Clear: Correct the open ShutdownDriver3
exceeded faulty wiring. or short, and then Reset
hardware limits. Other Motor:
4. Driverovercurrent, as set Controller. No Action
2 = Driver current by the Driver 3
exceeded Overcurrent parameter.
configured 5. See
over-current limits. Programmer»Controller
3 = Driver commanded Setup»Outputs》Driver
PWM 3»Driver 3 Overcurrent.
active, using
diagnostic pulses.
Voltage measured
high, should be low.
Typically caused by
driver failure, or driver
pin short to high.
4 = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
low, should be high.
Either open circuit, or
driver pin short to
ground.
5 = Driver commanded
PWM is
0, and voltage
measured low (should
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis
POSSIBLE CAUSES SET/CLEAR CONDITIONS FAULT ACTIONS
CODE Integrated Toolkit™)
10-4 Driver 4 Fault 1. Open or short on driver Set: Driver 4 is either ShutdownDriver4
0xA4 Driver_4_Fauit load. open or shorted, or
0x2163 2. Dirty connector pins at Driver 4 exceeded its Dual Drive
Fault Type(s): controller or contactor coil. overcurrent setting. This Motor:
1 = Driver current 3. Bad connector crimps or C/ear Correct the open ShutdownDriver4
exceeded faulty wiring. or short, and then Reset
hardware limits. 4. Driver overcurrent, as set Controller. Other Motor:
2 = Driver current by the Driver 4 No Action
exceeded Overcurrent parameter.
configured 5. See
over-current limits. Programmer»Controller
3 = Driver commanded Setup» Outputs»Driver
PWM 4»Driver 4 Overcurrent.
active, using
diagnostic pulses.
Voltage measured
high, should be low.
Typically caused by
driver failure, or driver
pin short to high.
4 = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
low, should be high.
Either wen circuit, or
driver pin short to
ground.
5 = Driver commanded
PWM is
0, and voltage
measured low (should
be high). Either open
circuit, or driver pin
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis
POSSIBLE CAUSES SET/CLEAR CONDITIONS FAULT ACTIONS
CODE Integrated Toolkit™)
10-5 Driver 5 Fault 1. Open or short on driver Set: Driver 5 is either ShutdownDriver5
0xA5 Driver_5_Fault load. open or shorted, or
0x2164 2. Dirty connector pins at Driver 5 exceeded its Dual Drive
Fault Type(s): controller or contactor coil. overcurrent setting. This Motor:
1 = Driver current 3. Bad connector crimps or Clear: Correct the open ShutdownDriver5
exceeded faulty wiring. or short, and then Reset Other Motor:
hardware limits. 4. Driver overcurrent, as set Controller.
2 = Driver current No Action
by the Driver 5
exceeded Overcurrent parameter.
configured 5. See
over-current limits. Programmer»Controller
3 = Driver commanded Setup»Outputs» Driver 5»
PWM Driver 5 Overcurrent
active, using
diagnostic pulses.
Voltage measured
high, should be low.
Typically caused by
driver failure, or driver
pin short to high.
4 = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
low, should be high.
Either open circuit, or
driver pin short to
ground.
5 = Driver commanded
PWM is
0, and voltage
measured low (should
be high). Either open
circuit, or driver pin
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis
POSSIBLE CAUSES SET/CLEAR CONDITIONS FAULT ACTIONS
CODE Integrated Toolkit™)
10-6 Driver 6 Fault 1. Open or short on driver Set: Driver 6 is either ShutdownDriver6
0xA6 Driver_6_Fault load. open or shorted, or
0x2165 2. Dirty connector pins at Driver 6 exceeded its Dual Drive
Fault Type(s): controller or contactor coil. overcurrent setting. This Motor:
1 = Driver current 3. Bad connector crimps or ShutdownDriver6
exceeded C/ear Correct the
faulty or short, and then Reset Other Motor:
hardware limits. 4. Driver overcurrent, as set Controller.
2 = Driver current by the Driver 6 No Action
exceeded Overcurrent parameter.
configured Note: Driver 6 is a digital
over-current limits. (On/Off) 1 Amp output.
3 = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
high, should be low.
Typically caused by
driver failure, or driver
pin short to high.
4 = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
low, should be high.
Either open circuit, or
driver pin short to
ground.
5 = Driver commanded
PWM is
0, and voltage
measured low (should
be high). Either open
circuit, or driver pin
 Table 24 Fault Code Troubleshooting Chart, cont'd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
10-7 Driver 7 Fault 1. Open or short on driver Set: Driver 7 is either ShutdownDriver7
0xA7 Driver_7_Fault load. open or shorted, or
0x2166 2. Dirty connector pins at Driver 7 exceeded its Dual Drive
Fault Type(s): controller or contactor coil. overcurrent setting. This Motor:
1 = Driver current 3. Bad connector crimps or ShutdownDriver7
exceeded C/ear Correct the
faulty or short, and then Reset
hardware limits. 4. Driver overcurrent, as set Controller. Other Motor:
2 = Driver current by the Driver 7 No Action
exceeded Overcurrent parameter.
configured Note: Driver 7 is a digital
over-current limits. (On/Off) 1 Amp output.
3 = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
high, should be low.
Typically caused by
driver failure, or
driver pin short tn
high.
4 = Driver commanded
PWM
active, using
diagnostic pulses.
Voltage measured
low, should be high.
Either open circuit, or
driver pin short to
ground.
5 = Driver commanded
PWM
is 0, and voltage
measured low
(should be high).
Either open circuit, or 1.A Driver Output is used for Set: Driver assignment Fault Action:
10-8 Driver
0xA8 Driver_Assignment two or more functions. conflict (i.e., duplicate None, unless a fault
0x2632 2. See items assigned to the action is
Fault Type(s): 5 Programmer»Controller same driver). programmed in
(X} = Driver number that Setup»IO Clear ： Resolve the VCL.
caused the fault. Assignments»Coil Drivers: conflicted driver
Main Contactor Driver, assignment, then Dual Drive
EM Brake Driver, Reset Controller. Same, both motors
Hydraulic Contactor
Driver.
 Table 24 Fault Code Troubleshooting Chart, cont'd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
10-9 Coil Supply 1. Short on driver loads. Set Short detected after ShutdownAII:
0xA9 Coil_Supply_Fault 2. Dirty connector pins at the sta 血 p check has
0x2?69 controller or device. passed. A low side driver ShutdownMotor
Fault Type(s): short is detected and the ShutdownMainCont
1 = Short to B- or 3. Bad connector crimps or actor
faulty wiring. respective fault action
hardware fault. fails to cut-off driver ShutdownEMBrake
2 = One or more drivers 4. Controller is defective. current. ShutdownThrottle
that Shutdowninterlock
Coil supply sta 血 p test ShutdownDriverl
have the drivers
checks configured as fails. Clear: Reset ShutdownDriver2
“Safety Designated' 1 Controller. ShutdownDriver3
did not shut down ShutdownDriver4
when commanded to ShutdownDriver5
do so. ShutdownDriver6
3 = Coil Simply startup ShutdownDriver7
enable ShutdownPD
check failed. FullBrake
4 = Coil Supply startup ShutdownPump
disable ShutdownCoilSuppl
check failed. y Shutdownvehicle
ShutdownLower
ShutdownLift
Dual Drive
Same, both motors
11-1 1.Analog 1 input voltage is
ANALOG 1 OUT OF RANGE Set: Fault Action：
0xB1 Analog_ above the parameter (1) Input voltage (on pin) None, unless a fault
1_0ut_0f_Range setting of Analog 1 High. is above the action is
0x2620 2. Analog 1 input voltage is parameter's setpoint programmed in
Analog_X_Out_of_Rang below the parameter threshold. VCL.
e setting of Analog 1 Low. (2) Input voltage (on pin)
Fault Type(s): is below the Dual Drive
1 = Above High limit 3. parameter's setpoint Same, both motors
2 = Below Low limit. Programmer»Controlle
Setup»Inputs»Analog 1. threshol
Clear: Return the
4. voltage to within the
Programmer»Controller
11-2 ANALOG 2 OUT OF RANGE See Analog 1 Out of Range. See Analog 1 Out of See Analog 1 Out of
0xB2 Analog_2_Out_Of_Ran Range. Range.
ge 0x2621
11-3 ANALOG 3 OUT OF RANGE See Analog 1 Out of Range. See Analog 1 Out of See Analog 1 Out of
0xB3 Analog_3_ Out_ Range. Range.
0f_Range 0x262 打
11-4 ANALOG 4 OUT OF RANGE See Analog 1 Out of Range. See Analog 1 Out of See Analog 1 Out of
0xB4 Analog_4_Out_Of_Ran Range. Range.
ge 0x262 孑
11-5 ANALOG 5 OUT OF RANGE See Analog 1 Out of Range. See Analog 1 Out of See Analog 1 Out of
0xB5 Analog_5_0ut_0f_Rang Range. Range.
e
0x2624
11-6 ANALOG 6 OUT OF RANGE See Analog 1 Out of Range. See Analog 1 Out of See Analog 1 Out of
0xB6 Analog_6_ Out_ Range. Range.
Of_Range 0x2625
11-7 7 OUT OF RANGE See Analog 1 Out of Range.
ANALOG See Analog 1 Out of See Analog 1 Out of
0xB7 Analog_7_Out_Of_Ran Range. Range.
ge
0x262 8 OUT OF RANGE See Analog 1 Out of Range.
11-8 ANALOG See Analog 1 Out of See Analog 1 Out of
0xB8 Analog_8_Out_Of_Ran Range. Range.
ge
0x2627
11-9 ANALOG 9 OUT OF RANGE See Analog 1 Out of Range. See Analog 1 Out of See Analog 1 Out of
0xB9 Analog_9_ Out_ Range. Range.
Of_Range 0x2628
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
11-11 ANALOG 14 OUT OF RANGE See Analog 1 Out of Range. See Analog 1 Out of See Analog 1 Out of
OxB Analog_ Range. Range.
14_0ut_0f_Range
B 0x262A
11-13 Analog 18 Out of Range See Analog 1 Out of Range. See Analog 1 Out of See Analog 1 Out of
OxB Analog_ Range. Range.
18_0ut_0f_Range
D Ox262B
11-14 Analog 19 Out of Range See Analog 1 Out of Range. See Analog 1 Out of See Analog 1 Out of
OxB Analog_ Range. Range.
19_0ut_0f_Range
E Ox262C
11-12 Analog Assignment 1. An Analog input is used for Set: An Analog input is Fault Action：
OxB Analog_Assignment two or more functions. used for two or more None, unless a fault
0x2631 2. An Analog input is outside functions or is outside action is
C Fault Type(s): 13 programmed inVCL.
the range of analog inputs. the range of analog
0( = 1-9,14,18-19,31} 3. See inputs.
X = Analog Input Programmer»Controller Clear: Resolve Dual Drive
number that caused Setup»IO assignment conflict, and Same, both motors
the fault. Assignments»Controls. then
12-1 Branding Error 1. Software and hardware Set: Software/hardware Shutdownvehicle:
0xC1 Branding_Error 0x2860 branding mismatch. incompatibility.
ShutdownMotor
Fault Type(s): 1 2. For technical support on Clears applicable:
this fault, contact the Load Branded software, ShutdownMainCont
Curtis distributor where or use Branded actor
you obtained your controller with the ShutdownEMBrake
controller or the Curtis correct device profile ShutdownThrottle
sales-support office in and the correct Curtis FullBrake
your region. Software Suite toolkit ShutdownPump
key. Dual Drive
Same, both motors
12-2 A cutback based on cell Set: See Fault Type. Fault Action:
0xC2 BMS Cutback loading has occurred. Clear: Resolve battery or
None, unless a fault
BMS_Cutback 0x2861 battery cell issue. action is
Fault Type(s): programmed inVCL.
1 = Battery Current
Cutback. Dual Drive
2 = Low Cell Cutback. Same, both motors
3 = High Cell Cutback.
 Table 24 Fault Code Troubleshooting Chart, cont'd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
12-5 PWM Input 10 Out of Range 1.This fault diagnostic Set The input frequency Fault Action:
0xC5 PWMJnput_10_ Out_ execution cycles every and/or duty-cycle on
None, unless a fault
0f_Range 0x2629 4msec. Input 10 exceeds the
Fault Type(s): The input is considered configured limits set by action is
disconnected if no PWM PWM_lnput_10_x_ programmed in
1 = The input is VCL.
disconnected. signal occurs for 16msec Duty_Cycle and
2 = The measured input or the measurements are l%M_lnput_10_x_ Dual Drive
frequency is below not updated every Frequency, where x = Same, both motors
16msec. (Low, High}.
the Cfear Reset controller.
(PWMJnput_10_Low 2. Mistuned parameters.
_ Frequency)-(PWM_ 3. Faulty wiring.
lnput_10_Frequency_
Fault_Tolerance).
3 = The measured input
frequency is above
the
(PWM_lnput_10_Hig
h_ Frequency)+
(PWM_
lnput_10_Frequency_
Fault_ Tolerance).
4 = The measured duty
cycle is
below set limits,
(PWM_lnput_10_Low
_
Duty_Cycle)-(PWM_
lnput_10_Duty_Cycle
_ Fault_Tolerance).
5 = The measured duty
12-7 cycleAnalogis 31 Out of Range See Analog 1 Out of Range. See Analog 1 Out of See Analog 1 Out of
0xC7 Analog_31_Out_Of_Ra Range. Range.
nge
0x2106 Dual Drive
12-8 lnvalid_CAN_Port 1. Mistuned Dual Drive CAN
Set;This fault is triggered Same, both motors
mvalid_CANjw NO
0xC8 parameters. when the Dual CAN Port
0x2107 (DualMotorCanPort^
2. Conflicting CAN Node IDs Dual Drive
Fault Type(s): for Dual Drive. parameter is set to a Same, both motors
The condition is CAN port that does not
checked at start-up, (i.e. exist on a controller set
during the dual drive up for Dual Drive.
initialization). Clear: Reset controller.
12-9 VOL Watchdog See the associated VCL Set The time interval of NO ACTION
0xC9 VCL_Watchdog 0x2?08 Functions, the VCL watchdog (WD^
・ Set_ Watchdog_ exceeded the timeout Dual Drive
value. Same, both motors
Timeoutf). Clear: Kick_ Watchdogf).
• Set_ Start and reset the
Watchdog_Fault_Action(). specified watchdog
. Kick_Watchdog(). timer.
The fault actions can be
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
12-11 Primary State Error If the fault persists, Contact Set Internal error with N0_ACTI0N
OxC Primary_State_Error Curtis. the controller. Kindly (controller is not
0x2113 reset controller. operable)
B Fault Type(s): Clear: Reset controller.
These are internal Dual Drive
issues either occurring Same, both motors
during startup,
parameter initialization,
secondary micro update
or other runtime issues.
1 = PRIMARY_DEVICE_
STARTUP = 0,
2=
PRIMARY_WAIT_KSI_
STABLE,
3=
PRIMARY_DEVICE_
STARTUP_VALID,
4=
PRIMARYJNITIALIZE_
PARAMETERS,
5=
PRIMARY_WAIT_FOR_
FIRST_SIGNALS,
6=
PRIMARY_WAIT_FOR_
SUPERVISOR,
7=
PRIMARY_RESTORE_
PARAMETER.FAIL,
8=
PRIMARY_SUPERV1SO
R_
FIRST_ SIG NALS_ER
ROR
9= 1. This fault diagnostic Set The inpiut frequency Fault Action:
12-1 PWM Input 29 Out of
2 PWM_lnput_29_Out_of execution cycles every and/or duty-cycle on
_Range 0x210D 4msec. The input is Input 29 exceeds the None, unless a fault
OxC Fault Typefs): considered disconnected if configured limits set by action is
C 1 = The input is no PWM signal occurs for PWMJnput_29_x_Duty_ programmed inVCL.
disconnected. 16msec or the Cycle and
2 = The measured input Dual Drive
measurements are not PWM_lnpuL29_x_ Same, both motors
frequency is below updated every 16msec. Frequency, where
the 2. Mistuned parameters. x=^Low, High).
(PWM_lnput_29_Low 3. Faulty wiring. Clear: Reset Controller.
_ Frequency) -
(PWM_
lnput_29_Frequency
_ Fault_Tolerance).
3 = The measured input
frequency is above
the
(PWMJnput_29_High
_ Frequency) +
(PWM_
lnput_29_Frequency
_ Fault_Tolerance).
4 = The measured duty
cycle
is below set limits,
(PWM_
lnput_29_Low_Duty_
Cycle)
-(PWMJnput_29_Dut
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis POSSIBLE CAUSES SET/CLEAR CONDITIONS FAULT ACTIONS
CODE Integrated Toolkit™)
12-1 PWM Input 28 Out of Range1. This fault diagnostic Set The mput frequency Fault Action:
3 PWMJnput_28_Out_of_ execution cycles every and/or duty-cycle on
Range 0x21OC 4msec. The input is Input 28 exceeds the None, unless a fault
OxC Fault Type(s): considered disconnected if configured limits set by action is
D 1 =The input is no PWM signal occurs for PWMJnput_28_x_Duty_ programmed inVCL.
disconnected. 16msec or the Cycle and
2 = The measured input Dual Drive
measurements are not PWM_lnpuL28_x_ Same, both motors
frequency is below updated every 16msec. Frequency, where
the 2. Mistuned parameters. x=^Low, High).
(PWM_lnput_28_Low 3. Faulty wiring. Clear: Reset Controller.
_ Frequency) -
(PWM_
lnput_28_Frequency
_ Fault_Tolerance).
3 = Hie measured input
frequency is above
the (PWM_
lnput_28_High_Freq
uency) +
(PWM_lnput_28_Fre
quency_
Faultjblerance).
4= The measured duty
cycle is below set
limits, (PWM_
lnput_28_Low_Duty_
Cycle) -(PWM
jnput_28_Duty_
13-1 Lift Input FauK The associated fault Set Faults from the ShutdownLift
0xD1 Liftjnput 0x2104 diagnostic with the assigned respective/ assigned
Fault Type(s): 1 lift-input source triggers this TiftJ 叩 ut_Source” are Dual Drive
fault. cascaded and reported. Same, both motors
For example: Clear: Resolve any input
If the LifLlnput_Source is an assignment conflict, or
analog input, then anyfaults out of- range faults, then
detected by the respective I 叩 Reset Controller.
ut fault diagnostics are
cascaded and reported
within this fault code.
Note: An analog input fault
diagnostics may be out of
range when set as a voltage
input or may include
13-2 Phase PWM Mismatch Internal to Controller Motor Set The difference Shutdownvehicle:
0xD2 Phase_PWM_Mismatch Phase PWM. between the
0x2101 commanded phase ShutdownMotor
Fault Type(s): PWM duty cycle and the ShutdownMainCont
0 = U phase. measured is greater actor
1 =V phase. than allowed. ShutdownEMBrake
2 = W phase. Clear: Reset Controller. ShutdownThrottle
FullBrake
ShutdownPump
Dual Drive
Same, both motors
 Table 24 Fault Code Troubleshooting Chart, confd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
13-3 Hardware Compatibility The OS (device profile, .cdev Set Incorrect OS (device Shutdownvehicle:
0xD3 Hardware_ file) is incompatible with the profile).
Compatibility 0x2870 controller. ShutdownMotor
Clear: Load the ShutdownMainCont
Fault Type(s): 1 The loaded software (.cdev) matching OS (device
is not compatible with the actor
profile). ShutdownEMBrake
controller hardware.
ShutdownThrottle
FullBrake
ShutdownPump
Dual Drive
Same, both motors
13-4 Lower Input FauK The associated fault SeZ: Faults from the ShutdownLower
0xD4 Lowerjnput 0x2105 diagnostic with the assigned respective/ assigned u
Fault Type(s): 1 lower-input source triggers LowerJnput_ Soured are Dual Drive
this fault. cascaded and reported. Same, both motors
For C/ear Resolve any input
If the LoweHnput_Source is assignment conflict,
an analog input, then any out-ofrange faults,
faults detected by the Reset Controller.
respective Input fault
diagnostics are cascaded
and reported within this fault
code. Note: An analog input
fault diagnostics may be out
of range when set as a
voltage input or may include
13-6 Hazardous Movement (1) Mistuned Set: Shutdowninterlock
0xD6 Hazardous_Movement Hazardous_Direction_ This fault detects
0x211C Response_Time parameter. hazardous movement Dual Drive
Fault Type(s): when the motor is Same, both motors
(2)
1 = The motor speed is Hazardous_Accel parameter. requested to be
in the opposite The first hazard is a
(2)
direction of ttie speed Hazardous_Speed_Error motor that is not able
request and the slow down if the throttle
motor fails to paramete goes to zero or the
accelerate in the ⑵ direction switch is notin
correct direction for a Hazardous_Throttle the direction of travel.
programmed time. In Response_Time parameter.
The second hazard is
the event of a motor that accelerates
change to neutral, the wrong way or goes
this hazard will be too fast.
detected if the motor Note: This fault only
fails to accelerate occurs when the Control
toward zero speed Mode Select is in
for a programmed Speed_Mode, Speed_
time. Mode_Express, or
2= The acceleration is Sen/oJWorfe.
in the opposite
direction Clear: Reset Controller.
of the difference Setting
between the operator Hazardous_Direction_
speed request and Response_Hme = 0 will
the motor speed. The disable these checks.
speed in the
commanded
than the commanded
 Table 24 Fault Code Troubleshooting Chart, cont'd
FLASH FAULT NAME (Curtis SET/CLEAR
POSSIBLE CAUSES FAULT ACTIONS
CODE Integrated Toolkit™) CONDITIONS
13-1 IMU Failure Check if configured correctly Sef: Internally set as per NO_ACTION
3 IMU_Failure or the vehicle is moving fault type.
0x2?14 when calibrating. Clear: Cycle KSI. Dual Drive
OxDD
Same, both motors
Fault Type(s):

1 = SPI Communication
Failure.
2 = Curtis Factory Self
Test
Failure.
3 = Run Time Check
Failure,
bad data received
from the IMU.
4 = Gyro Cal out of
range,
maximum calibration
Note: For faults not in the above tables, consult the System Information file (from the VCL Studio app).
Faults will vary based upon the device profile version or controller model.
6.3 Electric schematic diagram

CQD12/14/16/18/20-AC4 Electrical Schematic Diagram

CQD12/14/16/20-AC4-I Electric schematic diagram
CQD12/14/16/18/20-AD2 Electric schematic diagram
CQD12/14/16/18/20-AD2-I Electric schematic diagram
CQD12/14/16/18/20-AC5-I Electric schematic diagram
Date Service content Serviceman
 HANGCHA GROUP CO., LTD.

■ Address For: OVERSEAS USERS

■ Address: 666 Xiang Fu Road, Hangzhou City Lin'an District Zone,
Zhejiang, China ■ ZIP:311305
■ Fax: 0086-571-88926789 0086-571-88132890
■ Web: http://www.hcforklift.com ■ E-mail: [email protected]