FOREWORD

Battery counterbalanced forklift truck is designed on the base of advantages of

some trucks made by domestic and foreign manufacturers and developed in

introduced technology from abroad. These trucks are all suited for handling and

stacking packed goods in stations, ports, goods yards and warehouses and used widely

in food processing, light and textile, mining industries and other factories, with some

of attachments fitted, the trucks can be applied in more and more field.

These trucks feature a wide-visible hoisting system, full powered steering unit,

self-energizing brake, continuous speed control, overhead guard with opened port and

high quality motor, battery, so they have a lot of advantages such as good performance,

easy operation, wide visibility of operator, flexible steering, reliable braking, powerful

and smooth power, low noise, no contamination to environment and beautiful contour.

This manual states the trucks’ specifications, operation, maintenance, service,

main assemblies’ constructions and working principles so as to help operators to use

the trucks correctly and attain the highest functions. It is necessary to read over the

manual before they operate the trucks or service personnel serve these trucks.

The rules and notices in the manual should be abided seriously by all of relative

personnel to enable these trucks in optimized working state for long period and bring

the highest efficiency.

This manual content might not correspond with the actual condition because of

the improving of our products. Our products are subject to improvements and changes

without notice.
 CONTENTS
I. Safety Rules for Operation and Daily Maintenance of Forklift Truck……………1
II. Main Specifications of Forklift Truck…………………………………………….7
III. Construction, Principle, Adjustment and Maintenance of Forklift Truck………12
1. Transmission System………………………………………………….……..12
2. Brake System………………………………………………………………..19
3. Steering System…………………………………………………………….34
4. Electric System……………………………………………………………..42
5. Hydraulic System………………………………………………………139
6. Lifting System…………………………………………………………….163
Ι. Safety Rules for Operation and Daily Maintenance of Forklift Truck

It is important that driver and manager for forklift trucks remember the principle

of the “first safety” and ensure the safety operation as the description in

《OPERATION AND SERVICE MANUAL》&《OPERATION MANUAL》.

1. Delivery of Forklift Truck

It must be pay attention to the following items when you deliver forklift trucks

with container or trucks.

(1) Apply the parking brake.

(2) Fix the mast and the balance weight with steel wire. Wedge up all wheels.

(3) Sling points should be always at the positions specified in sling index plate when

hoisting up the forklift truck.

2. Storage of Forklift Truck

(1) Drain off fuel completely. Don’t drain off the cooling water containing antifreeze

and rustproof agent.

(2) Apply antirust to the surface of the parts not painted. Apply lubrication oil to the

lift chain.

(3) Lowing the mast to the lowest position.

(4) Apply the parking brake.

(5) Wedged up the wheels.

3. Precautions Before Operation

(1) Don’t check fuel leakage and lever or instruments at the place where there is open

flame. Never fill the fuel tank with the truck running.

(2) Check the tire inflation pressure.

(3)Check the devices of lighting, sound and alarm: check the lights, buzzer and horn

(button on the handle included).

(4) The forward-reverse lever should be in neutral.

(5) Check all the levers and pedals.

1
(6) Complete the provisions before starting.

(7) Release the parking lever.

(8) Make trying operation of the mast for lifting, lowing and Fwd/Bwd tilting and the

truck for steering and braking.

4. Operation of Forklift Truck

(1) Only trained and authorized operator shall be permitted to operate the truck.

(2) Wear all the safety guards, such as shoes, helmet, clothing and gloves while

operating the truck.

(3) Check all the control and warning devices before starting the truck. If any

damages or defects are found, operate it after repairing.

(4) At the rated loading center, either overload or overload operation is strictly

prohibited. The center of cargo should be in line with the frame center, not out of the

line. The fork should insert completely under the cargo and make the cargo placed on

it evenly. Do not raise an object with one fork end.

(5) The starting, turning, driving, braking and stopping operation of the truck should

be done smoothly. When steering on the humid or low friction road, the truck should

be decelerated.

(6) Travel with loads as low as possible and tilted backward.

(7) Be careful when traveling on a slope. When climbing grades with a slope of more

than 10%, the truck should forward travel, and when descending so grades, backward

travel. Never turning on a slope. Avoid loading and unloading operation when

descending.

(8) Pay attention to pedestrian, obstacle and bumpy road when driving. Pay attention

to the clearance over forklift truck.

(9) Never allow any persons to stand on the forks or the truck to carry persons.

(10) Never permit anyone to stand or walk under upraised forks.

(11) Don’t operate truck and attachment of it at any position out of the drive seat.

2
(12) On the high lift forklift truck, when the lift high more than 3m, it is noted that the

goods on it should not fall down or the protection measures must be taken if

necessary.

(13) Tilt the mast of the high lift forklift truck as backward as possible while the truck

working. Use minimum forward tilt angle and Min. reverse tilt when loading and

unloading.

(14) Be careful and slowly driving over a dockboard or bridge-plate.

(15) Shut down the truck and don’t stay on the truck when checking battery or fuel

lever.

(16) The unloaded forklift truck with attachments should be operated as a loaded

truck.

(17) Don’t handle unfixed stacked goods. Be careful to bulky goods to be handled.

(18) If leaving the truck, lower the forks on the ground and let the shift lever to

neutral, shut down the engine or cut down electric supply. If parking on a slope is

unavoidable, apply the parking brake and block the wheels.

(19) Don’t adjust the control valve and relief valve at will to prevent the damage of

hydraulic system and its components because of excessive pressure passing them.

(20) Inflate a tyre according to it’s stated air pressure. Never over inflate a tyre.

(21) According to the measure method specified in JB/T 3300, the max. noise at the

outboard of the truck should be not more than 80dB(A).

(22) Be familiar with and pay attention to the functions of the decals on the forklift

trucks.

5. Daily Maintenance of Forklift Trucks

(1) Inspection before startup

a) Hydraulic oil volume: oil level should stay in the middle of oil meter scale;

b) Check piping, joints, pumps and valves for leaks or damages;

c) Check service brake:

3
 The free travel of brake pedal should be within the range of 40mm;

The clearance between the front floor and the pedal should be bigger than 20mm;

d) Check parking brake. The unladen truck can park on the 15% grade ramp,

when the parking lever is pulled to the bottom;

e) Check instruments, lighting, switches and wiring to see if they work normally

or not.

(2) Oil used for forklift trucks

Recommended
Name Brand and temperature of using
brand
L-HM32 L-HV32 low
Sticky grade wearable temp. wearable
Hydraulic oil Chang cheng hydraulic oil hydraulic oil
Temp. of ≥-20 (cold
≥-5
using (℃) region)
Chong qing
Brake fluid 4604 compound brake fluid GB 12981 HZY4
yi ping
Lubricating
Chang cheng 3# lithium base grease (-20℃～+120℃)
grease
Gear oil of Sticky grade 80W/90GL-5
heavy-laden Hai pai Temp. of
-25～+49
truck using (℃)

● Apply lubricating grease NYOGEL 782G to the conductive plate which the

connecting point of the steering wheel horn switch acts on.

4
(3) The table of lubrication system

5
8. Truck for cold storage

H3 series battery counterbalanced truck for cold storage can work under

environment with a temperature not lower than -18℃ without time limit. For

environment with a temperature between -18℃ and -30℃, the truck can not work for

a long time continually. The working time between inside of cold storage and outside

of cold storage has same proportion. The working time inside of cold storage can

reach to 30minutes at most.

Note:

1) The truck for cold storage can not shut down power and stop in the cold storage or

the hydraulic system and electric system may be damaged.

2) Before going into the cold storage, the temperature of truck parts shall be increased

through hydraulic and travelling operation.

3) If condensate water is formed on truck surface when going out of cold storage, the

truck can only go into the cold storage again when the condensate water is dry

completely.

4) Use special oil for truck for cold storage. Maintain the truck regularly.

5) Shorten the time interval for lubrication to prevent the lubricating points from early

worn out.

6) Charge the truck out of cold storage.

Oil and grease for truck for cold storage

Oil type Manufacturer Code
Low freezing point hydraulic oil
Hydraulic oil Changcheng
HS46
Gear oil Longpan 75W/90
HP-R lubrication grease
Lubrication grease Kunlun
RHZ-KLHP-RGW

6
Ⅱ. Main Specifications of Forklift Truck

Enternal view of forklift trucks

7
 Main Specifications
CPD10 CPD15 CPD15 CPD18
Model Unit
HA /HB HA /HB HC /HD HC /HD
Rated capacity kg 1000 1500 1500 1750

Load center mm 500

Lifting height mm 3000
Free lifting height mm 150
Mast tilt angle
deg. 6/12
(front/rear) (K/T)
Fork dimension 770×100×
mm 920×100×35
(L*S*E) 32
Wheel base F mm 1280 1390
Tread (front/rear)
mm 890/920 920/920
(B1/B2)
Overall length (without
mm 2065 2175
fork) L2
Overall width mm 1086/1070
Overall height
(mast/overhead guard) mm 1995/2130
(C/D)
Seat height Q mm 1090
underground clearance
mm 120/110（in the middle of the truck）
(H1/H2)
Min. steering radius R mm 1770 1880
Travelling speed
km/h 14/15
(loaded/unloaded)
Lifting speed DC: 290/450 DC: 270/450 DC:280/530
mm/s
(loaded/unloaded) AC:350/490 AC:340/490 AC:330/490
Lowering speed
mm/s 450
(loaded/unloaded)
Gradeability
% 18 17 17 15
(loaded/unloaded)
front/rear tyre 6.50-10/16x6-8
traction motor kW 8.0 (AC)
8.6(DC）
oil pump motor kW 7.5(DC）10.0 (AC)
10.0 (AC)
48/400(standard 48/480(standard
Battery V/Ah
configuration) configuration)
Service weight kg 2680 2950 2980 3150

8
 CPD20 CPD25
Model Unit
HA /HB HA /HB
Rated capacity kg 2000 2500

Load center mm 500

Lifting height mm 3000
Free lifting height mm 170
Mast tilt angle (front/rear)
deg. 6/12
(K/T)
Fork dimension (L*S*E) mm 920×122×40 1070×122×40

Wheel base F mm 1535

Tread (front/rear) (B1/B2) mm 960/950

Overall length (without fork)
mm 2400
L2

Overall width mm 1150

Overall height (mast/overhead

mm 2000/2155
guard) (C/D)
Seat height Q mm 1110
underground clearance
mm 115（at mast）/145（in the middle of the truck body）
(H1/H2)
Min. steering radius R mm 2065
Travelling speed
km/h 14/15
(loaded/unloaded)
Lifting speed DC: 280/490 260/490
mm/s
(loaded/unloaded) AC: 350/440 310/440
Lowering speed
mm/s 450
(loaded/unloaded)
Gradeability
% 15
(loaded/unloaded)
front/rear tyre 7.00-12-12PR/18x7-8-14PR

traction motor kW 11.1 (AC)

10.5 (DC)
oil pump motor kW
12 (AC)
48/600(standard)
Battery V/Ah
48/700(optional)
Service weight kg 4050 4200

9
 CPD30 CPD35
Model Unit
HB HB
Rated capacity kg 3000 3500

Load center mm 500

Lifting height mm 3000
Free lifting height mm 145 150

Mast tilt angle (front/rear)

deg. 6/10
(K/T)
Fork dimension (L*S*E) mm 1070×125×45 1070×125×50
Wheel base F mm 1685

Tread (front/rear) (B1/B2) mm 1000/950

Overall length (without fork)
mm 2490 2560
L2
Overall width (tyre/frame
mm 1241/1225
width)
Overall height
mm 2075/2215 2180/2215
(mast/overhead guard) (C/D)
Seat height Q mm 1140
underground clearance
mm 145（at mast）/150（in the middle of the truck body）
(H1/H2)
Min. steering radius R mm 2210 2270
Travelling speed
km/h 12/13 12/12
(loaded/unloaded)
Lifting speed
mm/s 240/400 220/370
(loaded/unloaded)
Lowering speed
mm/s 400
(loaded/unloaded)
Gradeability
% 13 11
(loaded/unloaded)
28 × 9-15-12PR/18 ×
front/rear tyre 28×9-15/18×7-8
7-8-14PR
traction motor kW 11 (AC)

oil pump motor kW 15 (AC)

Battery V/Ah 48/700 48/840

Service weight kg 4760 5335

10
 Size and weight of the main parts that can be disassembled
CPD10 CPD15 CPD15 CPD18 CPD20 CPD25 CPD30 CPD35
Model Unit
Item HA /HB HA /HB HC /HD HC /HD HA /HB HA /HB HB HB
mm
Max. overall 300×900× 300×900× 300×900× 300×900× 497.5×955× 497.5×955× 405×895× 465×895×
Counterweight 1070 1070 1070 1070 1150 1150 1225 1225
size
kg
Weight 360 470 630 630 800 950 1000 1330
mm
Max. overall 1050×1414 1050×1414 1150×1427 1150×1427 1150×1427 1150×1427 1140×1578× 1140×1578×
Overhead ×1551 ×1551 ×1483 ×1483 ×1483 ×1483 1573 1573
guard size
kg
Weight 65 65 72 72 86 86 77 77
mm
Max. overall 1010×1125 1010×1275 1010×1275 1010×1275 1138×1320 1102×1464 1164×459× 1164×464×
mast（lifting
×1885 ×1885 ×1885 ×1885 ×1885 ×1895 1957 1957
height size
3000mm） kg
Weight 450 450 500 500 810 810 785 815

11
Ⅲ. Construction, Principle, Adjustment and Maintenance of Forklift Trucks

1. Transmission System

1.1 General description

The transmission system consists of reducer, differential assembly and drive axle.

With direct connection of the reducer’s drive gear and the travelling motor, the travel

speed of the truck can be changed with the speed of the motor, and the travel direction

can be changed with the rotation direction of the motor.

1.2 Reducer and differential

The reducer is installed between drive axle and travelling motor. The two pairs of

cylindric spiral gears of the mechanism reduce the speed of travelling motor output shaft

and increases the torque from output shaft. Then the torque is sent to differential. Refer

t o figure 1-1and 1-2.

The differential is installed on the front half housing through two ends bearing seat

and the front end is connected to axle housing. The differential housing is of integral type.

The differential includes two half-shaft gears and two planet gears. (See Fig. 1-3)

1.3 Drive axle

The drive axle is made up of axle housing, hub and wheel. it is installed in front of

the frame.

The housing is of wholly casted structure. The tyre is fixed to the hub with bolts and

nuts through rim. The hub is supported on axle housing through tapered roller bearing.

The power is transmitted to the half-shafts through the differential and the hub is driven

by half shaft. And thus the front wheels rotate. The half-shafts bear only the torque

transmitted to the hubs. In the inside of the hub are oil seals to prevent water and dust

from entering or oil leakage. (See Fig. 1-3)

The tyre, rim and the pressure of the front wheel are followed. (See Table 1-1)

12
 Table 1-1
Truck 1t,1.5t,1.8t 2t, 2.5 3t 3.5t
capacity
Tyre Refer to Refer to Refer to Refer to
specifications specifications specifications specifications
Rim 5.00F 5.00S 7.00-15 7.00-15

Tyre pressure 790kPa 860kPa 970kpa Solid tyre

1.gear ring 7.bearing 13.adjusting shim 18.gear shaft

2.planetary gear 8.reducer case 14.adjusting shim 19.bevel gear
3.gear shaft 9.bearing 15.oil seal 20.bearing
4.differential case 10.bearing seat 16. bevel gear 21.bearing seat
5.O ring 11.bearing 17.adjusting shim 22.washer
6.cover 12.nut

Figure 1-1 Reducer and differential（1-1.8t）

13
 Gear ring Differential gear
Shim
Tighten torque
Differential gear
Shim
Tighten torque
Half shaft gear

Gear

Transmission box housing

O ring Tighten torque

O ring

O ring
Locking plate O ring

Drive gear

Travelling motor

Figure 1-2 Reducer and differential (2-2.5t)

14
Figure 1-3 Reducer and differential (3-3.5t)

15
Figure 1-4 Differential

16
 Tighten torque

B view
A is full of lubricating grease Tighten torque
50%

1.Axle housing
2. Half shaft
3.Wheel brake
4.Brake drum B view
5.Oil seal
6.Tapered roller bearing
7.Hub
8. Tapered roller bearing
9.Oil seal
10.Tyre
11.Rim
12.Adjusting nut
13.Lock nut

Bolt with * torque

Figure 1-5 Drive axle

17
1.4 Hub assembling
(1) Fill the chamber of wheel hub with

lubricating grease about 100cc, and then fit the

hub on the axle.

(2) Screw down the hub nut to a torque of 1kg.m,

then loosen it for 1/2 turn.

(3) Measure the torque value that the wheel hub

Adjusting nut
starts rotating. When the torque value measured Locking plate
Lock nut
is up to 5-15kg.m, screw down the hub nut.
Figure 1-6 Adding lubricating grease

(4) Screw down the locking nut and lock the locking plate
(5) Reassembly of tyre

Fix the connecting air pole and cover on the tyre and install the rim. Pay attention to

the following cases:

NOTE: a) the exhaust valve rod points outside and lies on the gap of the rim.

b) Make sure the hub nut head point outside.

Figure 1-7 Starting torque measurement

18
 Rim bolt structure

Figure 1-8 Wheel assembling

(1) tyre (2) valve rod (3) cover (4) inner rim (5) outer rim (6) rim bolt

2. Brake System

2.1 General description

The brake system is the front two-wheel braking type consisting of brake pedal,

master cylinder and wheel brakes.

2.1.1 Brake pedal

The structure of the brake pedal is shown in Fig. 2-1. The brake pedal is mounted on

the transmission through bracket.

The force acts on the pedal is changed to brake fluid pressure through the push rod

of the master brake cylinder.

19
 Fig. 2-1 Brake pedal
2.1.2 Master cylinder
The cylinder contains valve seat, return spring, primary cup, piston and secondary

cup, which are all kept in place with a stop washer and a stop wire. The exterior of the

cylinder is protected from the dust by means of a rubber dust cover. The piston is actuated

through the push rod by operation of brake pedal. As the brake pedal is pressed, the push

rod pushes the piston forward. The brake fluid in the cylinder flows back to the reserve

tank through the return port until the primary cup blocks up the return port. After the

primary cup passes through the return port, the brake fluid in the cylinder is pressurized

and opens the check valve, flowing through the brake pipeline to the sub cylinder. Thus,

each sub cylinder piston is forced outwards. This brings the friction pieces on the brake

shoes into contact with the brake drum and slows or stops the truck. Meanwhile, the

cavity caused behind the piston is filled with brake fluid led through the return port and

inlet port. When the brake pedal is released, the piston is forced back by the return spring.

At the same time, the brake fluid in each sub cylinder is pressured by the return spring,

20
returning into the mast cylinder through the check valve. With the piston in its original

position, the fluid in the master cylinder flows into the reserve tank through the return

port. The brake fluid in the brake pipelines and sub cylinders has a residual pressure

proportioned to the set pressure of the check valve, which makes each sub cylinder piston

cup securely seated to prevent oil leakage and eliminates a possibility of air locking when

the truck is emergently braked.

Fig. 2-2 Master cylinder

(1) Connecting rod (2) Push rod (3) Dust cover (4) Snap ring (5) Secondary cup
(6) Piston (7) Primary cup (8) Spring (9) Check valve

2.1.3 Wheel brake

The wheel brake is of double brake shoe type which is fitted to the each end of the

gearbox & axle assembly.

The wheel brake is made up of two brake shoe, sub cylinder and adjuster.

The brake shoe, one end of it being connected to the anchor pin and the other to the

adjuster, is stressed on backing plate by the spring and spring pull rod.

In addition, a parking brake and a clearance self-adjusting mechanism are fitted on

the wheel brake. (See Fig. 2-8, 2-9, 2-10)

(1) Braking operation

The primary and secondary shoes are respectively forced by a force equal in value

21
by master cylinder until the upper end of the secondary shoe is against the anchor pin and

the brake shoe moves towards the rotation direction of the brake drum.

The friction force between the friction piece and brake drum increases when the

anchor pin is laid against. A large braking force is produced because the secondary brake

shoe bears a larger force from the primary shoe than from the sub cylinder. (See Fig. 2-3)

The operation of the brake is opposite from forward travelling when travelling

backward. (See Fig. 2-4)

Fig. 2-3 Braking operation in Fig. 2-4 Braking operation in

forward travel backward travel

(2) Parking brake

The parking brake is built in the wheel brake which is made up of push rod and pull

rod.

The pull rod is mounted to the primary shoe side by pin. The move of the pull rod is

transmitted to the secondary shoe side through push rod. (See Fig. 2-5)

22
 Fig. 2-5 Parking brake
(3) Clearance self-adjusting mechanism

A proper clearance between the friction piece and the brake drum is maintained by

the clearance self-adjusting mechanism. (See Fig. 2-6)

Fig. 2-6 Clearance self-adjuster

The clearance self-adjusting mechanism actuates only when the truck in reverse

travel.

▲Operation of the clearance self-adjuster

When brake during travelling backward, the secondary brake shoe contact with main

brake shoe and rotate together. Then the pulling rod turn right with point A as pivot and

thus B point is raised up. See figure 2-6. When brake is released, the pulling rod turn left

23
under the spring action and thus B point lowers. When the

clearance between friction disc and brake drum increases, b

rotating vertical dimension increases. The clearance

decreases with the elongating of adjusting rod when the

adjuster is stirred one gear. See figure 2-7. See the follow

table for clearance adjusting range:

Unit: mm
1.0～1.8t 2t,2.5t 3.0~3.5t

Clearance 0.35～0.55 0.40-0.45 0.25~0.4

Fig. 2-7 Clearance self-adjuster

24
 Fig. 2-8 Brake assembly
(1) Braking cable ass’y (2) Washer 8 (3) Bolt M8×20 (4) Ratchet pawl (5) Pin roll
(6) Torsional spring (7) Parking push rod (8) Spring (9) Rear brake shoe with friction plate
(10) Spring pull rod (11) Return spring for brake shoe (12) Guide pad (13) Guide plate
(14) Brake cylinder ass’y (15) Front brake shoe with friction plate (16) Bassplate ass’y
(17) Washer 10 (18) Spring washer (19) Pin roll for pull rod (20) Snap ring
(21) Parking pull rod (22) Spring pull rod (23) Spring seat (24) Spring (25) Plug
(26) Pullback spring (27) Clearance self-adjuster

2.1.4 Operating device of the parking brake

The parking brake lever is of a ratchet type. Different brake force can be achieved on

slope and ground.

25
 Brake force adjustment: When you turns the adjuster clockwise, the force increases,

otherwise, when you turns the adjuster counter clockwise, the force decreases. (See Fig.

2-9)

Pull force: 20 to 30kg.

Note: Adjuster is inside the cover. Cover need to be disassembled before

adjusting.

Fig. 2-9 parking brake shank

2.2 Maintenance of wheel brake

This paragraph covers the disassembly, reassembly and adjustment of the wheel

brake in the state of the wheels and hubs are disassembled. It also covers the adjustment

method of the brake pedal. (The description here is mainly for 2.5ton truck brake, the

other truck brake is similar to it in general.)

26
2.2.1 Wheel brake disassembly

(1) Remove the support pin, adjusting lever,

adjusting device and spring of secondary shoe. (See

Fig. 2-10)

Fig. 2-10

(2) Remove two shoes return springs. (See Fig.2-11)

Fig. 2-11

(3) Remove three hold-down springs. (See Fig.

2-12)

Fig. 2-12

(4) Remove the primary and secondary shoes. At the

same time, remove adjuster spring. (See Fig. 2-13)

Fig. 2-13

27
(5) Remove the brake line from the wheel

cylinder. Remove wheel cylinder

mounting bolts and detach the wheel

cylinder from the backing plate. (See Fig.

2-14)

Fig. 2-14

(6) Remove the E-retainer for securing the

parking brake cable to the backing plate.

Remove the backing plate mounting bolts

and detach the backing plate from the axle.

(See Fig. 2-15)

Fig. 2-15

(7) Remove the boot and push the piston assembly out of the operating cylinder. (See Fig.

2-16)

Fig. 2-16
2.2.2 Inspection of wheel brake

Inspect all parts to make sure if there’s any worn or damaged part. If unsatisfactory,

repair or replace with new one.

28
 (1) Check the operating cylinder inner

surface and the piston periphery surface

for rusting. Then, measure the clearance

between the piston and cylinder. (See

Fig.2-17)
Fig. 2-17
Standard: 0.03-0.10mm

Maximum clearance: 0.15mm

(2) Visually check the piston cup for damage or deformation. If unsatisfactory, replace

with new one.

(3) Check the free length of the operating cylinder spring. If unsatisfactory, replace it.

(4) Check the friction piece for thickness

to see if it is excessive worn. If necessary,

replace it. (See Fig. 2-18)

Unit：mm
1.0-1.8t 2.0～2.5t 3.0~3.5t
Standard 4.8 5.7 8.0
Limiting 2.5 3.5 6.0 Fig. 2-18

(5) Check the condition of the brake drum

inner surface. If any damage or excessive

wear is found, repair by machining or

replace it. (See Fig.2-19)

Unit：mm
1.0-1.8t 2.0～2.5t 3.0~3.5t
Standard Φ254 Φ280 Ф 314
Limiting Φ256 Φ282 Ф 316
Fig. 2-19

29
2.2.3 Wheel brake reassembly

(1) Apply brake fluid to the piston and the piston cup, and reinstall the spring, cup, the

piston and the dust cover in this order.

(2) Install the operating cylinder on the backing plate.

(3) Install the backing plate on the front axle.

(4) Apply heat-resisting grease on the points indicated in Fig. 2-20, with care not to

contaminate the friction piece with grease.

Fig. 2-20
(5) Install the brake cable assembly on the backing plate with an E-retainer.

(6) Install shoes on the backing plate with hold-down springs.

(7) Put the spring on the parking push rod

then install the rod on the shoe. (See Fig.

2-21)

Fig. 2-21

30
(8) Install the shoe guide plate on the

anchor pin, and install the shoe return

spring. (See Fig. 2-22)

Fig. 2-22
(9) Install the adjuster, adjuster spring, push rod and its return spring.

Pay attention to the following points:

a) Adjuster thread direction and its mounting direction.

b) Adjuster spring direction. (Do not allow the adjuster gear teeth to contact with the

spring)

c) Return spring direction of the push

rod: Spring hook at anchor pin side should

be located at the opposite side to push rod.

d) Make sure that the adjusting lever

end is in contact with the adjuster gear

teeth. (See Fig. 2-23)

Fig. 2-23

(10) Install the brake line on the operating cylinder.

(11) Measure the inner diameter of drum

and the outer diameter of brake shoe.

Adjust the adjuster to obtain the 1mm

difference needed between the drum inner

diameter and the friction piece outer

diameter. (See Fig. 2-24) Fig. 2-24

2.2.4 Operation test to clearance-self-adjuster

(1) Make the brake shoe diameter approach the specified mounting size, and pull the

31
adjusting level with your finger along the arrow marks to turn the adjuster gear. When

removing off your finger, the adjusting lever should return to its original position without

rotation of the adjuster gear.

Note: Even if the adjuster gear turn back along the adjusting lever motion

when removing your finger, the adjuster will still operate normally after it is built in

the machine.

(2) If the adjuster fail to do the above operation when the adjusting lever is pulled,

proceed with the following inspection:

a) Make sure that the adjusting lever, push rod and the return spring for push rod are

securely installed.

b) Check the push rod return spring and adjuster spring for deterioration, and also

check the adjuster gear for rotating condition and undue wear or damage of the meshing

section.

Fig. 2-25
2.2.5 Brake pedal adjustment

(1) Make the push rod short.

32
(2) Adjust the stopper bolt and the height of the pedal. (See Fig. 2-26)

(3) Press the brake pedal. Pull the push rod out until its front end comes into contact with

the master cylinder piston.

(4) Tighten the push rod locking nut.

Pedal height

Brake switch

Pedal limit
Lock nut

Fig. 2-26
▲ Brake switch adjustment

a) After you adjust the height of the brake pedal, loose the lock nut of the brake

switch.

b) Pull the plug out to let the lead separate.

c) Turn the switch to make the clearance about 1mm.

d) Make sure that when you press the brake pedal the brake lamp light at the same

time. ( See Fig.2-27)

33
 Fig. 2-27
2.2.6 Wheel brake troubleshooting (See Table 5)
Problem Possible cause Remedy
1) Fluid leaks from brake system. Repair
2)Poor adjustment of brake shoe clearance. Adjust the adjuster
3)Brake overheating. Check for dragging
4)Poor contact between the brake drum and Readjust
Poor braking
friction piece.
5)Foreign matter adhered on friction piece. Repair or replace
6)Foreign matter mixed in brake fluid. Check brake fluid
7)Poor adjustment of brake pedal. Adjust
1)Hardened friction piece surface or foreign Repair or replace
matter adhered thereto.
2)Deformed backing plate or loose bolts. Repair or replace
Noisy brake
3)Deformed shoe or incorrect installation. Repair or replace
4)Worn friction piece. Replace
5)Loose wheel bearing. Repair
1)Oil-contaminated friction piece. Repair or replace
2)Poor adjustment of brake shoe piece. Adjust the adjuster
Uneven
3)Malfunctioning sub cylinder. Repair or replace
braking
4)Shoe return spring deteriorated. Replace
5)Deflected drum. Repair or replace
1)Brake fluid leaks from braking system. Repair
Soft or
2)Poor adjustment of brake shoe clearance. Adjust the adjuster
spongy
3)Air mixed in brake system. Bleed air
brake
4)Poor adjustment of brake pedal. Readjust

3. Steering system

3.1 General Description

The function of steering system of forklift is to change the driving direction of the

forklift or keep the forklift in straight line driving. The performance of steering system

directly concerns with the driving safety, operation efficiency of forklifts and labor

intensity of drivers. The steering system is divided into two categories of mechanical

34
steering system (manual steering system) and power steering according to the power

source of steering. The mechanical steering system is operated to overcome steering

resistance moment fully by relying on the force and skill of driver, while in power

steering system, the energy consumed to overcome the steering resistance moment is

provided by prime mover and the driver can operate the system to control the turning

direction with very small force.

As requested by the working characteristic of the forklifts, the operation site and

driving pass are relatively narrow, changing-over is frequent and the minimum radius

turnings are often needed, therefore, the steering system is required to be reliable and

light in operation. Since the load of steering axle occupies about 60% of the vehicle

weight in case of idling, G-series forklifts of 1.0～2.5t produced by our Co. adopt fully

hydraulic power system to alleviate the labor intensity of the driver.

3.2 Working Principle

When the forklifts turn round, the steering moment applied by driver on the steering

wheel (steering control mechanism) makes steering wheel rotate and shift and is

transmitted to the steering gear through steering shaft. Steering gear sends the pressure oil

of appropriate volume to the steering oil cylinder through pipes and the oil cylinder

pushes steering wheel through trapezoidal steering mechanism, thus direction change is

realized.

The difference between fully hydraulic and hydraulic power steering gears is the

first substitutes the mechanical elements such as steering gear and longitudinal tie etc and

has high pressure oil pipe connecting fully hydraulic steering gear with oil cylinder. The

pressure-gradient control valve mounted in the loop of load- sensing and fully hydraulic

steering system can ensure distribution of flow to steering system first and sufficient oil

supply at any working conditions. There is less flow passing through steering gear when

35
it is at neutral position to save the energy.

3.3 Composition of Steering System

(1) Control mechanism of steering

Figure 3-1 Steering operating device

3.4 Steering Axle

The steering axle of the truck (See Fig. 3-2) includes axle body, steering cylinder, tie

rods and knuckle. The steering trapezium is made of cranks and blocks. When pressure

oil moves the cylinder piston rod, the tie rod revolves the knuckles, then the truck may be

steered. The steering axle is fixed with bolts through support on the tail bracket at rear of

the frame after bumper block is mounted on the front and end plate so that the axle can

sway around the pin roll on the end plate and obtains certain shock-absorbing effect due
to bumper block. Left and right knuckles are positioned at two sides of the steering axle

respectively. The rear wheel hubs are fitted to the knuckle shafts through tapered roll

bearings with oil seals keeping the grease in the chambers of the hubs and the knuckles.

The steering rim and the pressure of the steering wheel are followed:

Table 3-1
Truck model 1t、1.5t、1.8t 2t, 2.5t 3t 3.5t
Tyre size 16×8-8 18×7-8-14PR 18×7-8-14PR 18×7-8
Rim size 4.33R 4.33R 4.33R 4.33R
Tyre pressure 860kPa 900kPa 900kPa Solid tyre

36
 Fig. 3-2 Steering axle
(1) Kingpin (2) Needle bearing (3) Thrust bearing (4) oil seal (5) Steering hub
(6) Tapered roll bearing (7) Washer (8) lock nut (9) Hub cap (10) Tapered roll bearing
(11) Lock pin (12) Knuckle (13) Needle bearing (14) Adjustment washer
(15) dust roof cover (16) sealing surface (17) Steering cylinder (18) Steering axle body
(19) Tie rod (20) Pin roll

(1) Steering knuckle

Both steering knuckles are fitted between the upper and the lower steering axle body

through two king pins, thrust bearings, needle bearings, dust covers and seal rings. The

king pin is locked on the steering knuckle with a lock pin. The upper end of the knuckle

is supported on the steering axle body by thrust bearing. Both ends of the king pin are

supported on the steering axle body by needle bearing. (See Fig. 3-3)

37
 Figure 3-3 Steering knuckle
(1) Thrust bearing (2) Steering knuckle (3) Dust proof cover
(4) steering knuckle main pin (5) Needle bearing (6) Damping block
(2) Steering cylinder
The steering cylinder is of double-action piston type. Both ends of the piston rod are

connected with steering knuckles through connection rod. Left or right of the truck

turning is achieved with the help of the left or right travel of the piston rod driven by the

pressure oil from the powered steering unit. The seal unit is consist of the supporting ring

and O-ring seal, U-ring seal is adopted between the cylinder head and the piston rod. The

cylinder is fitted to the steering axle through two cylinder covers. (See Fig. 3-4)

38
 Figure 3-4 Steering cylinder
(1) cylinder barrel (2) supporting ring (3) cylinder cover (4) O ring
(5)O ring (6) O ring (7) U ring (8) dust proof ring (9) retainer ring
(10) piston rod assembly
(3) Hub

The hub is fixed to the steering knuckle with two tapered roller bearing. The wheels

are assembled on the hubs through rims. Oil seal is assembled on the inner side of the

bearing to keep the lubrication oil in the hub and steering knuckle cavity. The nut is used

to adjust the tightness of the nut.

3.5 Adjustment and Maintenance

3.5.1 Rear wheel bearig pre-load adjustment

(1) As shown in Fig. 3-5, fill up the chamber formed by wheel hubs, wheel hub bearings

and wheel hub covers with lubricating grease. Coat the lips of the oil seals with

lubricating grease.

(2) Press the hub bearing into the hub and fit the hub on the knuckle shaft.

(3) Fit a flat washer and tighten a castle nut to a torque of 206-235Nm (21-24kgm) and

loosen it, and then tighten it again to a torque of 9.8Nm (1kgm).

(4) To ensure firm installation of the hub, slightly knock at it with a wooden hammer and

in the meantime, rotate the hub for 3-4turns.

39
(5) Tighten the castle nut and align one of its notches with a cotter pin hole drilled in the

steering knuckle.

(6) Again slightly knock at the hub with a wooden hammer and in this time, rotate

manually the hub for 3-4turns to ensure its smooth rotation with a specified torque of

2.94-7.8Nm (0.3-0.8kgm).

(7) If the torque value necessary to rotate the hub is more than the specified one

above-mentioned, screw out the castle nut for 1/6 turn and measure the torque value then.

(8) When the torque value measured is up to the specified one, lock the castle nut with a

cotter pin.
Fill lubricating grease
(80% of the space)

Fill lubricating grease

(80% of the space)

Figure 3-5 Fill lubricating grease and pre-load adjustment

When changing the tires, the hub bolts should be coated with sealant after a new tire

is mounted to ensure the tightening torque of the hub bolts is 120-160N.m for1～2.5t

forklifts.

3.5.2 Maintenance and service of steering system

(1) The steering king pin needs to be checked every 40 hours and grease be replenished

to the bent neck type grease fittings of king pin every 300 hours, piston rod and link rod

of steering oil cylinder, rotation connection parts of right and left knuckle arm need to be

checked every 40 hours and lubrication grease replenished every 300 hours.

40
(2) Change the grease of the bearing of steering hub every 1200 hours.

(3) Pay attention to the working condition of steering system during routine maintenance.

The manual operation force on the steering wheel should be 6-20N during steering and

the difference of right and left acting force is not more than 5N. When the forklift runs in

straight line at maximum speed, obvious S-shaped phenomenon is not allowed. Make

analysis and remedies by contrasting Table 3-2 “Fault Analysis Table for Steering

System”.

3.6 Main Failure and Troubleshooting of the Steering System

3.6.1 Inspect after reassembling the steering system

(1) Turning the steering wheel right and left, inspect whether the steering power is

smooth.

(2) Inspect connection of the hydraulic pipeline whether is correct by turning the steering

hand-wheel ring and left.

(3) Lift up the rear wheels and slowly turn the steering hand-wheel ring and left several

times to exhaust air from the hydraulic pipeline and the steering cylinder.

3.6.2 Steering system troubleshooting

Table 3-2
Problem Analyses of trouble Remedies
Fail to turn Pump damaged or breaking down. Replace
hand-wheel Priority valve is blocked or damaged Clean or replace
Hose or joint damaged or pipeline blocked. Clean or replace
The pressure of the safety valve is too low. Adjust the pressure
Air in steering oil circuit. Exhaust air
Difficult to turn Steering unit fail to recover due to spring
Replace spring piece
hand-wheel piece damaged or elasticity-insufficient.
Oil leakage in the steering cylinder. Inspect the seal of the
piston
Truck’s snacking Spring damaged or elasticity-insufficient. Replace
or moving with Adjust flow divider valve
Steering flow is too large
oscillation flow
Too low oil level in the oil tank. Refill oil
Excessive noise
Suction pipeline or oil filter blocked. Clean or replace
Oil leakage Seals of guide sleeve, pipeline or joint Replace
damaged.

41
4. Electric system

4.1 General description

The standard configuration of the electric system include of two controllers. It can

succeed in operating the forklift low-noisily, efficiently, smoothly and safety.

The electric system is composed of instrument, control system, traction motor, pump

motor, battery pack, control switch, lighting and wiring harness etc..

Notice: Our Company has the right to improve on the production. Please

contact with our company if there is any difference between the product and the

manual.

The circuit diagram of electric system are shown below

42
Figure 4-1 Electric system principle diagram (CPD10，15-HB2、CPD15，18-HD2)

43
Figure 4-2 Electric system principle diagram(CPD10,15-HA1,CPD15,18-HC1)

44
Figure 4-3 Electric system principle diagram(CPD10,15-HA2,CPD15,18-HC2)

45
Figure 4-4 Electric system principle diagram(CPD15-HB3L,CPD15,18-HD3L)

46
Figure 4-5 Electric system principle diagram(CPD15-HA2L,CPD15,18-HC2L)

47
Figure 4-6 Electric system principle diagram(CPD15-HA3L,CPD15,18-HC3L

48
Figure 4-7 Electric system principle diagram(CPD15-HB7L,CPD15,18-HD7L)

49
Figure 4-8 Electric system principle diagram(CPD10，15-HB7,CPD15,18-HD7)

50
Figure 4-9 Electric system principle diagram(CPD15-HA1L,CPD15,18-HC1L)

51
Figure 4-10 Electric system principle diagram(CPD10,15-HA3,CPD15,18-HC3)

52
Figure 4-11 Electric system principle diagram(CPD10,15-HB3,CPD15,18-HD3)

53
Figure 4-12 Electric system principle diagram(CPD20，25-HB3)

54
Figure 4-13 Electric system principle diagram(CPD20，25-HB2)

55
Figure 4-14 Electric system principle diagram(CPD20，25-HA1)

56
Figure 4-15 Electric system principle diagram(CPD20，25-HA2)

57
Figure 4-16 Electric system principle diagram(CPD20，25-HB7)

58
Figure 4-17 Electric system principle diagram(CPD20，25-HA3)

59
Figure 4-18 Electric system principle diagram(CPD30，35-HB3、CPD30，35-HB3P)

60
Figure 4-19 Electric system principle diagram(CPD30，35-HB8)

61
Figure 4-20 Electric system principle diagram(CPD30，35-HB7、CPD30，35-HB7P)

62
Figure 4-21 Electric system principle diagram(CPD30，35-HB8P)

63
4.2 Instrument
4.2.1 CURTIS instrument
4.2.1.1 Panel layout

Figure 4-22 CURTIS instrment panel

(1) forward indicator (2) traction fault indicator (3) speed status indicator
(4) pump controller fault indicator (5) steering angle indiator (6) hand brake status indicator
(7) fault indicator (8) lifitng cut off indicator (9) travelling mode indicator
(10) selection button (11) selection button (12) speed indicator (13) battery condition
(14) menu button (15) hour meter (16) hackward indicator
(17) seat switch status indicaotr
4.2.1.2 Function and application
(1) LCD display

● Electricity quanity indicator: the indicator figure is , there

are ten bars; when the electricity quanity is lower than 2 bars, the figure
flickers to alarm low electricity quanity. When the battery electricity quanity is lower

than lifting lock set value, the figure turns on. means the percentige of
the current elecricity quanity.

● Working mode display: the display firgure is ; when the truck is

64
under E mode, the displaying figure is ; when the truck is under S mode, the

displaying figure is . The working mode can be setted through the two
button outside of the instrument. The default working mode is E mode.

● Steering angle indicator: the dispalying figure is . When steering right,

the figure is ; when travelling forward, the figure is ; when steering right,

the figure is .

●Speed indicator : the displaying figure is , the displaying range

is 0～99.9.

Choose metric system or british system through CAN. The default is metric system.

● Hour meter: the displaying figure is , displaying precision is

0.1 hour. The displaying range is 0～99999.9h. When the hour meter begins to

counting, letter “h”flickers.

● Forward and backward indicator: the displaying figure is . When the

truck travels forward, the is displayed; when the truck travels backward, the

is displayed.
● Fault code display: the displaying figure is

. It shows traction, pump controller

and steering controller fault code. if the truck does not have steering controller,

does not display.

● Seat switch indicator: the dispalying figure is .

● Battery electricity quanity alarm indicator: the displaying figure is .

When the battery quanity is lower than 20%, the alarm flickers.
65
(2) LED display

● : alarm indicator. When there is improper operation (for example ,

operator has been out of truck, but the hand brake is not applied), the indicator turns
on.

● : the indicator turns on when there is traction, pump controller or steering

controller fault.

● lifting lock alarm. The indicator turns on when battery electricity

quantty is lowered than lifting lock set value.

● parking brake indicator.

4.2.2 ZAPI instrument

4.2.2.1 Panel layout

Figure 4-23 ZAPI SMART meter panel

(A) hour meter (B) fault display (C) battery capacity display
(D) display screen (E) for spare (F) Hand brake state indicatro
(G) Seat switch alarm light (H) Exit button (I) parameter down
(J) parameter up (K) menu up (L) menu down (M)menu
4.2.2.2 Function and application

SMART DISPLAY is an intelligent dashboard connected to the truck system by

CANBUS line. This dashboard provides the diagnostic and set-up of the whole truck
66
system.

Connecting the ZAPI handset or PCWIN tool to SMART DISPLAY, it is

possible to read and modify the setting of all the modules present on the CANBUS

net. The display implements an interface to the operator through a main page and a

number of submenus.

a) Turn on the key switch. When the instrument gets power “HELI AC

SYSTEM” is displayed on the LED screen. After system self-testing, battery

capacity, truck speed, the default setting (economic mode) and traction hours will be

indicated on the main page.

Fig. 4-24 Display of the ZAPI instrument when power on (fault-free)

b) Battery capacity display: There are 20 grids on the battery capacity

indicator. After the truck is powered, the indicator is fully lit (20 grids) if the

battery is fully charged. After battery discharge, the battery capacity is reducing, so

are the grids of the indicator. When 20 grids of the battery capacity indicator are all

off, the fault warning symbol and battery low symbol will flash at the same

time and the travelling speed slow down, lifting action cut off. Charge the battery in

time.

c) Traction travelling mode display: the driver can choose the mode through the

mode switch. The current mode is shown on the meter (refer to figure 4-11). There

are two modes for choose: E refers to economic mode and S refers to slow speed

mode.

d) Fault code display : If fault appears, is often on and refer to Table 4-1

for the fault code (the first line) displayed in the WINDOW，the control module No.

(the second line) of CANBUS net where the fault happens and CANBUS net

67
information of ZAPI.
Fault code
故障码
控制模块编号
Control module No.

Fig. 4-25 Fault display interface of ZAPI instrument

Table 4-1 ZAPI CANBUS net information

Number associated in CANBUS net Module
01 SICOS
02 TRACTION
03 TRACTION MASTER
04 TRACTION SLAVE
05 PUMP
06 EPS-AC
09 MHYRIO
16 SMART DISPALY

4.2.3 Instrument for inmotion controller

4.2.3.1 Layout of panel

A. Operation mode display B. Time C.Navigation key D. hour meter

E. Back F. Enter G. Speed H.Display of steer wheel angel

I. Numeric keyboard J. Display of dump energy

Indicators: ①-pump controller fault indicator ②-Turtle speed indicator

68
③-Fault warn ④-low dump power indicator
⑤-Lifting lock indicator ⑥-Seat indicator ⑦-Parking brake indicator
⑧-Neutral indicator ⑨-Warning light
4.2.3.2 Function and application

a) Operation mode

It shows current operation mode and there are two gears E and S.

b) Time

Real time is shown through hour-minute-second.

c) Hourmeter

The digit means truck working time. When the key switch is on, the hourmeter

begins working.

d) Travelling speed

It shows current truck travelling speed and the unit is KM/h or MPH.

e) Display of steer wheel angle

The arrow stands for the travelling direction of steering wheel.

f) Battery dump power

It shows current battery dump power. There are 10 squares. For the first 8

squares, one square will be off when the electricity power reduces by 10% each time.

When the dump power is only 10%, the last two squares will be off at the same time.

g) Lifting lock indicator

When lifting is lock, the figure turns on. the figure will not display with the

lifting figure at the same time.

h) Fault code display

It shows current fault code.

i) LED indicator

When the key switch is on, the instrument will check 8 LED automatically. The 8

LED will turn on successively and then turn off.

When battery dump power is no more than 20%, low battery dump power
69
indicator will turn on; when battery dump power is lower than 10%, the lifting lock

indicator will be on.

When the driver leaves the seat, the seat indicator will be on; when the parking

brake switch is applied, the parking brake indicator will be on.

4.2.4 Songzheng instrument

4.2.4.1 Panel layout

5 6 7
4
8

3
9

2 10

11

1
12
17
16 15 14 13

Figure 4-26 Songzheng instument panel

1. battery electricity quanity 2. Total working time 3. Light sensor
4. truck gears 5. Controller mode display 6. Fault display
7. current rotating speed display 8. Hand brake display 9. Fault indicator
10. fault state 11. Pump prohibited state display 12. Working time of this travel
13. enter 14. Page down 15. Page up 16. Backspace 17. Current speed

4.2.4.2 Instrument parameter introduction

(1) Instrument interface display tree diagram

70
 主显界面
Press the enter 5S for
Home
a while to enter
menu from home

1.参数 2.监控 3.开机画面 4.驱动故障类型 5.泵控故障类型 6.时钟

设置 菜单 ON/OFF 1/2 1/2 设置

1.1小时计归零 2.2泵电机控制器 2.1驱动电机

OK 监控 控制器监控
1.2.1单体充电
1.2电池参数
满电压 2.2.1泵电机
设置
相电流 2.1.1加速器 2.1.2加速器 2.1.3加速器 2.1.4制动踏板
1.2.2单体充电
1.3液晶对比度 指令 映射 电压 指令
空电压 2.2.2泵电机
百分比 转速
1.2.3单体放电 2.1.5制动踏板 2.1.6制动踏板 2.1.7模拟1 2.1.8模拟2
满电压 1.4泵禁止 2.2.3泵控制器
映射 电压 输入 输入
电量百分比 温度
1.2.4单体放电
空电压 1.5密码 2.2.4泵电机 2.1.9互锁 2.1.10给定 2.1.11开关1 2.1.12开关2
设置 温度 状态 方向 状态 状态

1.5.1密码 1.5.2新密码 2.1.13开关3 2.1.14开关4 2.1.15开关5 2.1.16开关6

输入 状态 状态 状态 状态

2.1.17开关7 2.1.18开关8 2.1.19开关16 2.1.20驱动1

状态 状态 状态 状态

2.1.21驱动2 2.1.22驱动3 2.1.23驱动4 2.1.24驱动5

状态 状态 状态 状态

2.1.25驱动6 2.1.26驱动7 2.1.27内部15V 2.1.28

状态 状态 输出 5V输出

2.1.29 2.1.30外部 2.1.31主接触器 2.1.32比例控制

12V输出 供电电流 驱动 电流

2.1.33比例驱动 2.1.34驱动3 2.1.35输出 2.1.36电容

输出 输出 转矩 电压

2.1.37锁线 2.1.38电机 2.1.39电机 2.1.40车速

电压 转速 温度 相电流

2.1.41控制器 2.1.42主接触器 2.1.43运行 2.1.44电机过温

温度 状态 状态 限制

2.1.45控制器 2.1.46欠压 2.1.47过压 2.1.48驱动故障

过温限制 限制 限制 限制比

2.1.49再生 2.1.50电池
限制 电压

71
 1.Parameter setting 2. Monitor menu
1.1 hour meter clear OK 2.1 drive motor controller monitor
1.2 battery parameter setting 2.1.1 Accelerator order
1.2.1 single cell charging full of voltage 2.1.2 Accelerator mapping
1.2.2 single cell charging empty voltage 2.1.3 Accelerator voltage
1.2.3 single cell discharging full of voltage 2.1.4 brake pedal order
1.2.4 single cell discharging empty voltage 2.1.5 brake pedal mapping
1.3 Liquid crystal contrast percentage 2.1.6 brake pedal voltage
1.4 pump prohibitive electicity quanity 2.1.7 analog 1 input
percentage 2.1.8 analog 2 input
1.5 password setting 2.1.9 interlock state
1.5.1 password input 2.1.10 preset direction
1.5.2 new password 2.1.11-2.1.19 switch 1-8,16 state

2.1.20-2.1.26 Drive1-7 state

2.1.27 internal 15Voutput 2.2 pump motor controller
2.1.28 5v output monitoring
2.1.29 12V output 2.2.1 pump motor phase current
2.1.30 External power supply 2.2.2 pump motor speed
current 2.2.3 pump controller temperature
2.1.31 main contactor drive 2.2.4 pump motor temperature
2.1.32 proportion control current 3. Startup ON/OFF
2.1.33 proportion drive output 4. Drive fault type 1/2
2.1.34 drive 3 output 5. Pump control fault type 1/2
2.1.35 output torque 6. Clock set
2.1.36 capacitance voltage
2.1.37 locking wire voltage
2.1.38 motor speed
2.1.39 motor temperature
2.1.40 speed phase current
2.1.41 controller temperature
2.1.42 main contactor state
2.1.43 operation state
2.1.44 motor over temperature limit
2.1.45 controller over temperature
limit
2.1.46 under voltage limit
2.1.47 over voltage limit
2.1.48 drive fault limit ratio
2.1.49 regenerating limit
2.1.50 battery voltage

(2) Parameter explanation

● Startup ON/OFF: Turn on and off the meter startup page.

72
● Drive fault type 1/2: 1 means the drive fault communication type is CAN

communication; 2 means drive fault type is fault code communication; (for the meter

with the function)

● Pump control fault type 1/2: 1 means the pump control fault communication type

is CAN communication; 2 means pump control fault type is fault code communication;

(for the meter with the function)

● Clock set: Set the meter time to be actual time. The time needs reset if there is a

power failure.

● Hour meter clear: The parameter can clear the hour meter. The hour meter means

the meter total time. (The function needs to enter password.)

● liquid crystal contrast percentage: through the parameter, the contrast can be

adjusted ( it can not be adjusted to 0 or 100%)(The function needs to enter password.)

● Pump prohibitive electricity quantity percentage: through the parameter, adjust the

electricity quantity when pump stops lifting or tilting. (The function needs to enter

password.)

● Password input: Before setting the parameter, the parameter can only be modified

after reenter the password. (The default password is 000001).

●New password: Modify the password after enter password through the parameter.

● Drive motor controller monitor: Under the menu, the travelling controller state is

monitored.

● Pump motor controller monitor: Under the menu, the pump controller state is

monitored.

4.2.5 Fanji instrument

73
 11
15 4
1 5 8

16 12
9
2 6
17
13
10
3 7
18
14

No. Meaning of the figures No. Meaning of the figures

1 Warning of exceeding system 10 Indicator of over high temperature
maintenance time
2 Seat switch indicator (optional) 11 energy mode shifting button (L-M-H)
3 12 Turtle speed/up and down/system
Parking brake indicator
reset
4 13 Up and down/shifting between
Battery dump energy cumulative time, cumulative mileage
and load weight
5 14 Diagnosis mode button/return to
Travelling speed indicator
home page
6 Travelling speed and fault code 15 Fault indicator
7 Cumulative time/cumulative mileage/ 16 Light indicator (invalid)
f load weight
8 Display of energy mode 17 Steering light indicator (invalid)
9 18 Indicator of low brake liquid level
turtle speed
(invalid)

74
1.Warning of exceeding system maintenance time

The regulated system maintenance interval is set in the system. When the regulated time is reached,

the figure will be shown to remind operators to maintain the truck. At moment, the function is invalid.

2. Seat switch indicator (optional)

When the operator leaves the seat, the indicator will be shown in the instrument. It means the seat

switch is disconnected. At this time, the truck can not travel and lift. The function is valid only OPS

seat is selected.

3. Parking brake indicator

When the parking brake is applied, the indicator will be shown. The indicator will disappear when the

parking brake is released.

4. Battery dump energy

The figure shows battery dump energy. it means the dump energy is more when there is more

lattices.

When the dump energy is less than 20%, that means there is only 2 lattices, the indicator of dump

energy will flickers and at this time, the speed will be limited to be lower than 50% of the minimum

speed. When the dump energy is about 10%, the fault code will be shown on the instrument. At this

time, the speed will be reduced by half and lifting function is invalided. (It can be set according to

75
customer’s requirement.)

Note ：
When there is only two lattices, at this time, the dump energy is about 20% to 30%. Please stop
operating the truck and charge the battery in time, or the battery service lift will be badly affected. (It
can be set according to customer’s requirement.)

5. Travelling speed indicator

It is the indicator to show travelling speed. The lattices are more when the speed is faster. 9

lattices mean maximum speed and 0 lattice means the speed is 0.

6. Travelling speed

It shows truck’s travelling speed.

7. Cumulative time/cumulative mileage/ load weight

The instrument will display Cumulative time, cumulative mileage and load weight. Press the

button 13 for about 3s, then the Cumulative time, cumulative mileage and load weight will be shown

circularly one by one.

Display of Cumulative time

It shows the cumulative time that the truck has worked.

Display of cumulative mileage

It shows the cumulative mileage that the truck has worked.

Display of load weight

It shows the load weight. Normally, the function is valid.

8. Display of energy mode

76
 There are three energy modes, that is L（economic）,M(standard) and H(high). Through the

button11, the three modes will shift circularly. The power of three modes is increasing successively

but the working time is reducing. Normally, it is recommended to work under L or M mode. Work

under H mode when large power is required such as climbing a slope with large gradient and so on.

9. Turtle speed

When pressing the button 12, the indicator of turtle speed will be shown and it means the turtle

mode works. When the truck is under turtle mode, no matter which mode is truck is (either L, M or H),

the speed of travelling motor reduces and the travelling speed slows down. The turtle mode has no

effect on pump motor.

10. Indicator of over high temperature

When the temperature exceeds the regulated value set by the system, the figure will be shown on

the instrument. The figure will be shown either when the travelling and pump driver reach to 90

degree or oil pump motor reaches to 145 degree or the travelling motor reaches to 120 degree. At this

time, the temperature of the truck is over high and it is prohibited to operate the truck. Operate after

the truck cools down.

When looking for the relative parameters of motor or controller under diagnosis mode, the figure

will be shown also.

Note：
 The protection value of travelling motor temperature and oil pump motor temperature can be
reset through connecting upper computer software and controller.

11. Energy mode shifting button (L-M-H)

77
The button has two functions: one is to shift among three energy mode (L, M and H) and one is to

shift among three interfaces.

Press L/M/H button in the homepage, three modes are shifting among L, M and H on the right corner

of the instrument.

When pressing the ENTER button for about 5s and the instrument enters diagnosis mode. Then press

L/M/H button, the screen will shift among recorded fault query interface, software version interface

and truck parameters lists interface circularly.

4.3 Controller

The counterbalanced forklift of this series adopts the CURTIS motor controller

imported from America or ACE2 motor controller imported from Italy or China

Songzheng controller, so it has advantages of advanced technology of high frequency

MOS tube, superior speed regulating performance, good safety, flexibility and first-class

protection etc.

The controller assembly includes motor controller, contactor, relay set, fuse ,OPS

warning buzzer, electronic protector (CURTIS system), radiation fan (ZAPI system）and

the related harness.

Notice: The manufacturer will provide quality warranty for motor controller

and the manufacturer will be informed in time for after sales service in case of fault.

Please do not open it for maintenance without authorization of manufacturing. The

users will be responsible for the personal and property losses caused by maintenance

at their own will.

78
 4.4 Motor

4.4.1 Motor specification

Table 4-2 Motor specification

Truck CPD10～15HB CPD30~

Item CPD10～15-HA CPD20～ 35HB
CPD18HC CPD15～ CPD20～25-HA
（C） 25-HB
18-HD
TSW132/4-195LT TSW132/4-195LT3 TSW132/4-195 TSP180/4-14 TSP180/4-14
Travelling TSP180/4-140
31-1 1-1 LT31-1 0 0
motor model 11.1KW/42H
Rated power 11.1kW/42Hz
Rated voltage
8kW/44Hz 8kW/44Hz 8kW/44Hz 11.1kW/42Hz Z
34V
Rated current 34V 34V 34V 34V 34V
159A
Rated speed 190A 190A 190A 159A 159A
1228r/min
1280r/min 1280r/min 1280r/min 1228r/min 1228r/min
Lifting motor XQD-7.5-3S XQD-8.6-3S XQD-10-4S
model
Series excitation Series excitation Series excitation
Excitation way
Rated power 7.5kW 8.6kW / 10.5kW /
Rated voltage 48V 48V 48V
Rated current 210A 260A 275A
Rated speed 1550r/min 1550r/min 1600r/min
TSW112/4-150 TSP112/4-19 YDB15-4HL
Lifting motor LP52-2 5
model 15KW/76.5H
Rated power
Rated voltage
/ / 10kW/75Hz / 12kW/75Hz Z
Rated current 31V 31V 31V
Rated speed 278A 278A 395A
2153r/min 2153r/min 2200r/min

4.4.2 Check and maintenance of the DC motor

(1) Daily check

a) Insulated resistance. Limit value (≥1 M)

b) Rotor should running agilely without touch.

c) Check up the motor connection whether exact and firm.

d) Check up between commutating piece of commutator whether clean.

Notice: During maintenance, the oil contamination on the commutator should

be wiped clean by lint free cloth dipped in alcohol and electric brush powder

between commutators should be clean up with hairbrush.

79
 e) The fastener whether become flexible and brush rack whether firm.

f) The space between the brush holder of brush rack and the surface of commutator

whether correct and transmuted. (2~4mm)

g) Whether the brush is integrity and glides agilely, the pressure of the balance

spring in gear.

h) The area of interface between brush and commutator should not less than 80%,

and require polished with 00 type of thin emery cloth before instead.

(2) Daily maintenance

Notice the surface of motor, for example the mud or other adherent matter on the

housing, to avoid affect motor dispel heat. Check every half a year in gear, main work

as:

a) Check outside and surface of motor and clean, cleanup dust.

b) Check, clean and replace bearing, carefully notice whether exist abnormity noise.

c) Check and replace the brush, check and maintain the commutator.

It is normal that the surfaces of commutator assume accordant light red after used a

long time.

Carve and polish the brush

a) Polish the brush with 00 type of thin emery cloth, drag the emery cloth right or

left during polishing.

b) After polishing brush with emery cloth and cleanup the commutator, the motor

should running with limit speed to assure safety, until the working surface of brush

polished.

(3) Working environment

a) Not higher than 1200m altitude.

b) Temperature between -25ºC ~ +40ºC.

80
 c) Relative humidity large to 100%, form curding dew at surface of motor.

(4) Faults and troubleshoot

The faults of DC motor mostly focus on the commutator department, characteristic

and causation as the following table.

Table 4-3 Faults and troubleshoot of motor

No. The characteristic of commutator Causation
1 All sheet copper is black. Wrong press of brush.
Between commutating piece or armature winding
The commutating piece change black in
2 short, welding bad or the commutating piece and
group with regulation.
armature winding bad or turn off.
The commutating piece change black in The center of commutator moved, and the surface
3
group without regulation. of commutator is not circle or flat.
The motor vibrate, the space between brush
holder and brush is too big, the space between
The brush is frayed, change color and
4 brush holder and the surface of commutator is too
disintegrated.
big. The talc between the commutating piece
extruded, the material or type of brush is wrong.
Motor over loading, the commutator is not clean,
the brush contact is bad, the press is not enough
5 The sparkle of commutator is big. or the brush is locked, brush rack become flexible
or vibrate, wrong the polarity of pole and
sequence.
The sparkle of brush is big, the contact between
6 Brush and brush plait heat. brush and soft wire is bad, the section area of soft
wire is too small.
7 Exist noise during the brush running. The surface of commutator is not enough smooth.

Notice: In case of backfire, one must shut off the power when checking and

maintaining the motor.

4.5 Battery

4.5.1 Specifications of battery

Table 4-4 Specifications of battery (standard)

Truck
CPD10～ CPD15～ CPD20～
model CPD30~35-HB
15-HA(B) 18-HC(D) 25-HA(B)
Item
Model 5PZS 400 6PZS 480 5PzS 600(H) 7PZS700H

Capacity 400Ah 480Ah 600Ah/5 700AH/5

Voltage 48V 48V 48V 48V
No. of the cell 24 24 24 24

81
 Notice: High-capacity or import battery can be provided if the user need.

4.5.2 Use of battery

The correct use and daily maintenance of lead-acid battery have a great influence on

the performance and service life of battery, therefore, the users must make maintenance

and service by contrast with the actual condition and according to the maintenance

instruction provided by manufacturer.

4.5.3 Maintenance of battery and matters for attention

(1) The surface of battery should be kept clean and dry. Its terminal and wiring parts

should be frequently maintained and loosening or poor contact found should be timely

eliminated.

(2) No conductive articles are allowed to put on battery to avoid its short circuit.

(3) The first charge of new battery before use is the initial charge and charges in the later

use course are the common ones. The charging time of the common charge is different

with battery capacity and discharging degree and usually discharging of 70%～100%

needs continuous charge of about 8～12 hours.

(4) Open the filling cap during battery charging and close it when charging is finished.

(5) Hydrogen and oxygen gas are separated out during battery charge, therefore, ensure

good ventilation condition and prohibit the fire and smoke to prevent explosion.

(6) In use and charging course, the natural evaporation and electrolysis of water content

in electrolyte will result in level decrease of electrolyte and increase of density, so

distilled water should be frequently added in order to keep height and density of

electrolyte normal.

(7) In the course of use, the excessive discharge (i.e. the voltage drop of monomer battery

is lower than 1.70V) and excessive charge should be avoided, because, these would

seriously affect the service life and performance of battery.

82
(8) Battery after use should be charged within 24 hours. Failure to charge the battery

timely, undercharge, excessive discharge or unused for a long time without additional

charging will vulcanize polar plate of battery and result in performance degradation and

use difficulty when serious.

(9) In the course of use, equalizing charge should be made to the battery once a month so

that all monomers of battery can reach well-balanced and good state when in use.

4.5.4 Care and storage

(1) The battery should be stored in a warehouse which is dry, well ventilated and away

from direct shinning. The temperature inside should stay between 5-40℃。

(2) Keep the battery from the heat source at least at a distance of 2m.

(3) The battery should not lie upside down or on the side. It should not bear any

mechanical shock or any heavy load.

(4) Keep off any liquid and harmful foreign matter. Be care with the falling of the any

metal impurity.

(5) Do not store the battery with electrolyte in. If it is necessary, charge the battery fully.

Adjust the lever and density of the electrolyte well. Charge the battery once a month

during its storage.

Notice:

(1) During battery charging, the charge should be temporally suspended in the

place where the temperature of electrolyte exceeds 40ºC.

(2) In battery charging, the service life of battery will be affected if the

temperature of electrolyte is more than 50ºC.

(3) Do not charge the battery at low temperature (e.g. cold outdoor), this would

affect the service life of battery.

Notice:

83
 (1) The rated voltage of traction battery is not the safe voltage and there is

electric shock injury danger if touched, so take safety precautions.

(2) Traction battery is lead-acid battery and electrolyte is dilute sulphuric acid.

So when the battery is tested, fed and adjusted etc, wear safety device to avoid

accident.

(3) The shell of charger is of metal conductor, therefore the reliable connection

of grounding protection line of charger should be ensured to prevent the electric

shock accident.

(4) Pulling out battery connectors should be avoided when charger is not

turned off. Special care should be taken as this will make battery undercharged

which produces dangerous electric spark.

4.5.5 Fault and troubleshooting

The causes that make the battery fault are various, except the quality manufacture

and transport storage, mostly due to the improper maintenance. Find out faults and

analyze the causation in time, take effective measure as soon as possible to exclude.

Table 4-5 Fault and troubleshoot of battery

Fault Characteristics Causation Repair measure
1) Decrease of the battery 1) Inefficient first charging. 1) Adopt the measure
capacity. 2) Inefficient charging for a of balanced charging
2) Low density of the long time. when the actuality is
electrolytic ( below the 3) Discharging for many not severity.
normal lever). times. 2) Adopt the
3) High battery voltage when 4) No timely charging after hydrotherapeutics
beginning or finishing the discharging. when the actuality is
charging. 5) High density of the severity.
Pole plate 4) Air bubble in the early electrolytic. 3) Do not over
sulfide time of charging or 6) Low lever of electrolytic. discharging.
beginning. 7) No timely balanced 4) The density of the
5) High rising of the charging. electrolytic should
electrolytic temperature 8) Too low or high below the regular lever.
when charging. discharging current. 5) The lever of the
9)Impure of the electrolytic and content
electrolytic. of the impurity should
10) Short inside or be in the prescribed
creepage. range.
Inside short 1) Low battery voltage or 1) Curve pole plate; 1) Replace the plate.

84
 circuit close to zero indeed when expanded reactive matter; 2) Clean the precipitate
charging. desquamated reactive and conductor.
2) Few or no air bubble at matter. 3) Replace the plate.
the end of the charging. 2) Much precipitate.
3) High rising of electrolytic 3) Falling of conductor to
temperature or slow or no the battery.
rising of electrolytic density.
4) Low battery voltage under
the condition of open circuit
or a quick drop to the limit
value when discharging.
5)Serious self-discharging.
1) Decrease of the battery 1) Being unsuitable to the 1) Clean the precipitate
capacity. electrolytic quality when the actuality is
2) Turbid electrolytic. standard. not severity.
Shedding off 3) Much precipitate. 2) Frequent discharging and 2) Discard when
of the charging or over charging severity.
reactive or discharging.
matter 3)High electrolytic
temperature when charging.
4) Outside short circuit
when discharging.

4.5.6 Introduction on battery side changing way

Traditional lifting method is standard for electric truck’s battery changing and side

changing way is optional for H3 series 3-3.5t truck. To be more specified, battery side

changing ways include two ways, one is side-pull way and the other is side-lift way. For

the side lift way, it means when changing battery, lift the battery with a forklift truck. We

recommend the side lift way for 3-3.5t forklift truck because it is heavy. For the side pull

way, it means when changing the battery, pull the battery to the transfer trolley and then

change the battery. This way may be used for 1-2.5t forklift truck because the truck is

light. Please refer the following information for details.

4.5.6.1 Side lift way for battery changing

85
(1) Turn the key switch to off position and unlock the valve operation. Turn the
bracket for valve operation upside down.
(2) Turn on the hood hook and open the hood. Disconnect the power plugs and
sockets and remove the battery lock pin.
(3) Remove the plate and door on the right side of the truck.
(4) Remove the battery pre-tighten bar and turn the battery lock plate upside down.

86
 1

3 2

1. Open the hood 2. Unlock the valve operation

3. Remove the lock pin 4. Turn the battery lock plate

(5) Lift the battery with the other forklift truck to change the battery.

(6) Install the battery according to the procedures in reverse order.

4.5.6.2 Side pull way for battery changing

87
(1) Turn the key switch to off position and unlock the valve operation. Turn the
bracket for valve operation upside down.
(2) Turn on the hood hook and open the hood. Disconnect the power plugs and
sockets and remove the battery lock pin.
(3) Remove the plate and door on the right side of the truck.
(4) Remove the battery stop pin on the transport holder. Pick up the transport holder with

pallet truck and make it be close to the truck body. Adjust the position of transport holder

to make truck body to be aligned with the arrows on the transport holder and thus to make

it to be centering with battery.

88
(5) Make the pillar on the transport holder be aligned with the round hole on truck and
nylon piece contact with truck body.
(6) Remove the battery pre-tighten bar and turn the battery lock plate upside down. Pull
the battery to the transport holder.
(7) Install battery stop pin on the transport holder, lower the pallet truck to make the pillar
on the transport holder to be away from the round hole on the truck body. Back up to shift
the pallet truck out.
(8) Install the battery according to the procedures in reverse order.

4.5.6.3 notes
(1) When handling the battery with pallet truck, make sure the stop pin of the
transport trolley is well installed.

(2) When the battery is installed, make sure the battery lock plate is lowered and

89
 the pre-tighten bar is well installed.

(3) when the battery is installed, make sure the battery lock pin is well installed.

(4) Never put your feet under the transport holder.

(5)If possible, please wear protective clothes and gloves.

(6)It is prohibited to knock the battery pole and wire clamp.
(7)Avoid strong shock during transporting.
(8) Recheck if the battery is well installed.
4.6 Daily Maintenance

(1) Check the wear condition of the contactor. Change it if necessary. Check the contactor

every three months.

(2) Check the pedals or manual inching switch; measure the voltage drop between the

inching switch ends; there is no resistance when the inching switch is closed; there is

ringing sound when release. Check every three months.

(3) Check the main circuit, connecting cable among battery, converter and motor. Make

sure the well insulation condition of the cables and circuits are tightly connected. Check it

90
every three months.

(4) Check the mechanical moving of the pedal and knob; check if the spring is out of

shape; check if the spring of the potentiometer can reach to the max. length or set length.

Check it every three months.

(5) Check the mechanical moving of the contactor every three months; if there is any

damage or condition affecting the safety, contact with dealers.

Notice: After chopper is installed, raise the wheel of vehicle (off the ground) for

test. In this way, there will be no danger even connection is wrong.

After electric lock switch is off, there is a certain voltage left in filter capacitor

within a period of time. Cut off the battery power first if the inverter is repaired at

this time and then connect the resistance of 10～100Ω to the positive and negative

poles of inverter to make the voltage on the capacitor short-circuited.

4.7 Troubleshoot

4.7.1 CURTIS control system

This control system use serial mode to input the fault code of travel and pump

controllers into the instrument and display on the instrument with the form of digital.

“TRAVEL” indicates the travel controller and “HYD” indicates the pump controller.

(1) 1236/1238 series controllers

Table 4-6 Fault code and troubleshooting of 1236/1238 series controllers

Code Programmer LCD display Possible cause Set/Clear conditions
External short of phase U, V or W
Phase current exceeded
motor connections.
12 Controller Overcurrent the current
Motor parameters are mis-tuned.
measurement limit.
Controller defective.
Leakage to vehicle frame from phase Controller current
13 Current Sensor Fault U, V or W (short in motor stator). sensors hove invalid
Controller defective. offset reading.
External load on capacitor bank (B+ The voltage of
14 Precharge Failed connection terminal) that prevents the capacitor is low.
capacitor bank from charging.

91
 The temperature of controller is lower The temperature of
Controller Severe controller is lower than
15 than -40℃.
Undertemp
Controller defective. -40℃.
The temperature of controller exceed
Controller Severe 95℃. The temperature of
16
Overtemp Excessive load on vehicle. controller exceed 95℃.
Improper mounting of controller.
The selection of controller’s voltage
parameter is wrong.
Overcurrent when start. Capacitor voltage too
17 Sever Undervoltage Battery resistance too high. low inside the
Battery disconnected while driving. controller.
Battery fuse burn or main contact not
actuation.
The selection of controller’s voltage
parameter is wrong.
Battery resistance too high for given Controller’s capacitor
18 Sever Overvoltage
regen current. voltage too high.
Battery disconnected while regen
braking.
Controller is operating in an extreme
Controller Overtemp environment. The temperature of
22
Cutback Excessive load on vehicle. controller exceed 85℃.
Improper mounting of controller.

The batteries need recharging.

The selection of controller’s voltage
parameter is wrong.
External oversize load lead to reduce Controller’s capacitor
23 Undervoltage Cutback
the battery voltage. voltage low.
Battery resistance too high.
Battery loosen.
Main contact get out of, fuse burn.
Battery voltage too high while regen
braking.
The selection of controller’s voltage
Capacitor bank voltage
24 Overvoltage Cutback parameter is wrong.
exceeded the set value.
Battery resistance too high.
Battery disconnected while regen
braking.
5V supply (pin 26)
25 5V Supply Failure 5V supply overload. outside the 5V±10％
range.
Digital Output 6
26 Digtial Out 6 Overcurrent Digital Output 6 overcurrent. (pin19) current
exceeded 15mA.
Digital Output 7
27 Digtial Out 7 Overcurrent Digital Output 7 overcurrent. (pin20) current
exceeded 15mA.
28 Motor Temp Hot Cutback Motor temperature is too high. Motor temperature is

92
 The parameter adjustment of too high.
temperature sensor is wrong.
Motor temperature sensor is not Motor temperature
connected properly. sensor input (pin8) is at
29 Motor Temp Sensor Fault
The parameter adjustment of the voltage rail (0 or
temperature sensor is wrong. 10V).
Open or short on driver load.
Coil1 Driver Open/Short Check COIL1 for open
31 Bad contact.
(Main Open/Short) or short.
Wiring error.
Open or short on driver load.
Coil2 Driver Open/Short Check COIL2 for open
32 Bad contact.
(EMBrake Open/Short) or short.
Wiring error.
Open or short on driver load.
Check COIL3 for open
33 Coil3 Driver Open/Short Bad contact.
or short.
Wiring error.
Open or short on driver load.
Check COIL3 for open
34 Coil4 Driver Open/Short Bad contact.
or short.
Wiring error.
Open or short on driver load.
Check PD for open or
35 PD Open/Short Bad contact.
short.
Wiring error.
Motor encoder failure. Check encoder for
36 Encoder Fault
Wiring error. fault.
Motor phase is open. Check motor phase U,
37 Motor Open
Bad crimps or faulty wiring. V or W for open.

Main contactor welded.

Check B+ or B-
An alternate voltage path (such as
voltage of main
38 Main Contactor Welded external precharge resistor) is
contactor and
providing a current to the capacitor
controller.
bank.
Main contactor did not close.
Main contactor tips are oxidized.
Main Contactor Did Not External load on capacitor bank that Check contactor and
39
Close prevents capacitor bank from fuse.
charging.
Blown B+ fuse.
41 Throttle Wiper High Throttle pot wiper voltage too high. Replace throttle 1.
Bring throttle pot2
wiper (pin16) voltage
42 Throttle Wiper Low Throttle pot wiper voltage too low.
above the fault
threshold.
43 Pot2 Wiper High Throttle pot2 wiper voltage too high. Replace throttle 2.
Bring throttle pot2
Throttle pot2 wiper (pin17) voltage is wiper (pin17) voltage
44 Pot2 Wiper Low
lower than set value. above the fault
threshold.
Pot low (pin18) current exceeds
45 Pot Low Overcurrent Check pot low.
10mA.
Modification controller
Modification controller parameter and
46 EEPROM Failure parameter and cycle
cycle KSI.
KSI.

93
 Throttle initial value >25% or applied Check F, R, interlock
47 HPD/Sequencing Fault
in incorrect sequence. and throttle.
After strike EMR, F, R, interlock and Check F, R, interlock
48 EMR REV HPD
throttle don’t return 0. and throttle.
49 Parameter Change Fault Cycle KSI.
CAN Communications CAN communications do not built, Check CAN
51
Fault the instrument doesn’t respond. communication
CAN communications between
instrument and controller is fault Check CAN
52 CAN PDO Timeout
while travelling, the instrument communication
doesn’t respond.
53-67 OEM Fault VCL running overtime.
68 VCL Run Time Error Modify VCL.
External Supply Out of 12V，5V supply output current out of Check for power
69
Range range. supply load.
71 OS General Operating system error. Cycle KSI.
72 PDO Timeout CAN communication overtime. Cycle KSI.
Stalled motor. Check brake.
73 Stall Detected
Velocity sensor failure. Check encoder.
Encoder failure. Check encoder.
Motor doesn’t match under unloaded
Motor Characterization Match again.
87 state.
Fault
Motor parameter out of the range of
controller.

Motor type is out of OS system. Select correct motor

89 Motor Type Fault
type, cycle KSI.
The VCL software in the controller Download the correct
91 VCL/OS Mismatch doesn’t match the OS software in the VCL and OS software
controller. into the controller.
Vehicle movement sensed after the
Adjust the braking
92 EM Brake Failed to Set EM brake has been commanded to
force of the EM brake.
set.
Encoder LOS (Limited Cycle KSI.
93 Motor encoder failure.
Operating Strategy) Check encoder.
EMR timeout timer has expired or Cycle KSI again.
94 Emer Rev Timeout
EMR input is closed. Check EMR for close.
The hardware in the controller doesn’t
95 Illegal Model Number Replace controller.
match the software in the controller.

(2) 1253 series controller

Table 4-7 Fault code and troubleshooting of 1235 series controllers

Code Status LED Description Possible cause
No power or defective
LED OFF
controller.
Controller or microprocessor
Solid ON
fault.
Controller operational, no
0,1 ■¤
known faults.
1,1 ¤¤ EEPROM fault. 1) EEPROM data lose or damaged.

94
 2) EEPROM checksum error. Can be
cleared via modify any parameter
value in program menu of 1311.
1) MOSFET shorted.
1,2 ¤¤¤ HW FAILSAFE
2) Motor connection is open.
1,3 ¤¤¤¤ MOTOR SHORTED Motor is shorted.
2,1 ¤¤¤ UNDERVOLTAGE CUTOFF Battery voltage < LOVLOT CUTOFF
1) Controller received effective lift
lockout signal.
2,2 ¤¤¤¤ LIFT LOCKOUT
2) SS LIFT LOCKOUT parameter is
not set correctly.
1) Improper sequence of throttle/SS
SEQUENCE ERROR (Statup input and KSI or interlock input.
2,3 ¤¤¤¤¤
lockout) 2) Wrong startup lockout type selected.
3) Misadjusted throttle.
1) Throttle wire open/short.
2,4 ¤¤¤¤¤¤ THROTTLE FAULT 2) Defective throttle.
3) Wrong throttle type selected.
3,1 ¤¤¤¤ CONT DRVR OC Contactor coil shorted.
1) Main contactor is welded.
2) “CONTACT CNTRL” setting is not
3,2 ¤¤¤¤¤ MAIN CONT WELEDE
correct.
3) Main contactor driver shorted.
1) Precharge circuit failure.
3,3 ¤¤¤¤¤¤ PRECHARGE FAULT 2) External short or leakage between
B+ and B-.
1) Main contactor coil connection
loose.
3,4 ¤¤¤¤¤¤¤ MAIN CONT DNC 2) Main contactor did not close.
3) CONTACT CNTRL parameter not
correct.
1) Battery voltage < LOVOLT
CUTBACK.
4,1 ¤¤¤¤¤ LOW BATTERY VOLTAGE
2) Corroded battery terminal.
3) Loose battery or controller terminal.
1) Battery voltage > overvoltage
4,2 ¤¤¤¤¤¤ OVER VOLTAGE shutdown limit.
2) Operation with charger attached.
1) Temp > 85℃ or < -25℃.
2) Excessive load on pump motor.
4,3 ¤¤¤¤¤¤¤ THERMAL CUTBACK 3) Improper mounting of controller.
4) Working in extreme environment.
5) Thermistor failure.

4.7.2 ZAPI control system

4.7.2.1 ZAPI AC2/ACE2 controller
(1) Common fault of travelling system (The second line of instrument indicates “ON
NODE 2”)

95
 Table 4-8 Common fault of travelling system of AC2/ACE2
Fault
Implication Note Measures
Code
The fault is in the internal memory for storing and
regulating parameters. When the fault appears, the
machine automatically stops. If the fault still exists, when
EEPROM
13 EEPROM KO reconnecting it after switching off the electric lock,
damaged
change the controller. If the fault disappears, the
parameters previously stored will be replaced with default
value.
LOGIC Logic card Current protection function failure of logic card: change
17
FAILURE #3 failure 3 the controller.
LOGIC Logic card Circuit failure of phase voltage feedback hardware on
18
FAILURE #2 failure 2 logic card. Change the controller.
The failure produced when the function of low or over
voltage acts. In 24V system, the voltage detected by
controller exceeds 45V or lower than 9V. In 48V system,
the voltage detected by controller exceeds 65V or lower
than 11V. Possible causes:
(1) Check if there is short circuit in the electric circuit
system such as DC-DC and brake coils etc or if the input
LOGIC Logic card
19 power supply contact of controller is good.
FAILURE #1 failure 1
(2) If the battery voltage is excessively low or high.
(3) Check B+ and B and see if the power cable on the
wiring terminal of contactor etc is tightly fixed.
(4) If the voltage calibration parameter of controller is in
consistent with actual voltage.
(5) There is circuit fault of overvoltage protection
hardware on logic card, change the controller.
Cause：The high-end voltage of MOS during startup is
66% smaller than the capacitor voltage or this voltage is
smaller than the required value in the operation of motor.
Possible causes:
(1) Wiring of motor is incorrect or there is circuit problem
30 VMN LOW Low VMN in motor. Check if three-phase connection of motor is
correct, if there is any leakage of electricity on ground and
circuit break of motor coil.
(2) If actuation of main contactor is rigid and if there is
any wearing on contact?
(3) Change the controller .
Cause：During startup, the low-end voltage of MOS tube
is 10% higher than that of normal battery voltage or the
phase voltage is higher than 1/2 of battery voltage.
Possible cause：
31 VMN HIGH High VMN (1) The wiring of motor is incorrect or there exists
problem in motor circuit . Check if three-phase connection
of motor is correct, if there is any leakage of electricity on
the ground and circuit break of motor coil. (2) Change the
controller
When the coil of main contactor is closed, the controller
CONTACTOR Adhesion of
37 should first check if the contact of main contactor is
CLOSED contactor
adhered. Try to discharge the capacitance. If the

96
 capacitance voltage is reduced by 20% of the battery
voltage, the fault possibly appears.
(1) Suggest to check if the contact of contactor is adhered
or change the contactor.
Logic card drives the coil of main contactor, but the
contactor does not close, possible causes:
CONTACTOR Contactor
38 (1) Mechanical fault and locking etc of contactor.
OPEN open
(2) Poor contact of contactor.
(3) If contactor works normally, change the controller.
The signal output by current sensor detected by
High standby micro-control system exceeds the scope allowed for
53 STBY I HIGH
current non-operation current. The trouble has nothing to do with
the peripheral parts, so the controller needs to be changed.
When the electric lock is switch on, inverter will charge
the capacitance through power resistance and check if
capacitance is fully charged within the time stipulated,
otherwise, the capacitance voltage remains 20% lower
than battery voltage, the inverter will give alarm and the
Wrong main contactor will not close.
CAPACITOR capacitance
60 Possible causes：
CHARGE charge
(1) Peripheral equipment, e.g. DC-DC, motor or other
equipment etc interfere with the charging process of
controller and these interferences need to be eliminated.
(2) The charging resistance is disconnected, there is fault
on charging circuit and power module ,so controller needs
to be changed.

In case that total power is allowed, the temperature of

controller exceeds 85℃( it relates to the parameter
“ MAXIMUM CURRENT”.)
Their corresponding relations are as follows: Parameter
set alarm temperature
MAXIMUM CURRENT=50% 96℃
MAXIMUM CURRENT=60% 94℃
MAXIMUM CURRENT=70% 92℃
MAXIMUM CURRENT=80% 90℃
Over-high MAXIMUM CURRENT=90% 88℃
62 TEMPERAURE
temperature MAXIMUM CURRENT=100% 86℃
Now, the max. current of controller decreases with the
increase of the max. current temperature. When the
temperature is 105℃, the current of controller decreases
to zero.
The fault appears if chopper is in the cold state:
(1) Temperature calibration parameter of logic card is
incorrect, check parameters.
(2) The internal temperature sensor of controller has
trouble and change the controller.
If temperature digital switch of motor is turned on or
MOTOR High motor
65 analog signal exceeds the cutoff value, the trouble is
TEMPERAT. temperature
produced. When the motor temperature reaches 120℃, the

97
 controller gives alarm, the vehicle can move at this time.
But the max. current and performance are cut down.
When the motor temperature reaches 125℃, motor stops
working. Now try to lower the temperature of the motor.
If the fault still exists when motor is cooled, check the
circuit and change the controller if he circuit is OK.
If parameter of “BATTERY CHECK” for battery test is
not set as 0 and when charging capacity of battery is lower
than 15% and there is no grid on instrument, fault alarm is
BATTERY Low capacity
66 given and the lifting function is locked, now charge it
LOW of battery
timely. In case the battery has electricity, check if the
value of parameter “ADJUST BATTERY” of controller is
consistent with battery voltage.
When electric lock is close, the microprocessor will detect
if driver of main contactor is short-circuited and alarm
DRIVER Short circuit
74 will be given if yes. Check if there is short circuit on the
SHORTED of driver
positive pair A 16 of main contactor coil or negative pole.
Change the controller if everything is OK.
Fault of The coil of main contactor can not be normally driven and
CONTACTOR
75 contactor change the controller if the coil of main contactor has no
DRIVER
driver fault.

Detection time : Standby state

The alarm indicates the voltage of accelerator is 1V larger
than the min. value set in the signal scope （PROGRAM
VACC）of accelerator.
Accelerator Possible causes：
78 VACC NOT OK (1) The upper and lower voltage limit values of
error
accelerator have not been collected and do it again when
entering into PROGRAM VACC.
(2) Accelerator error: Accelerator pedal possibly fails to
return or internal error of accelerator.
(3) The failure of controller
Possible causes for incorrect starting sequence:
(1) Direction switch is closed before starting.
Incorrect
INCORRECT (2)Incorrect operation sequence.
79 starting
START (3)Incorrect wire joining.
sequence
(4)If the trouble still can not be eliminated, change the
controller.
The machine will keep on detecting. But when there are
Forward and
signals requesting operation from two directions at the
backward
same time, alarm is given. Possible causes:
signals exist
(1) The wire is damaged.
80 FORW+BACK at the same
(2) Direction switch fault.
time(adhesion
(3)Improper operation.
of direction
(4) Change the controller if the trouble still can not be
switch )
eliminated.
ENCODER The controller detects the great difference between two
82 Encoder error
ERROR consecutive speed readings of encoder. As the encoder in

98
 the system can not change great speed within very short
time, so, the encoder may have the trouble (the circuits of
one or two encoders are destroyed or broken). Check the
mechanical and circuit function of the encoder. The alarm
is possibly caused by the electromagnetic noise on the
bearing of sensor. If not, change the controller.
If “2.5 POT” is set as “ON”, controller will check the
max. and min values of potentiometer recorded during
Programming programming. If the min. value of forward is smaller than
PROG VACC
220 error of the max. value of backward or the min. value of backward
NOT OK
accelerator is bigger than the max. value of forward, the fault will
appear. Check if the potentiometer is correct, or make a
data acquisition again.
In CAN communication network, a controller receives a
signal that the other controller can not make normal
communication and the controller always is always in the
WAITING FOR Waiting for
222 waiting state until CAN communication network is
NODE node signal
completely normal. Check why the wiring of the modules
that fails to communicate is abnormal and see if the
software edition or parameter setting is correct.

During startup, watchdog circuit is activated before

software is started. The watchdog signal is invalid in
WATCHDOG Watchdog standby or operation state( alarm state)
223
#1 fault 1 Fault analysis：Hardware circuit of watchdog or output of
micro-controller is damaged. The above two cases have
nothing to do with external parts, so change the controller.
When the electromagnetic brake connecting to the output
terminal of CNA#18IS or auxiliary coil is shorted, the
fault signal is produced. Withdraw from the fault state
through releasing brake after eliminating the overload
Short circuit condition so that the running request is valid.
COIL
224 of auxiliary
SHORTED EF Fault analysis：Generally, the fault code indicates that the
coil
trouble is on the harness or loading coil. So check the
connection between controller output and load first. If
there is no trouble of external load, the trouble is inside
the controller and the controller needs to be changed.
Cause：During startup, the watchdog circuit is activated
before software is started. The watchdog signal is invalid
WATCHDOG Watchdog (alarm state)in case of standby or operation state.
227 Fault analysis: The hardware circuit of watchdog or
#2 fault 2
output of micro-controller is damaged. The above two
cases has nothing to do with external parts, so change the
controller.
When tiller input switch is off, about 30S later, the main
TILLE
228 TILLER OPEN contactor will be off and warning is given. The warning
off
disappears for next operation.
When the safety input switch is off, so is the main
contactor, meanwhile the electromagnetic brake or
SAFETY Safety Input
229 auxiliary output coil is driven. Check if the port of A11 is
INPUT fault
correctly connected. Change the controller if other parts
are correct.

99
 CAUSE: When the short circuit coil of main contactor is
connected to the output port of CAN#16, the fault signal
is produced. After overload is removed, it automatically
Coil short withdraw from fault state through releasing brake and
COIL circuit of then the running instruction is valid.
230
SHORTED MC main Fault analysis：Generally, the fault code indicates that the
contactor trouble is on the harness or loading coil. So check the
connection between controller output and load first. If
there is no trouble of external load, the trouble is inside
the controller and the controller needs to be changed.
Short circuit fault of the coil protection circuit used to
COIL Fault of coil
drive main contactor, electromagnetic brake or auxiliary
231 SHORTED HW protection
devices
KO circuit
Fault analysis: Change the controller

At start-up stage, if controller detects that there is low

logic level signal when key switch is off, there is a fault.
Fault analysis: Most possibly is that the voltage is
excessively low, suggest to check the followings :
(1) If the key switch is based on external load (e.g. the
starting of DC-DC converter, the input signal of relay or
contactor switch is lower than starting voltage).
(2) Check the positive and negative poles of power cable
KEYOFF Short circuit
232 and cell end and the connection between –BATT and
SHORTED of key switch
+BATT of main contactor and controller. It must be
connected with screw and the torsion scope is
13NM~15NM..
(3) If no voltage drop has been detected on the power
supply line, the fault signal is produced every time when
the key switch is on. The fault may be possibly in the
hardware of the controller; therefore, the controller needs
to be changed.
Software will check the power bridge before main
contactor is closed: It converts into low-end power of
Short circuit
POWER MOS MOS and the phase voltage value drops to –BATT (rise to
233 of power
SHORTED +BATT). If the change of phase voltage value does not
MOS
conform to the instruction, this fault signal is produced.
Change the controller.
Handbrake input signal is valid when the running
instruction is issued.
Fault of Resolution：Possible causes for the fault :
235 HANDBRAKE handbrake (1) Handbrake switch is damaged or wiring is wrong.
switch (2) Handbrake switch works normally. In TESTER menu,
handbrake is always ON. This is a logic fault, so change
the controller.
The maximum current gain parameter is a factory set
value, which indicates that the max. current regulating
CURRENT Fault of
236 parameter program has not be used.
GAIN current gain
Resolution: Correctly set program for current gain
parameter by ZAPI technical personnel.
The fault signal is produced when A/D of all analog
ANALOG Fault of
237 signals is converted into a fixed value and delay exceeds
INPUT Analog Input
400 millisecond. This function is used to check the fault

100
 of A/D converter or analog signal conversion.
Fault analysis: Change the controller if the fault always
exists.
During startup, the feedback value of high end voltage of
VMN is not at about 2.5V. The circuit of controller is
damaged.
Fault analysis : The following checks are suggested:
WRONG ZERO Wrong Zero
238 (1) Internal connection of motor.
VOLTAGE Voltage
(2) Power cable connection of motor.
(3) Drain current between motor and vehicle casing.
(4) If the motor connection is good, the problem is inside
the controller and changes it.

Driver short circuit of safety output.

Fault analysis: Check if there is short circuit or Low
SAFETY Failure of
239 impedance push-pull output betweenA19 and -BATT. If it
OUTPUT safety output
is the circuit trouble of driver of logic card, change the
controller.
Before driving the coil of main contactor, controller tests
MOS driver or the auxiliary output drive is the invalid
HARDWARE Hardware
240 watchdog circuit signal. If it is not driven, there produces
FAULT circuit fault
a fault signal.
Fault analysis: Change the controller.
When key is switched on, the program is a positive value
in flash memory and the fault signal is produced in case of
negative value.
FLASH Flash Fault analysis: The problem is on flash memory of
241
CHECKSUM Memory fault microcontroller. The flash memory may be damaged or
the program stored destroyed. Try to reset the program of
logic card. The fault exists in the microcontroller if the
fault still exists, Change the controller.
Under normal condition， if the target speed is greater
than10 Hz and the rotation speed of motor higher than 1.5
Feedback Hz, the feedback signal of encoder checked by controller
ENCODER
242 signal fault of should exceed a threshold value. If not, the controller will
LOCKED
encoder give alarm. Test the motor encoder and see if motor or
wiring is normal and if installation correct. Change the
controller if periphery is normal.
Phenomenon：The output signal of temperature sensor of
Fault of motor exceeds the scope.
SENS MOT
243 temperature Solution: Check the value of sensor and connection of
TEMP KO
sensor wires and the fault is inside the controller in case of no
problem found.
During software testing, there are many reasons for such
SOFTWARE fault such as: CAN communication fault and EEPROM
244 Software error
ERROR READ/WRITE ERROR etc. Check the parameter of
“DEBUG MODE”, the value must be “OFF”.
Wrong contents are found when testing the main memory:
WRONG RAM Dynamic
245 The registration address is “DIRTY” and the fault will
MEMORY memory fault
restrict the operability of vehicle.

101
 Fault analysis: Switch on the key after switching it off and
change the controller if the trouble still exists.
Auxiliary Auxiliary coil drive circuit can not drive load. The
AUX DRIVER
246 output drive equipment or drive coil is damaged. Change the
OPEN
fault controller.
The fault will be hinted when calibrating the current gain.
DATA Data
247 No treatment is needed and it will automatically disappear
ACQUISITION acquisition
when calibration is finished.
CAN communication fault between pump and traction.
NO CAN NO CAN
248 Check CAN wiring, software setting and edition
MESSAGE signal
information.
CHECK UP It is the time for service and maintenance is needed.
249 Service time
NEED

The output signal of temperature sensor of controller

THERMIC Temperature exceeds the range.
250
SENS KO sensor fault The fault has nothing to do with external parts and change
the controller.
During startup, the controller tests if the voltage of battery
is within the nominal scope. Check if the value of
WRONG SET Wrong set of BATTERY VOLTAGE parameter in the menu conforms to
251
BATTERY battery that on the voltmeter. If not, make them conform to each
other with the function of ADJUST BATTERY.
Change the battery.
Wrong selection of SLIP PROFILE PARAMETERS.
253 SLIP PROFILE Slip fault Check the setting of these values in the hardware setting
parameters.
Short circuit of the driving electric circuit of the
Auxiliary electromagnetic brake or auxiliary electric brake. Check if
AUX DRIVER
254 drive there is short circuit between the A16 and BATT.
SHORTED
shorted Circuit ault of the drive unit of the logic card; change the
controller.

(2) Common fault of pump control system (The second line of instrument indicates “ON

NODE 5”)

Table 4-9 Common fault of pump control system

Fault
Implication Note Measures
Code
The fault is in the internal memory for storing and regulating
parameters. When the fault appears, the machine
EEPROM automatically stops. If the fault still exists, when reconnecting
13 EEPROM KO
damaged it after switching off the electric lock, change the controller. If
the fault disappears, the parameters previously stored will be
replaced with default value.
LOGIC Logic card Current protection function failure of logic card: change the
17
FAILURE #3 failure 3 controller.
LOGIC Logic card Circuit failure of phase voltage feedback hardware on logic
18
FAILURE #2 failure 2 card. Change the controller.
19 LOGIC Logic card The failure produced when the function of low or over voltage

102
 FAILURE #1 failure 1 acts. In 24V system, the voltage detected by controller
exceeds 45V or lower than 9V. In 48V system, the voltage
detected by controller exceeds 65V or lower than 11V.
Possible causes:
(1) Check if there is short circuit in the electric circuit system
such as DC-DC and brake coils etc or if the input power
supply contact of controller is good.
(2) If the battery voltage is excessively low or high.
(3) Check B+ and B and see if the power cable on the wiring
terminal of contactor etc is tightly fixed.
(4) If the voltage calibration parameter of controller is in
consistent with actual voltage.
(5) There is circuit fault of overvoltage protection hardware on
logic card, change the controller.
Cause：The high-end voltage of MOS during startup is 66%
smaller than the capacitor voltage or this voltage is smaller
than the required value in the operation of motor.
Possible causes:
(1) Wiring of motor is incorrect or there is circuit problem in
30 VMN LOW Low VMN motor. Check if three-phase connection of motor is correct, if
there is any leakage of electricity on ground and circuit break
of motor coil.
(2) If actuation of main contactor is rigid and if there is any
wearing on contact?
(3) Change the controller .
Cause：During startup, the low-end voltage of MOS tube is
10% higher than that of normal battery voltage or the phase
voltage is higher than 1/2 of battery voltage.
31 VMN HIGH High VMN Possible cause：
(1) The wiring of motor is incorrect or there exists problem in
motor circuit . Check if three-phase connection of motor is
correct, if there is any leakage of electricity on the ground and
circuit break of motor coil. (2) Change the controller
The signal output by current sensor detected by micro-control
High
STBY I system exceeds the scope allowed for non-operation current.
53 standby
HIGH The trouble has nothing to do with the peripheral parts, so the
current
controller needs to be changed.
When the electric lock is switch on, inverter will charge the
capacitance through power resistance and check if capacitance
is fully charged within the time stipulated, otherwise, the
capacitance voltage remains 20% lower than battery voltage,
the inverter will give alarm and the main contactor will not
Wrong close.
CAPACITOR capacitance
60 Possible causes：
CHARGE charge
(1) Peripheral equipment, e.g. DC-DC, motor or other
equipment etc interfere with the charging process of controller
and these interferences need to be eliminated.
(2) The charging resistance is disconnected, there is fault on
charging circuit and power module ,so controller needs to be
changed.
TEMPERAU Over-high In case that total power is allowed, the temperature of
62
RE temperature controller exceeds 85℃( it relates to the parameter

103
 “ MAXIMUM CURRENT”.)
Their corresponding relations are as follows: Parameter set
alarm temperature
MAXIMUM CURRENT=50% 96℃
MAXIMUM CURRENT=60% 94℃
MAXIMUM CURRENT=70% 92℃
MAXIMUM CURRENT=80% 90℃
MAXIMUM CURRENT=90% 88℃
MAXIMUM CURRENT=100% 86℃
Now, the max. current of controller decreases with the
increase of the max. current temperature. When the
temperature is 105℃, the current of controller decreases to
zero.
The fault appears if chopper is in the cold state:
(1) Temperature calibration parameter of logic card is
incorrect, check parameters.
(2) The internal temperature sensor of controller has trouble
and change the controller.
If temperature digital switch of motor is turned on or analog
signal exceeds the cutoff value, the trouble is produced. When
the motor temperature reaches 120℃, the controller gives
alarm, the vehicle can move at this time. But the max. current
MOTOR High motor
65 and performance are cut down. When the motor temperature
TEMPERAT. temperature
reaches 125℃, motor stops working. Now try to lower the
temperature of the motor.
If the fault still exists when motor is cooled, check the circuit
and change the controller if he circuit is OK.
When electric lock is close, the microprocessor will detect if
driver of main contactor is short-circuited and alarm will be
DRIVER Short circuit
74 given if yes. Check if there is short circuit on the positive pair
SHORTED of driver
A 16 of main contactor coil or negative pole. Change the
controller if everything is OK.
Detection time : Standby state
The alarm indicates the voltage of accelerator is 1V larger
than the min. value set in the signal scope （PROGRAM
VACC）of accelerator.
VACC NOT Accelerator Possible causes：
78 (1) The upper and lower voltage limit values of accelerator
OK error
have not been collected and do it again when entering into
PROGRAM VACC.
(2) Accelerator error: Accelerator pedal possibly fails to return
or internal error of accelerator.
(3) The failure of controller
Possible causes for incorrect starting sequence:
(1) Direction switch is closed before starting.
Incorrect
INCORRECT (2)Incorrect operation sequence.
79 starting
START (3)Incorrect wire joining.
sequence
(4)If the trouble still can not be eliminated, change the
controller.
ENCODER Encoder The controller detects the great difference between two
82
ERROR error consecutive speed readings of encoder. As the encoder in the

104
 system can not change great speed within very short time, so,
the encoder may have the trouble (the circuits of one or two
encoders are destroyed or broken). Check the mechanical and
circuit function of the encoder. The alarm is possibly caused
by the electromagnetic noise on the bearing of sensor. If not,
change the controller.
If the parameter of the “SAFE OUT CONFIG” is 1, the
SEAT Seat switch fault may occur. If the traction seat switch signal is different
221
MISMATCH signal fault from the pump controller sear switch signal, the fault may
occur. Check the seat switch connecting.
In CAN communication network, a controller receives a
signal that the other controller can not make normal
communication and the controller always is always in the
WAITING Waiting for
222 waiting state until CAN communication network is
FOR NODE node signal
completely normal. Check why the wiring of the modules that
fails to communicate is abnormal and see if the software
edition or parameter setting is correct.
During startup, watchdog circuit is activated before software
is started. The watchdog signal is invalid in standby or
WATCHDOG Watchdog operation state( alarm state)
223
#1 fault 1 Fault analysis：Hardware circuit of watchdog or output of
micro-controller is damaged. The above two cases have
nothing to do with external parts, so change the controller.
Cause：During startup, the watchdog circuit is activated before
software is started. The watchdog signal is invalid (alarm
WATCHDOG Watchdog state)in case of standby or operation state.
227
#2 fault 2 Fault analysis: The hardware circuit of watchdog or output of
micro-controller is damaged. The above two cases has nothing
to do with external parts, so change the controller.
When the safety input switch is off, so is the main contactor,
SAFETY Safety Input meanwhile the electromagnetic brake or auxiliary output coil
229
INPUT fault is driven. Check if the port of A11 is correctly connected.
Change the controller if other parts are correct.
At start-up stage, if controller detects that there is low logic
level signal when key switch is off, there is a fault.
Fault analysis: Most possibly is that the voltage is excessively
low, suggest to check the followings :
(1) If the key switch is based on external load (e.g. the starting
of DC-DC converter, the input signal of relay or contactor
Short circuit switch is lower than starting voltage).
KEYOFF
232 of key (2) Check the positive and negative poles of power cable and
SHORTED
switch cell end and the connection between –BATT and +BATT of
main contactor and controller. It must be connected with
screw and the torsion scope is 13NM~15NM..
(3) If no voltage drop has been detected on the power supply
line, the fault signal is produced every time when the key
switch is on. The fault may be possibly in the hardware of the
controller; therefore, the controller needs to be changed.
Software will check the power bridge before main contactor is
POWER Short circuit closed: It converts into low-end power of MOS and the phase
233 MOS of power voltage value drops to –BATT (rise to +BATT). If the change
SHORTED MOS of phase voltage value does not conform to the instruction,
this fault signal is produced. Change the controller.

105
 The fault signal is produced when A/D of all analog signals is
Fault of converted into a fixed value and delay exceeds 400
ANALOG
237 Analog millisecond. This function is used to check the fault of A/D
INPUT
Input converter or analog signal conversion.
Fault analysis: Change the controller if the fault always exists.
During startup, the feedback value of high end voltage of
VMN is not at about 2.5V. The circuit of controller is
damaged.
WRONG Fault analysis : The following checks are suggested:
Wrong Zero
238 ZERO (1) Internal connection of motor.
Voltage
VOLTAGE (2) Power cable connection of motor.
(3) Drain current between motor and vehicle casing.
(4) If the motor connection is good, the problem is inside the
controller and changes it.
Driver short circuit of safety output.
Failure of Fault analysis: Check if there is short circuit or Low
SAFETY
239 safety impedance push-pull output betweenA19 and -BATT. If it is
OUTPUT
output the circuit trouble of driver of logic card, change the
controller.
Before driving the coil of main contactor, controller tests
MOS driver or the auxiliary output drive is the invalid
HARDWARE Hardware
240 watchdog circuit signal. If it is not driven, there produces a
FAULT circuit fault
fault signal.
Fault analysis: Change the controller.
When key is switched on, the program is a positive value in
flash memory and the fault signal is produced in case of
negative value.
Flash
FLASH Fault analysis: The problem is on flash memory of
241 Memory
CHECKSUM microcontroller. The flash memory may be damaged or the
fault
program stored destroyed. Try to reset the program of logic
card. The fault exists in the microcontroller if the fault still
exists, Change the controller.
Under normal condition， if the target speed is greater than10
Hz and the rotation speed of motor higher than 1.5 Hz, the
Feedback feedback signal of encoder checked by controller should
ENCODER
242 signal fault exceed a threshold value. If not, the controller will give alarm.
LOCKED
of encoder Test the motor encoder and see if motor or wiring is normal
and if installation correct. Change the controller if periphery is
normal.
Phenomenon：The output signal of temperature sensor of
Fault of motor exceeds the scope.
SENS MOT
243 temperature Solution: Check the value of sensor and connection of wires
TEMP KO
sensor and the fault is inside the controller in case of no problem
found.
During software testing, there are many reasons for such fault
SOFTWARE Software such as: CAN communication fault and EEPROM
244
ERROR error READ/WRITE ERROR etc. Check the parameter of
“DEBUG MODE”, the value must be “OFF”.
Wrong contents are found when testing the main memory: The
WRONG Dynamic
registration address is “DIRTY” and the fault will restrict the
245 RAM memory
operability of vehicle.
MEMORY fault
Fault analysis: Switch on the key after switching it off and

106
 change the controller if the trouble still exists.
DATA The fault will be hinted when calibrating the current gain. No
Data
247 ACQUISITIO treatment is needed and it will automatically disappear when
acquisition
N calibration is finished.
NO CAN NO CAN CAN communication fault between pump and traction. Check
248
MESSAGE signal CAN wiring, software setting and edition information.
CHECK UP It is the time for service and maintenance is needed.
249 Service time
NEED
The output signal of temperature sensor of controller exceeds
THERMIC Temperature the range.
250
SENS KO sensor fault The fault has nothing to do with external parts and change the
controller.
During startup, the controller tests if the voltage of battery is
within the nominal scope. Check if the value of BATTERY
Wrong set
WRONG SET VOLTAGE parameter in the menu conforms to that on the
251 of
BATTERY voltmeter. If not, make them conform to each other with the
battery
function of ADJUST BATTERY.
Change the battery.
SLIP Wrong selection of SLIP PROFILE PARAMETERS. Check
253 Slip fault
PROFILE the setting of these values in the hardware setting parameters.

4.7.2.2 ZAPI HP-CAN controller

(1) Common fault of control system (The second line of instrument indicates “ON NODE

5”)

Table 4-10 Common fault of control system

CODE NOTE
13 EEPROM KO
241 CAN BUS KO
243 KEYOFF
244 WATCHDOG
76 COIL SHORTED
74 DRIVER SHORTED
53 STANDBY HIGH CURRENT
30 VMN LOW
49 CURRENT ALWAYS EQUAL 0
33 FULL CONDUCTION KO
78 VACC NO OK
62 THERMIC SENSOR KO
66 BATTERY LOW
79 INCORRECT START
7 CHOPPER NOT CONFIG
242 BATTERY OVERVOLTAGE
246 WAIT MAIN CONTAC

(2) Fault explain of HP-CAN controller

107
 a) < BATTERY LOW >

The battery charge is low.

The alarm is signalled only if the BATTERY CHECK option has been selected. All

functions except hydrdrive are inhibited.

b) < INCORRECT START >

A running request is present on key startup.

Possible causes:

● Operator error.

● Request microswitch stuck.

c) < STANDBY HIGH CURRENT >

Test carried out in standby, checks that the current is nil. If this is not verified, an

alarm is signalled. This alarm shuts down the machine.

Possible causes:

● Current sensor broken and logic failure.

First replace the logic, and if the defect persists, replace the power unit.

d) < CURRENT ALWAYS EQUAL 0 >

Test carried out in running. Checks that the current during running is greater than a

minimum value. If not, an alarm is signalled and the machine is shut down.

Possible causes:

● The current sensor is faulty. Replace the power unit.

e) < WATCH-DOG >

The test is made in both running and standby. It is a self-diagnosis test within the

logic. If an alarm should occur, replace the logic.

f) < COIL SHORTED >

Cause:

108
 This alarm occurs when there is a short circuit of LC coil connected to driver output

of the HP CAN. After the overload condition has been removed, the alarm exits

automatically by releasing and then enabling an hydraulic demand.

Troubleshooting:

● The typical root cause for this error code to be displayed is in the harness or in

the load coil. So the very first check to carry out concerns connections between controller

outputs and loads.

● In case no failures/problems have been found

g) < DRIVER SHORTED >

Cause:

The driver of the main contactor coil is shorted.

Troubleshooting:

● Check if there is a short or a low impedance pull-down between NMC and

–BATT.

● The driver circuit is damaged in the controller, which has to be replaced.

h) < VMN LOW >

Cause:

The pump motor output is lower than expected, considering the pwm applied.

Troubleshooting:

● If the problem occurs at start up (the LC does not close at all), check:

- Motor internal connections (ohmic continuity).

- Motor power cables connections.

- If the motor connection are OK, the problem is inside the controller.

● If the problem occurs after closing the LC (the LC closed and then opens back

again), check:

109
 - Motor connections.

- If motor windings/cables have leakages towards truck frame.

- If no problem are found on the motors, the problem is inside the controller.

● If the alarm occurs during motor running, check:

- Motor connections.

- If motor windings/cables have leakages towards truck frame.

- That the LC power contact closer properly, with a good contact.

- If no problem are found on the motors, the problem is inside the controller.

i) < DRIVER SHORTED >

Cause:

The driver of the main contactor coil is shorted.

Troubleshooting:

● Check if there is a short or a low impedance pull-down between NMC (CNA#26)

and –BATT.

● The driver circuit is damaged in the controller, which has to be replaced.

j) < NO FULL COND. >

The test is carried out in full conduction. If, in this condition, the VMN is found to

be greater than 1/3 VBATT, the diagnostic circuit is faulty, causing a safety risk, and thus

machine operation is inhibited. If the defect persists, replace the logic.

k) < CAN BUS KO >

Cause:

No Can messages received by the HP CAN microcontroller from other devices

(CAN BUS nodes).

Troubleshooting:

This alarm could be caused by a can bus malfunctioning, which blinds

110
communication. Otherwise it is an internal fault of the controller which must be replaced.

(3) Common fault for ZAPI instrument system (The second line of instrument indicates

“ON NODE 16”）

Table 4-11 Common fault for instrument system
Fault
Implication Note Measures
Code
Trouble is in the internal memory to store and regulate
the parameters. Machine will automatically stops in case
of trouble. The controller should be changed if the
EEPROM
13 EEPROM KO trouble still exists after reconnection when the electric
damaged.
lock is turned off. If the trouble disappears, the
parameters stored before will be replaced with default
value.
Circuit failure of A19 or A20 output port，change the
LOGIC Logic card
18 instrument if it has nothing to do with external
FAILURE #2 failure 2
components.
Drive coil short circuit: Test if there is short circuit on the
76 COIL SHORT Coil short device connecting with output port of the instrument,
otherwise, change the instrument.
Instrument no longer receives the data from CAN BUS
data wire. In case that the fault code and other alarm
signal are displayed together, the fault may possibly be
CAN
CAN BUS KO on the CAN interface of the instrument, because the
102 communication
MASTER instrument can not receive any message. So, suggest to
failure
check the wiring and connection of CAN , or the CAN
interface fault of other modules will appear in the CAN
network.
SERVICE Maintenance is
103 It is the time for maintenance (service).
REQUIRED Needed.
The input of hydraulic oil level is valid during startup.
Trouble Diagnosis：
Check if the related digital input on instrument （A9）is
valid（Refer to TESTER MENU）
HYDRAULIC Check the effective level form（+VB or GND） of the
104
OIL input end (Refer to SET OPTION MENU).
(1) If the input is valid, check the relating switch, circuit
and oil level.
(2) If the input is invalid, there might have an input
circuit trouble in the intelligent instrument.

4.7.3 INMOTION control system

Table 4-12 INMOTION controller fault code and troubleshooting

111
Fault
Fault Remedy
code
20 ERROR: Acceleration pedal is activated when starts. Release acceleration pedal
21 ERROR: Direction switch is activated when starts. Shift direction switch to neutral gear
ERROR: front and rear direction switches are direction switch failure
22
activated at the same time.
ERROR acceleration pedal analog quality exceeds
23 Acceleration pedal fault or recalibrate
range
analog quality
24 ERROR: acceleration pedal analog failure
ERROR : CAN communication of driver failure Check CAN bus or controller;
31
Or Instrument is disconnected.
32 ERROR: Low battery voltage Charging is needed.
34 ERROR: CPU inner failure It is suggested to change hardware test.
36 ERROR: Tilt switch is activated when starts. Restore tilt switch.
37 ERROR: Side shift is activated when starts. Restore side shift switch.
ERROR : Attachment switch is activated when Restore attachment switch.
38
starts.
39 ERROR: Lifting switch is activated when starts. Restore lifting switch.
Lifting analog quantity is damaged or
40 ERROR: lifting analog quantity exceeds range.
recalibrate analog quality
ERROR: steering angle analog quantity exceeds steering angle analog quantity is damaged
43
range. or recalibrate analog quality
44 WARNING of traction driver speed protection Alarm of high truck speed
45 WARNING: fault of traction driver encoder Check if encoder harness is poor connected.
81 WARNING: low traction driver temperature Over low environment temperature
Traction driver temperature is over high and
82 WARNING: high traction driver temperature
its power is limited.
83 ERROR: traction driver temperature sensor failure Change driver
84 WARNING: low traction motor temperature Over low environment temperature
Traction motor temperature is over high and
85 WARNING: high traction motor temperature
its power is limited.
Traction motor temperature sensor is
86 ERROR: traction motor temperature sensor failure abnormal and please check sensor or
harness.
Traction motor speed encoder is abnormal
87 ERROR: traction motor speed sensor failure
and please check encoder or harness.
The input voltage connected to driver is
88 WARNING: high traction driver DC bus voltage
detected to be over high.
89 WARNING: low traction driver DC bus voltage Charge the battery or check power harness.
Safe protection after refreshing procedures.
90 WARNIN: traction driver default value is loaded.
it will be ok after restart the key switch.
WARNING : traction driver performance limiting Low battery quantity and truck performance
91
mode is limited.
Check if the output port harness is short
97 ERROR: traction driver output port failure. circuit or open circuit(such as main
contactor, backward relay and so on).
98 WARNING： traction driver over current or short Check power harness

112
 circuit
101 ERROR: traction motor driver short circuit
102 ERROR: high traction driver temperature Cool driver
103 ERRO: high traction motor temperature Cool motor
104 ERROR: traction driver over current Check power harness
105 ERROR: overtime of traction driver precharging Change precharging resistance
Driver input voltage is overlow, please
110 ERROR: low traction driver DC bus voltage check battery voltage or check if contactor
is connected.
111 ERROR: high traction driver DC bus voltage
driver input voltage is overhigh, please
ERROR: high traction driver DC bus check battery voltage.
112
voltage( hardware monitor)
Check motor encoder and temperature
114 ERROR: interior power supply failure
sensor harness
121 WARNING: low pump driver temperature Overlow environment temperature
Pump driver temperature is high and its
122 WARNING: high pump driver temperature
power is limited.
123 ERROR pump driver temperature sensor failure Change driver
124 WARNING: low pump motor temperature Overlow environment temperature
Pump motor temperature is overhigh and its
125 WARNING: high pump motor temperature
power is limited.
Pump motor temperature sensor is
126 ERROR: pump motor temperature sensor failure abnormal and please check sensor or
harness.
Pump motor speed encoder is abnormal and
127 ERROR: pump driver speed sensor failure
check encoder or harness.
The input voltage connected to driver is
128 WARNING: pump driver DC bus voltage is high.
detected to be overhigh.
129 WARNING: pump driver DC bus voltage is low. Charge or check the power harness.
Safe protection after refreshing procedure
130 WARNING: pump default value is loaded.
and it will be ok after restart the key.
Battery quantity is low and charge the
132 WARNING : pump driver performance is limited.
battery.
Check if output port harness has short
137 ERROR: pump driver output port failure
circuit or open circuit.
WARNING: pump driver over current or short
138
circuit. Check power harness.
141 ERROR: pump drive short circuit
142 ERROR: pump driver temperature is high. Cool driver.
143 ERROR: high pump motor temperature. Cool motor.
144 ERROR: pump driver current calibrating failure Restart.
145 ERROR pump driver precharging overtime Change precharging resistance.
Driver input voltage is overlow and check
150 ERROR: pump driver DC bus voltage low. battery voltage or check if contactor is
connected.
151 ERROR: pump driver DC bus voltage high. Driver input voltage is overhigh and check

113
 ERROR pump driver DC bus voltage high (hardware battery voltage.
152
monitor)
Check motor encoder and temperature
153 ERROR pump driver interior fault.
sensor harness.
154 ERROR: pump driver speed control failure. Check encoder or harness.

4.7.4 Songzheng control system

Table 4-13 Songzheng controller fault code and troubleshooting

No. fault phenomenon Fault name Fault reasons Fault remove condition
1. contactor
disconnected 1.Connect the phase
immediately after it Open circuit of There is more than one line correctly.
1
is closed. motor phase line phase line is unconnected. 2.Turn on the key
2 fault codes 3-7 switch.
alarm.
1.Main contactor is open circuit or
1.connect DRV1 coil;
disconnected. short circuit of DRV1 short circuit or
2 2.restart the interlock
2. Fault codes main contactor DRV1open circuit
switch
3-1alarm. coil
1. Main contactor
does not 1.change main
connected. main contactor contactor
3 main contactor sticks
2. Fault codes3-8 sticks 2. restart the interlock
alarm in 2 switch
seconds.
1. Main contactor
1.Make sure B+ 、
does not
B-connection is
connected. precharging
4 Precharging failure correct.
2. Fault codes1-4 fault
2. restart the interlock
alarm in 2
seconds. switch
1.controller output
Turn off key switch, preset Neutral gear and oil
failure;
5 High foot pedal direction or oil throttle is throttle is no more than
2. Fault codes
less than 25%. 25%.
4-7alarm.
1.Limut the max.
current of the
Battery
controller in Battery voltage≤ allocated
6 Under voltage voltage >(allocated
proportion; under voltage ±2V
under voltage+2V)±2V
2.fault codes 2-3
alarm.
battery voltage≤ serious
under voltage under voltage
1 Controller output
value ±2V (note: serious Battery
failure Severe under
7 under voltage voltage >(serious under
2.fault codes 1-7 voltage
value=allocated voltage voltage+2V)±2V
alarm.
value+ battery voltage
power extraction range)
8 1.Limut the max. Over voltage Battery voltage ≥ allocated Battery

114
 current of the over voltage ±2V voltage<allocated over
controller in voltage +2V)±2V
proportion;
2.fault codes
2-4alarm.

1 Controller output Battery voltage≥ serious 1. battery voltage

failure Serious over over voltage±2V (note: <serious over voltage
9 serious over
2.fault codes voltage ±2V.
1-8alarm. voltage=allocated over 2. restart the key.
voltage +10V）
1.Limut the max.
current of the
Motor
controller in Motor over Motor temperature ≥motor
10 temperature<motor
proportion; temperature over temperature value
over temperature value
2.fault codes
2-8alarm.

1.Limut the output

of controller to Motor Motor temperature sensor is Connect the motor
11 be 50% of its temperature unconnected or its output temperature sensor
max. sensor fault forms short circuit to earth. correctly.
2.fault codes
2-9alarm.
1 Controller output 1.controller
Controller Controller temperature
failure temperature >-40℃
12 temperature is
2.fault codes ≤-40℃ ；
over low.
1-5alarm. 2.restart the key
1.Limut the max.
current of the
controller
controller in Controller temperature Controller temperature
13 temperature
proportion; ≥85℃ <85±℃
over high
2.fault codes 2-2
alarm.

1 Controller output Controller 1.controller temperature

Controller temperature
14 failure temperature <95℃；
≥95℃
2.fault codes over high 2.restart the key
1-6alarm.
External +5V voltage
External +5Vvoltage <4.5V
External 5V ≥4.5V and ≤5.5V.
or >5.5V
fault External power output
Fault codes 2-5,6-9 External power output
15 External power current≥allocated min.
alarm. current<allocated min.
supply over current value and
current value or >allocated
loaded ≤allocated max. current
max. current value.
value.

115
 1. Accelerator
Accelerator is disconnected
equivalent output is
Accelerator or accelerator output voltage Connect the accelerator
16 0.
output is high. ≥5.5V. correctly.
2. fault codes 4-1
alarm.

1. oil throttle
equivalent output
is full brake Brake output is Brake is disconnected or Connect the brake
17 value. high. output ≥5.5V correctly.
2. Fault codes 4-3
alarm。
1. oil throttle
equivalent output
is 0.
2. brake equivalent Accelerator or brake low Connect the accelerator
18 Accelerator over
output full brake end current is too large or brake correctly
current
value. (100mA)
3. fault codes 4-5
alarm.
1 Controller output 1. Make sure hardware
1. Correct data can not be
failure EEPROM write is connected correctly.
19 written into EEPROM.
2.fault codes 4-6 failure 2. Write correct data.
2. The data written in is out
alarm. 3. restart the key.
of range.
1. controller
operates with 1. It is unable to read correct 1. Make sure hardware
default EEPROM read date from EEPROM. is connected correctly.
20
parameter; failure. 2. The read data is out of the 2. Write correct data.
2. Fault codes 4-8 range.
alarm.
1 Controller output Important
Upper computer modified
failure parameter
21 important parameter after Restart the key.
2. Fault codes 4-9 modification
the contactor is closed.
alarm. fault
1 Controller output
failure Controller over Controller output phase
22 Restart the key.
2. Fault codes current current ＞700A
1-2alarm.
1 Controller output
DSP
failure Fault occurs when allocating
configuration Restart the key.
23 2. Fault codes 1-1 DSP parameter.
parameter fault.
alarm.
1 Controller output MCU and DSP
failure CAN Communication fault
24 Restart the key.
2. Fault codes 2-1 Transmit-receive between MCU and DSP
alarm. fault

4.7.5 Fault code of Fanji control system

116
Battery overvoltage protection

 Fault code:1

 Fault level:1

 Fault reason: the instant battery voltage is detected to be over 63V through internal

measuring of the control units.

 Remedy：

1、 Check if the connection between battery and controller system cable is well.

2、 Check if the battery voltage is normal.

3、 Replace the control unit.

Battery undervoltage protection

 Fault code :2

 Fault level:1

 Fault reason: the instant battery voltage is detected to be under 24V through internal

measuring of the control units.

 Remedy :

1、 Check if the battery is well connected and if the poles of battery are rusted.

2、 Check the battery condition. If the electrolyte is used up, the undervoltage

protection will be activated. Or the fault will be activated when large current

application (for example, full load working of oil pump motor and drive motor)

when the battery energy is low.

3、 Replace the control unit。

Before starting, the acceleration pedal is pressed.

 Fault code :3

117
 Fault level :1

 Fault reason: the operator presses the acceleration pedal ahead when the system is

self checking (the main circuit breaker is disconnected).

 Remedy:

1、 If it is caused by pressing the acceleration pedal ahead, restart after releasing the

acceleration pedal.

2、 Check and calibrate the acceleration pedal’s value. Check if the minimum and

maximum voltage of acceleration pedal is accurate. Recalibrate when the value

is not accurate through connecting upper computer monitoring software or

meter.

3、 Check if the control unit of main harness is well connected with the accelerator

pedal. If the connection is well, press the acceleration pedal through the upper

computer monitoring software, observe the feedback voltage of the pedal is

within normal range.

-17(12V)

-30(ground connection)

-18(input of pedal feedback signal)

4、 Replace the control unit。

Flash memory fault

 Fault code:5

 Fault level :1

 Remedy : there is one or several control parameters of truck or motor in the control

unit exceeding allowable range or fault occurs when verifying through writing in

(inconsistency between writing and reading).

118
 Remedy :

1、 Reload default value: through FJ monitoring software, change the corresponding

new value of the parameter to ON. turn off the system and then turn on, the

system will export the default value.

2、 If the fault can not be solved through remedy 1, replace the control unit.

Low voltage of pre-charging capacitor

 Fault code :6

 Fault level :1

 Remedy :when the motor is working, the voltage of pre-charging capacitor is lower

than 70% of the battery voltage.

 Remedy:

1、 Start working when the contactor is connected after the power up.

2、 Check if the main circuit breaker is well connected with main harness. The

correct connection is below：

-29(positive pole )

-15(negative pole)

3、 Check if the main fuse is well.

4、 Replace the main circuit breaker.

5、 Replace the control unit.

Unsaturation or overcurrent of driving motor power module

 Fault code:8

 Fault level :1

 Fault reason: the actual current of drive power module exceeds limit value.

119
 Remedy：

1、 Check if there is short circuit between drive module and cables of three phases

of motor (there is short circuit between cables of three phases or between cable

of one phase and truck body). Check if the coils of motor have burning smell.

2、 Check if the control unit and drive module is well connected.

3、 Disconnect the connection between power module and UVW cables. Check if

the resistances between power module + /-terminals and UVW terminals are

consistency with high resistance of multimeter. If there is one pair of resistance

having large difference with the others, it means that the power module is burnt.

Change the power module.

4、 Replace the control unit.

The charging of pre-charging capacitor is too fast.

 Fault code:9

 Fault level:1

 Fault reason: when the power is on, the increase of pre-charging capacitor is too fast.

 Remedy ：

1、 Replace the main circuit breaker.

2、 Replace the power module one by one to exclude drive and oil pump power

module.

3、 Replace the control unit.

Overheat of oil pump motor module

 Fault code:10

 Fault level:6

120
 Fault reason :the temperature of oil pump motor power module exceeds 90℃.

 Remedy：

1、 The fault may be caused by insufficient cooling. Check the cooling performance

between power modules and aluminum plate and between aluminum plate and

frame. Even and proper heat conducting silicone grease between modules and

aluminum and between aluminum plate and frame ensures effective cooling.

Note: read the temperature of power module of oil pump motor through Fanji

upper computer software or instrument.

2、 If the cooling performance of the modules are normal, please check if the oil

pump is normal. Check if the lifting potentiometer of control valve’s operating

lever and each switch control signal can reset normally or not in particular;

secondly, the oil pump power module may need to be changed.

3、 Replace the control unit.

When the system is starting, the pre-charging capacitor does not discharge

effectively.

 Fault code :11

 Fault level :1

Fault reason: When the power is on, the pre-charging capacitor does not discharge

effectively.

 Remedy：

1、 Check if the oil pump motor and oil pump power module are well connected;

check if the oil pump motor module and control unit are well connected.

2、 Replace the oil pump motor power module.

3、 Replace the main circuit breaker.。

121
 4、 Replace the control unit.

Lower battery voltage

 Fault code:12

 Fault level :3

 Fault reason : battery voltage is lower than the protection value of discharging.

 Remedy ：

1、 Charge the battery. Note: if the battery voltage is still lower than the reset value

of battery after charging, in that case, the fault will not disappear. The fault will

disappear only when the battery voltage after charging is higher than battery

reset value. And in that condition, the truck can be allowed to work normally.

2、 Measure the battery voltage. If the measured value disagrees with the battery

discharging protection value, replace the control unit.

High temperature of drive motor

 Fault code:13

 Fault level :5

 Fault reason: the temperature of drive motor will reach to the maximum temperature

set by customer soon.

 Remedy：

1、 Check if connection between the motor temperature sensor and main harness is

normal.

2、 If the fault occurs when the temperature of motor is not high:

1) Measure the resistance between the two lines of motor temperature sensor

through handhold multimeter. Compare the measured value with truth table

122
 of motor temperature sensor. If the measured value disagrees with the

motor actual temperature, change the temperature sensor.

2) Replace the control unit.

3、 If the fault occurs when the motor temperature is high:

1) If the value from the upper computer software or meter agrees with motor

actual temperature, check if the motor case is clean and if the cooling

performance of motor is normal.

2) Check if the drive motor is normal; check if there is any abnormal

phenomenon such as brake locking.

High temperature of oil pump motor

 Fault code:14

 Fault level :6

 Fault reason: the temperature of oil pump motor will reach to the maximum

temperature set by customer soon.

 Remedy：

1. Check if connection between the motor temperature sensor and main harness is

normal.

2. If the fault occurs when the temperature of motor is not high:

1) Measure the resistance between the two lines of motor temperature sensor

through handhold multimeter. Compare the measured value with truth table of motor

temperature sensor. If the measured value disagrees with the motor actual

temperature, change the temperature sensor.

2) Replace the control unit.

3. If the fault occurs when the motor temperature is high:

123
 1) If the value from the upper computer software or meter agrees with motor

actual temperature, check if the motor case is clean and if the cooling performance of

motor is normal.

2) check if the motor is normal especially check if there is long time continue

working of oil pump motor caused by abnormal reset of potentiometer of control lever’s

operation lever pr switch signal. Long time working of oil pump motor will cause high

temperature.

Current loss of drive motor

 Fault code:15

 Fault level:1

 Fault reason: the motor phase current is not zero when starting the system.

 Remedy：

1. Check if the connection between motor power module and control unit is well.

2. Replace the power module.

3. Replace the control unit.

Overcurrent of main circuit breaker

 Fault code:17

 Fault level:1

 Fault reasons: overcurrent of main circuit breaker.

 Remedy：

1. Check if there is short circuit if main circuit breaker coil.

2. Replace the main circuit breaker.

3. Replace the control unit.

124
Overheat of drive motor power module

 Fault code:20

 Fault level :5

 Fault reason: the temperature of driver motor power module exceeds 90℃.

 Remedy：

1、The fault may be caused by insufficient cooling. Check the cooling performance

between power modules and aluminum plate and between aluminum plate and frame.

Even and proper heat conducting silicone grease between modules and aluminum

and between aluminum plate and frame ensures effective cooling.

Note: read the temperature of power module of oil pump motor through Fanji upper

computer software or instrument.

2、 if cooling performance of the above modules are well, check if the drive motor is

normal. Abnormal working of motor will cause overhearing of power module; secondly,

the power module may need to be changed.

3. Replace control unit.

Unsaturation or overcurrent of oil pump motor power module

 Fault code:24

 Fault level :1

 Fault reason: the actual current of oil pump motor power module exceeds limit value.

 Remedy：

1. Check if there is short circuit between oil pump module and cables of three phases

of motor (there is short circuit between cables of three phases or between cable of

one phase and truck body). Check if the coils of motor have burning smell.

2. Check if the control unit and drive module is well connected.

125
 3. Disconnect the connection between power module and UVW cables. Check if the

resistances between power module + /- B terminals and UVW terminals are consistency

with high resistance of multimeter. If there is one pair of resistance having large

difference with the others, it means that the power module is burnt. Change the power

module.

4. Replace the control unit.

Current loss of oil pump motor

 Fault code:36

 Fault level:1

 Fault reason: the current of oil pump motor is not zero when starting the system.

 Remedy：

1、 Check if the connection between oil pump power module and control unit is

well;

2、 Replace the oil pump power module.

3、 Replace the control unit.

Output fault of control unit’s 5V voltage

 Fault code:37

 Fault level:1

 Fault reason: the voltage of control unit’s K1-16 connector is lower than 4.3V.

 Remedy ：

1、 Check if the 5V output has ground connection and check the connection of

encoders of each motor is correct.

2、 Check if the external elements using 5V output are well one by one.

126
 3、 Replace the control unit.

Output fault of control unit’s 12V voltage

 Fault code:38

 Fault level:1

 Fault reaosns: the voltage of control unit’s K1-17 connector is lower than 10.5V.

 Remedy：

1、 Check if the 12V output has ground connection, normally it may be caused by

the following parts:

 Acceleration pedal ;

 Lifting sensor;

 Steering sensor;

 Instrument.

2、Check if the external elements using 12V output are well one by one.

3、Replace the control unit.

When the system is started, the order lever of oil pump motor is activated.

 Fault code :50

 Fault level:7

 Fault reason: when the system is started, the switch signals such as lifting

potentiometer, tilting lever and other auxiliary function switch are activated.

 Remedy：

1、 Reset all orders that have been activated. (Including lifting potentiometer and all

switch signals.)

2、 Check if the voltage of lifting potentiometer exceeds set value. Calibrate with

127
 Fanji upper computer software.

3、 Replace the control unit.

The truck stops working because the driving motor is overheat.

 Fault code:61

 Fault level:1

 Fault reason: the measured temperature of driving motor exceeds the maximum

temperature set by customer.

 Remedy：

See the remedies in fault code 13.

The seat switch is not closed when starting.

 Fault code:63

 Fault level :warning

 Fault reason: when the system power is on, the seat switch is not closed; or the seat

switch disconnecting time exceed the time set in “seat switch delay” after the main

circuit breaker is closed.

 Remedy：

1、 Check if the seat switch is well connected or damaged.

2、 Replace control unit.

Fault of starting condition

 Fault code:64

 Fault level: warning

 Fault reason: When starting the truck, the forward and backward switch is activated.

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 Remedy：

1、 Check if the forward and backward switch when starting the truck is activated.

2、 If the direction switch is not activated, check if the connection between direction

switch and main harness is well. Check with Fanji upper computer software.

3、 Replace the direction switch.

4、 Replace the control unit.

The truck stops working because the oil pump motor is overheat.

 Fault code:65

 Fault level:1

 Fault reason: the measured temperature of oil pump motor exceeds the maximum

temperature set by customer.

 Remedy ：

See the remedies of fault code 14.

The truck stops working because the driving motor power module is overheat.

 Fault code:66

 Fault level:1

 Fault reason: the temperature of driving motor power module exceeds 95℃.

 Remedy：

See the remedies of fault code 20.

The truck stops working because the oil pump power module is overheat.

 Fault code:68

 Fault level:1

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 Fault reason: the temperature of oil pump motor power module exceeds 95℃.

 Remedy：

See the remedies of fault code 10.

Fault of temperature sensor of driving motor power module

 Fault code :71

 Fault level:5

 Fault reason: the feedback value of driving motor power module’s temperature

sensor exceeds measurement range.

 Remedy：

1、 Check if the connection between driving motor power module and control unit is

well.

2、 Replace driving motor power module.

3、 Replace control unit.

Fault of temperature sensor of oil pump motor power module

 Fault code:72

 Fault level:6

 Fault reason: the feedback value of oil pump motor power module’s temperature

sensor exceeds measurement range.

 Remedy：

1、Check if the connection between driving motor power module and control unit is

well.

2、 Replace driving motor power module.

3、 Replace control unit.

130
Fault of oil pump encoder

 Fault code:73

 Fault level:2

 Fault reason: when the oil pump motor is working, the encoder signal (A channel or

B channel) lost suddenly.

 Remedy：

1、 Check it the following devices are connected to encoder properly:

 Motor

 Grounding connection：K1-30 connector

 +5V：K1-16 connector

 A channel ：K1-35 connector

 B channel：K1-36 connector

2、 If the connections are well, replace the encoder.

3、 Replace the control unit.

Fault of driving motor’s encoder

 Fault code:74

 Fault level:2

 Fault reason: when the driving motor is working, the encoder signal (A channel or B

channel) lost suddenly.

 Remedy：

1. Check it the following devices are connected to encoder properly:

 Motor

 Grounding connection：K1-30 connector

 +5V：K1-16 connector

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  A channel ：K1-32 connector

 B channel：K1-33 connector

2. If the connections are well, replace the encoder.

3. Replace the control unit.

Fault of driving motor’s temperature sensor

 Fault code:77

 Fault level:8

 Fault reason: the temperature of driving motor is high than oil pump motor’s and the

temperature difference between two motors exceed 70℃.

 Remedy：

1、 Check if the connection between driving motor’s temperature sensor and main

harness is well.

2、 Replace the driving motor’s temperature sensor.

3、 Replace control unit.

Fault of oil pump motor’s temperature sensor

 Fault code:79

 Fault level:8

 Fault reason: the temperature of oil pump motor is high than driving motor’s and the

temperature difference between two motors exceed 70℃.

 Remedy :

1. Check if the connection between oil pump motor’s temperature sensor and main

harness is well.

2. Replace the oil pump motor’s temperature sensor.

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 3. Replace control unit.

Fault of driving motor power module’s temperature sensor

 Fault code:80

 Fault level:8

 Fault reason: the temperature of driving motor power module is higher than oil pump

motor power module’s and the temperature difference between two motor power

module exceeds 70℃.

 Remedy:

1、 Check if the connection between control unit and drive module is well.

2、 Replace the driving power module.

3、 Replace control unit.

Fault of oil pump motor power module’s temperature sensor

 Fault code:82

 Fault level:8

 Fault reason: The temperature of oil pump motor power module is higher than

driving motor power module’s and the temperature difference between two motor

power module exceeds 70℃.

 Remedy:

1、 Check if the connection between control unit and oil pump module is well.

2、 Replace oil pump motor power module.

3、 Replace control unit.

CRC fault

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 Fault code:83

 Fault level:1

 Fault reason: the software version is not correct.

 Remedy:

1、 Return to parameters when delivery with Fanji upper computer software.

2、 If the fault still occurs, replace the control unit.

Fault of truck starting sequence

 Fault code:85

 Fault level:9

 Fault reason: when operating the truck, the direction switch is not turn on before

stepping on acceleration pedal.

 Remedy：

1、 Release the acceleration pedal, activate the direction switch first and then step on

acceleration pedal.

Fault of steering sensor

 Fault code :91

 Fault level:5

 Fault reason: the feedback voltage of steering sensor exceeds calibrating range.

 Remedy：

1、 Check if the following connection is correct:

 K1-17(12V)

 K1-30(grounding connection)

 K1-31(input of steering sensor feedback signal)

134
 2、 If the connection is well, recalibrate the value in clockwise direction, middle

value and value in anti-clockwise direction of steering sensor.

3、 Replace the steering sensor and recalibrate.

4、 Replace the control unit.

Fault of acceleration pedal

 Fault code:92

 Fault level:2

 Fault reason : the feedback voltage value of acceleration pedal is larger than the sum

of minimum value and half of the difference between maximum value and minimum

value, but at this time, the acceleration pedal switch is not connected.

 Remedy:

1、 Check and calibrate acceleration pedal value. Check if the minimum voltage

value and maximum voltage value of acceleration pedal is correct. If it is not

accurate, reset with upper computer software.

2、 Check if the connection between main harness’s control unit and acceleration

pedal is well; if the connection is well, step on the acceleration pedal with upper

computer software and observe if the feedback value of pedal is within normal

range.

 K1-17(12V)

 K1-30(grounding connection)

 K1-18(input of pedal feedback signal)

3、 Replace acceleration pedal.

4、 Replace control unit.

135
Fault of lifting potentiometer

 Fault code:93

 Fault level:2

 Fault reason: the feedback voltage value of lifting potentiometer is larger than the

sum of minimum value and half of the difference between maximum value and

minimum value, but at this time, the lifting switch is not connected.

 Remedy：

1、 Check if the lifting potentiometer’s voltage exceeds the set range. Recalibrate

with Fanji upper computer software.

2、 Replace lifting potentiometer.

3、 Replace the control unit.

Fault of oil pump motor’s temperature sensor

 Fault code:94

 Fault level:6

 Fault reason: the feedback resistance of oil pump motor’s temperature sensor exceeds

normal range and it approaches to 0.

 Remedy：

1、 Check if the connection of oil pump motor’s temperature sensor and main

harness is well.

2、 Replace the oil pump motor’s temperature sensor.

3、 Replace the control unit.

Fault of driving motor’s temperature sensor

 Fault code :95

136
 Fault level:5

 Fault reason: the feedback resistance of driving motor’s temperature sensor exceeds

normal range and it approaches to 0.

 Remedy：

1、 Check if the connection of driving motor’ s temperature sensor and main harness

is well.

2、 Replace driving motor temperature sensor.

3、 Replace control unit.

Open circuit of oil pump motor’s temperature sensor

 Fault code :96

 Fault level:6

 Fault reason: the feedback resistance of oil pump motor’s temperature sensor exceeds

normal range and it approaches to infinity.

 Remedy：

1、 Check if the connection between oil pump motor’s temperature sensor and main

harness is well.

2、 Replace oil pump’s temperature sensor.

3、 Replace the control unit.

Open circuit of driving motor’s temperature sensor

 Fault code:97

 Fault level:5

 Fault reason: the feedback resistance of driving motor’s temperature sensor exceeds

normal range and it approaches to infinity.

137
 Remedy ：

1、 Check if the connection of driving motor’s temperature sensor and main harness

is well.

2、 Replace driving motor’s temperature sensor.

3、 Replace the control unit.

The pre-charging of capacitor is too slow.

 Fault code :98

 Fault level:1

 Fault reason: the increasing of pre-charging capacitor’s voltage is too slow when the

truck is self checking.

 Remedy ：

1、 Check if the connection of control unit and two power modules is well.

2、 Replace the power modules one by one to check the driving and oil pump power

modules.

3、 Replace the control unit.

Note:

1. The truck will travel with the defaulted setting (economic mode) when the signals

of the two modes (economic mode/slow speed mode) of the traction system are

transmitted to the controller at the same time or they are not transmitted to the

controller at the same time.

2. The truck will travel with the limited speed when the steering signal device is

ineffective.

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5 Hydraulic System

5.1 General Description

The hydraulic system consists of oil pump, control valve, priority valve, lift cylinder,

tilt cylinder, high & low pressure oil pipe an joint etc.. The pump is driven directly by the

electromotor. The hydraulic oil flow to control valve through the pump and are distribute

to cylinders by the control valve.

5.1.1 Oil pump

The main parts of the gear oil pump for forklift are a pair of external gears mutually

meshed and their working principle is as shown in Fig. 5-1.

Fig 5-1 Working principle of gear pump

(1) Oil suction cavity (2) Oil pressing cavity

A pair of meshed involute gear is mounted inside the housing, the two end face seals

of gear and gear separate the pump housing into two sealing oil cavities as shown 1 and 2

in the Fig. When the gear of gear pump rotates in the direction shown in the Fig, the

volume of space shown by 1 (engaging part for gear disengagement) changes from small

to big and forms vacuum. The oil in the oil tank enters into oil suction cavity under the

action of atmospheric pressure to fill the intertooth space through the oil suction pipe of

pump. While 2 indicates that the volume of space (engaging part for gear entering)

139
changes from big to small and press the oil into pressure oil circuit, i.e.1 is oil suction

cavity, 2 is oil pressing cavity and they are separated by meshing point of two gears. With

constant rotation of gear, the suction and discharge outlets of the pump continuously

absorb and drain oil.

Oil pump is to turn the mechanical energy of motor into hydraulic energy, so the oil

pump is the actuating unit of hydraulic system of the forklift.

The main pump consists mainly of a pump body, a pair of gears, lining plates and oil

seals. This pump uses pressure-balance type bearings and a special lubrication method so

as to minimum the clearance of the gear face. (See Fig. 5-2)

Fig. 5-2 Main pump

(1) Pump body (2) Driving gear (3) Driven gear (4) Front cover (5) Rear cover
(6) Lining plate (7) Seal ring (8) Ring (9) Oil seal (10) Snap ring

5.1.2 Control Valve

The external of the control valve as shown in Fig. 5-3.

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 Fig. 5-3 Control valve

The control valve adopts two pieces and four body type. The hydraulic oil from

working pump distributes the high-pressure oil to the lifting cylinder or tilting cylinder

through the control of valve stem. There are safety relief and tilt-locking valves inside the

control valve. The safety relief valve is at the top of oil inlet of control valve to control

the pressure of the system. The tilt-locking valve is on the tilt valve block and is mainly

used to prevent the serious consequence due to wrong operation of control rod when the

tilt cylinder has no pressure source. The check valve is mounted between oil inlet and

inlet port of lifting valve block and between oil inlets of lifting and tilt valve blocks.

141
(1) Spool operation (take the tilt spool

valve for example)

a) Neutral position (See Fig. 5-4)

The high-pressure oil from lift pump

returns to the oil tank through the

mid-passage.

Fig. 5-4 Neutral position

b) Pushing-in of spool (See Fig. 5-5)

In this time, the spool is pushed in to

close the mid-passage. This causes the oil

from the main oil-inlet to push up the inlet

check valve and to flow into the port “B”.

The return oil from the port “A” flows

Fig. 5-5 Push in spool
through the low-pressure passage to the

tank and the spool is restored to its neutral

position by the return spring.

c) Drawing-out of spool (See Fig. 5-6)

With the mid-passage closed, the oil

from the main oil-inlet pushes up the

check valve and flows into the port “A”.

The return oil from the port “B” flows

Fig. 5-6 Draw out spool
through the low-pressure passage to the

tank. The spool can be restored to its

neutral position by return spring.

142
(2) Motion of safety relief valve

The relief valve is mounted between “HP” nozzle of oil pump and “LP” passage. Oil

passing through lifting valve C acts on different areas of diameters “A” and “B”, thus, “K”

of check valve and “D” of overflow lift valve are on the valve seat as shown in Fig. 5-7.

When the pressure regulated in “HP” passage of oil pump acts on the spring of pilot valve,

the check valve “E” will open. The oil flows into “LP” side through holes around the

valve as shown in Fig. 5-8.

Fig. 5-7 Fig. 5-8

Once the pilot valve “E” opens, the pressure inside valve “C ” will drop, valve “E”

and valve “C” are on the valve seat. The liquid flowing to the rear of the valve “D” will

be closed, so the pressure inside will be decreased. (See Fig. 5-9)

The “HP” passage pressure and inside pressure of oil pump are not even, the valve

“D” opens with the action of pressure difference and oil directly flows into the low

pressure circuit“LP”. (Refer to Fig. 5-10).

Fig. 5-9 Fig. 5-10

143
(3) Action of tilt-lock valve

Tilt spool valve housing contains a tilt-lock valve. The tilt lock valve is intended to

prevent vibrations of the mast resulting from the negative pressure in the tilt cylinder and

also to avoid danger incurred from mishandling of the spool. When the lift motor isn’t

running, the mast doesn’t be tilted forward by push the tilt lever.

See Fig. 5-11, when the spool is pushed in. See Fig. 5-12, when the lift motor stops.

a) The spool is pushed in

The pressure oil flows through the port “B” to tilt cylinder and moves the tilt-lock

valve to let the port “A” connect with the low-pressure tank. The tilt cylinder and the

mast is tilted forward.

Fig. 5-11
b) The spool is pushed in (when the lift motor stops)

When the lift motor stops, no pressure oil flows to the tilt-lock valve. The port “A”

can’t connect with the low-pressure tank and the mast doesn’t be tilted forward.

Fig. 5-12
(4) Operation of the control valve

The control valve is operated with the valve levers. All valve levers are assembled

144
together with a shaft and the shaft is assembled on the valve joint plate with the bracket.

The valve levers operate the control valve with the joints. (See Fig. 5-13)

Fig. 5-13(a) Operation of the control valve (1-2.5t)

145
Fig. 5-13(b) Operation of the control valve (3-3.5t)

146
 As you see in Fig. 5-14, the mast lift up when you push the lift lever forward, the

mast fall down when you pull the lift lever backward. The mast tilt forward when you

push the tilt lever forward, the mast tilt backward when you pull the tilt lever backward.

Fig. 5-14 The symbol on the operation lever

(5) Setting pressure of the control valve (See Fig. 5-15)
The pressure of the safety valve shall not be adjusted by non-professional personnel.

The adjustment shall follow following procedures:

a) Screw off the plug of the measuring hole on the inlet of the control valve. Install

an oil pressure gauge capable of measuring 25MPa.

b) Operate tilting lever and measure the pressure at the end of the cylinder stroke.

c) If the oil pressure is different with the specified value, loosen the locking nut of

the relief valve and turn the adjusting screw left and right until the pressure reaching the

specified value. Turn left when the pressure is high and turn right when the pressure is

low.

d) Tighten the nut after adjusting.

147
 Fig. 5-15

5.1.3 Lift cylinder

The lift cylinder is of single-acting piston type. It consists of cylinder body, piston,

piston rod, cylinder cap, cut-off valve and oil seals. The cylinder head is equipped with

bushing and oil seal and the bushing supports the piston rod and the oil seal keeps dust

off. (See Fig. 5-16)

When the hoist valve of control valve is placed at lifting position, hydraulic oil

enters into the lower part of piston of hydraulic cylinder from pressure-gradient control

valve to selector valve to push rising of piston and lifting of the goods. When the hoist

valve of control valve is placed at descending position, the piston rod drops with the

action of goods, mast, fork bracket and piston itself, the hydraulic oil is pressed back to

oil tank. If the cut-off valve is mounted at the bottom of cylinder (See Fig. 5-17), it can

play the role of protection if the mast rises when high-pressure pipe cracks.

148
 Fig. 5-16 Lift cylinder
1. Bolt M16×1.5×40 2.washer 16 3.chain wheel 4. Snap ring 40
5. Chain wheel assembly 6.spacer bush 7. Bolt M12×1.25×25
8. Bolt M12×1.25×50 9.U type bolt 10.Nut M10×1.25 11.waher 10
12.washer 10 13. Pin B10×26 14. Adjusting block 15.Oil cylinder support block
16. Nut M12×1.25 17.Piston rod 18.dust proof ring 40×52×7/10 19.guide sleeve
20. Seal ring 40×50×6 21. Steel-backed bearing 4030 22.Shim 23. Screw M5×6
24. O ring d49.7×2.4 25. Cylinder body 26. Steel cable baffle ring
27.support ring 50×10×2.5 28. Valve assembly 29. Piston
30. Adjusting sleeveφ 48×40.5 31.retaining plate 50×40×3
32.seal ring for hole 50×40×6 33.shim 34.sleeve 35.steel-cable baffle ring for hole
36.Spherical nut 37. Nut M14×1.5 38. Pin 3.2×30

149
5.1.4 Cut-off valve

The cutoff valve is mounted at the bottom of the hoist cylinder (See Fig. 5-17) to

prevent the goods from falling suddenly when the high pressure pipe is broken. The oil

from hoist cylinder passes through the hole A on the outer circumference of the spool

when returning to oil tank, if flow rate of oil through the hole is less than the setting value

of the valve and the pressure difference before and after spool smaller than spring force,

the spool will not move at this time and slide valve does not work. If the flow rate

through the spool hole exceeds the setting value due to high pressure pipe cracking or

other reasons, the pressure difference before and after spool will be larger than the spring

force and move the spool to the left. In this way, hole A is closed, only small amount of

oil flows out from the small clearance of spool and valve bush and the goods descends

slowly.

Flow less than the setting valve

Broken

Flow more than the setting valve

Fig. 5-17 Working principle of the cut-off valve

5.1.5 Flow regulator valve

The flow regulator valve, located in the lift cylinder circuit to limit the descending

150
speed of loaded forks, has the construction as shown in Fig. 5-18.

When the lift spool is placed in the “lift” position, the oil from the control valve

flows through the oil chambers A and B, oil holes C, D, E and F, and the chamber G to

the lift cylinder without any regulation. When the lift spool is placed in the “down”

position, the oil pusses the orifice plate and a pressure difference generates between the

chambers A and B, the pressure difference overcomes the force of the spring and moves

the valve core right, thus the oil flow being decreased by narrowing of the hole D and C,

and reduces the oil flow passing through the orifice plate.

Fig. 5-18 Flow regulator valve

(1) Nipple (2) Spring (3) Ring seal (4) Snap ring (5) Spool (6) Sleeve (7) Steel ball
(8) Spring of the check valve (9) Valve body

5.1.6 Tilt cylinder

The tilt cylinder is of double-action and piston type hydraulic cylinder and is

mounted at both sides of mast with its piston rod end connecting with mast. The bottom

of tilt cylinder is connected through dowel with connecting end of frame and mast and the

forward and backward tilting of the mast are fulfilled by the motion of tilt cylinder.

The tilt cylinder consists primarily of piston, piston rod, cylinder body, cylinder base,

guide sleeve and seals. The piston, welded to the piston rod, is fitted with two Yx-rings

and one wear ring on its circumference. A bushing press-fitted to the inner side of the

guide sleeve supports the piston rod. The guide sleeve is with dust seal, snap ring,

151
Yx-ring and O-ring to prevent oil leakage and keep dust off. Fitted with them, the guide

sleeve is screwed into the cylinder body. When piston moves, oil enters from one port and

exits from the other. The piston rod is furnished with adjusting threads to adjust the

difference between the dip angles. (See Fig. 5-19)

When the tilt lever is pushed forward, the high-pressure oil enters into the cylinder

body from the cylinder tail, moving the piston forward and causing the mast assembly to

tilt forward until 6 degrees. When the tilt lever is pulled backward, high-pressure oil

enters into the cylinder body from the guide sleeve and moves the piston backward,

tilting the mast assembly backward.

Fig. 5-19 Tilt cylinder

(1) Ear ring (2) Dust ring (3) Snap ring (4) Yx-ring (5) O-ring (6) Guide sleeve
(7) Bushing (8) O-ring (9) Piston rod (10) Cylinder body (11) Yx-ring (12) Wearing
(13) Piston (14) Yx-ring

5.1.7 Oil tank

Oil suction filter is fixed in the oil tank while the return oil filter is fixed in the oil

returning pipelines to make sure the cleanness of the supplied oil.

5.1.8 Hydraulic oil circuit

The hydraulic system principle diagram see Fig. 5-20 and the hydraulic oil circuit

see Fig. 5-21A and 5-21B.

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 Fig. 5-20 Hydraulic system principle diagram
(1) Oil tank (2) Oil suction filter (3) Pump motor (4) Gear pump (5) Steering unit
(6) Steering cylinder (7) Control valve (8) Flow regulator valve (9) Cut-off valve
(10) Lift cylinder (11) Tilt cylinder (12) Return oil filter

153
Fig. 5-21A hydraulic oil circuit (2-2.5t)

Fig. 5-21B hydraulic oil circuit (1-1.8t)

154
5.2 Maintenance，Fault Analysis and Remedies

5.2.1 Maintenance

Check if there is any seepage and serious oil leakage on the pipe fittings of hydraulic

drive system, hoist cylinder, tilt cylinder, oil pump, fully hydraulic steering gear and

steering cylinder before and after each shift. Check if the working oil inside work oil tank

is sufficient and check and clean the strainer mesh of oil filter mounted in the work oil

tank once every week.

Normally, change the oil in the work oil tank once every 1200-1500 hours of work

and mixed use of oils of different brands is not allowed.

5.2.2 Maintenance of lift pump

(1) Disassembly

Before disassembling the pump, put the removed parts on the paper or cloth. Don’t

damage the parts. (See Fig. 5-23)

a) Hold the pump cleaned in a vice by lightly clamping the flange section.

b) Remove bolts 11, pump cover 5, pump body 1.

c) Remove lining plate 6, drive gear2, driven gear 3.

d) Remove the seal ring 7 and ring 8 from front cover or rear cover.

Notice: Don’t remove the seal ring and ring from the front cover and rear cover,

if the seal ring and ring needn’t be replaced.

155
 Fig. 5-22 Gear pump
(1) Pump body (2) Drive gear (3) Driven gear (4) Front cover (5) Rear cover
(6) Lining plate (7) Seal ring (8) Ring (9) Oil seal (10) Snap ring

(2) Inspection

Check the disassembled parts and wash them with light oil. Don’t wash the rubber

items with light oil.

a) Body inspection (See Fig. 5-23)

If the contact length between pump

body lumen and gear longer than 1/2 long

of the perimeter, replace the pump body.

Fig. 5-23

156
 b) Lining plate inspection (See Fig.

5-24)

Inspect the contact surface of the

lining plate. If the surface is worn or its

thickness is smaller than the specified

value, replace the lining plate. Fig. 5-24

The specified thickness of the lining

plate: 4.94mm.

c) Front and rear pump cover

If the color changed range of the

inner surface of the bushing exceed

150 °, replace the bushing.

Fig. 5-25
d) Inspect the drive gear and the

driven gear from front and rear. If they are

worn excessively, replace them. If the

dimension “D” is smaller than the

specified value, replace them in pairs. Fig. 5-26

D=20.961mm

e) Replace seal rings, bushings, seal

rings, rings, oil seals and snap rings as

required. Fig. 5-27

157
(3) Reassembly

a) Fixed the front cover on the

clamping. (See Fig. 5-28)

Fig. 5-28

b) Install a new seal ring on the front

cover of the pump.

Notice: Don’t twist.

Fig. 5-29
c) Install a new ring on the front

cover of the pump. The direction of the

installation see Fig. 5-30.

Fig. 5-30
d) Install the pump body on the front

cover. Pay attention to the direction of the

pump body.
Fig. 5-31

e) Install the lining plate on the

groove of the front cover, don’t confuse

the inlet oil port and the outlet oil port.

Pay attention to the direction of the lining Fig. 5-32

plate.

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 f) Install the drive gearon the pump

body with the side of the spline

downward.

Fig. 5-33
g) Install the driven gear on the pump

body as the direction shown in Fig. 5-34.

Fig. 5-34

h) Install the lining plate on the

side of the gear, don’t confuse the inlet oil

port and the outlet oil port.

Fig. 5-35

i) Install a new seal ring and a new

ring on the groove of the rear cover. Apply

lubricating grease on the seal ring.

Fig. 5-36
j) Install the rear cover on the pump

body with it’s seal ring downward, don’t

confuse the inlet oil port and the outlet oil

port. Fig. 5-37

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 k) Tighten up the connecting bolts

with a specified torque of 9 to 10kg.m

after all.

Fig. 5-38
l) Take down the pump from the

clamping. Apply lubricating grease on the

outside circle and lip of the oil seal, install

it on the front cover with mould. Fig. 5-39

m) Install the snap ring with callipers,

fixed the oil seal.

Fig. 5-40

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(4) Test run

The test run is a running-in period for the oil pump and a inspection whethter the running of

the pump is normal. Test the oil pump on the test station. And also the test can be done on the

forklift truck according to the following procedures:

(If the oil pump needs maintenance because of serious wear or its being stuck caused by the

hydraulic oil, change the hydraulic oil or filter before carrying out the test run on the forklift

truck.)

a) Install the pump onto the truck and the pressure gauge onto the pressure test end of the

control valve.

b) Loose the adjusting screw of the relief valve and make the pump running at a speed of

500～1000rpm for 10 minutes. Make sure the oil pressure be lower than 10kg/cm2.

c) Increase the pump speed to 1500～2000rpm for 10 minutes.

d) Make the pump running at a speed of 1500～2000rpm for 5 minutes and increase the

pressure to 210kg/ cm2 by 20～30kg/cm2 each time. Then make each oil circuit works for 5

minutes and then change the oil filter.

Inspect the temperature of the oil, the temperature of the surface of the pump and the running

noise when increasing the oil pressure. If the oil temperature or the temperature of the pump’s

surface increases to a over high degree, reduce the load and lower the oil temperature. And then

go on carrying on the trail.

e) Make the relieving pressure at 210kg/ cm2 after the test and measure the flowl. Measure

the oil lever through the lifting speed.

5.2.3 Troubleshooting
Trouble Cause Trouble shooting
1) Excessive wearing between the oil 1) Replace the wearable parts or oil
pump gear and pump body and pump.
wider-than-normal gap.
Insufficient 2) Wearing and wider-than-normal gap of 2) Replace with new piston sealing ring.
lifting the piston sealing part in the lifting
capacity or cylinder, excessive inner leakage.
unable to lift 3) Failure of safety valve spring of control 3) Replace with new spring.
valve.
4) Excessive oil leakage due to wearing 4) Chromium plating the valve rod to
between the control valve rod of control couple with the hole with the gap at
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 valve and valve body. 0.01～0.02.
5) Oil leakage among valve bodies of the 5) Change the sealing ring, screw tight
control valve . the screw in sequence.
6) Oil leakage in hydraulic pipe. 6) Check to see whether there is damage
to the sealing ring or connecting nut and
screw tight the pipe joint.
7) Higher-than-normal temperature of 7) Replace the unqualified hydraulic oil,
hydraulic oil (should be ≤80℃), excessive stop operation to lower oil temperature
oil dilution and insufficient flow. and try to find the cause of over high oil
temperature.
8) Excessive load. 8) Lift load according to requirements.
1) Oil leakage due to wearing of ring seal 1) Replace the ring seal.
at fasteners.
2) Hydraulic oil is contaminated with air 2) Discharge air and add hydraulic oil.
to form foam, air leakage at oil suction
pipe-work, insuffi-
Insufficient
cient hydraulic oil.
pressure of
3) Damaged ring seal inside the pump 3) Replace.
oil pump
cover groove.
4) Wearing of the end face of bearing 4) Replace.
sleeve.
5) Oil pump gear wears. 5) Replace the oil pump.
6) Wrong rotation direction of oil pump. 6) Correct.
Trouble Cause Trouble shooting
1) Inner leakage of control valve. 1) Replace O-ring seal, repair valve rod
and reassign the coupling gap between
valve rod and hole to 0.01～0.02.
Excessive self 2) Inner leakage due to the damaged 2) Replace.
tilting of the O-ring seal of piston rod of the tilting
tilting cylinder cylinder.
3) Oil leakage due to the damaged 3) Replace.
YX-ring seal and O-ring seal in the pilot
sleeve.
1) Insufficient oil supply of oil pump, 1) Select appropriate oil pump or check
the slow-steering hand wheel feels to see if the oil pump is normal.
relatively light and the fast-steering
hand wheel heavy.
2) Air in the steering system, foam in 2) Discharge air in the system and check
oil, making irregular noise, the hand the oil suction pipe-work.
Heavy Steering wheel can rotate while the oil cylinder
can not keep continuous motion.
3) Failure of the steel ball one-way 3) Check if the steel ball exists and if
valve in the valve body, both the fast and there is dirty stuff blocking the steel
slow steering hand wheels are heavy, balls.
also no pressure at steering.
4) Pressure of the overflow valve is 4) Adjust pressure of the overflow valve
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 lower than working pressure or the or clean it.
overflow valve is blocked by dirty stuff,
light steering in case of light or no load,
heavy steering when adding load.
5) Excessive viscosity of the oil liquid 5) Use oil liquid with recommend-
ded viscosity.

6. Lifting System

6.1 General Description

The lifting system is of the two-stage roller type with veritical up and down. It consists of the

inner mast, the outer mast and the lift bracket.

6.2 Inner and Outer Masts

The inner and outer masts both are welded parts. The bottom of outer mast is connected with

the drive axle and the weight mainly support on the axle housing. The outside middle of outer

mast is connected with the frame by tilt cylinders. The mast assembly can be tilted forward and

backward by operating tilt cylinders. The outer mast has C-shaped cross section. The outer mast

fixed with main rollers and side rollers on the top of it. And the inner mast has L-shaped cross

section. It fixed with main rollers at the bottom of it. The main rollers bear both radial force and

lateral force by adjusting it’s clearance. The inner mast moves up and down smoothly with the

main and side rollers rolling.

The maintenance of the roller and the side rollers on the inner and outer masts belong to

exalted maintenance. Please be careful.

6.3 Lift Bracket

The lift bracket moves up and down smoothly along the channel of the inner mast with main

rollers. The main roller is fixed on the axis of the main roller by snap ring. And the axis of the

main roller is welded on the lift bracket. But the side roller is assembled on the lift bracket with

bolts. Main rollers sustain the longitudinal loads. And side rollers sustain the transverse loads.

When forks reach its maximum height, the upper pair of main rollers will come out from the inner

mast top.

6.4 Layout of Rollers (1-1.8t)

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 Ten main rollers are separately installed on the upper end of the outer mast (two), lower end

of the inner mast (two) and both side of the lift bracket upright (six).

Eight side rollers are separately installed on the upper end of the outer mast (two), lower end

of the inner mast (two) and the lift bracket (four).

The main rollers in the middle of the outer mast fork bracket upright bear both the front and

rear load and side load, other main rollers only bear the front and rear load. Side rollers bear the

left and right side load. with the main rollers and side rollers, the inner mast and fork brakcet

move smothly.
Inner mast Fork bracket
Side roller (fork bracket upper end)
Lower end upper end
Adjusting with shim

Fork bracket main Main roller

roller Outer mast upper end

Main roller Limit cushion

Inner mast lower end Adjusting with adjusting
shim

Lifting
cylinder

Figure 6-1 roller layout

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 Side roller in fork bracket upper end
0-0.5mm Adjusting shim contacting by one face
Adjusting shim
Main roller at the
lower end of the
inner mast

Roller at the
upper end of
plate contacting by
outer mast is
one face
free from
Note: apply grease to the main roller
adjusting.
surface and mast contacting surface

Figure 6-2 adjusting method and requirement of main roller and side roller

Clearance 0-0.5mm
contacting by
The second one face
Plate B roller on fork Plate B
bracket

Adjusting shim Adjusting shim

Figure 6-3 adjusting method and requirement of fork bracket second roller

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 Free from clearance adjusting
Adjust clearance with inner mast
plate B (see figure 6-3)

Free from clearance adjusting

Figure 6-4 fork bracket roller adjusting method and instruction

6.5 Layout of Rollers (2-2.5t)

Ten main rollers are separately installed on the upper end of the outer mast (two), lower end

of the inner mast (two) and both side of the lift bracket upright (six).

Eight side rollers are separately installed on the upper end of the outer mast (two), lower end

of the inner mast (two) and the lift bracket (four).

With the aid of main rollers and side rollers to sustain the longitudinal and transverse load,

the inner mast and the lift bracket can operate smoothly.

Side roller Inner mast Main roller Fork bracket

Outer mast

Lifting
cylinder

Figure 6-5 roller layout

Note: (a) side roller clearance is 0.5mm.
(b) Apply grease on main roller surface and mast contacting surface.

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6.6 Maintenance

6.6.1 Adjust lift cylinder

It must readjust stroke of the lift cylinder when the lift cylinder, the inner mast or the outer

mast is replaced. As following:

(1) Place piston rod heads into the upper beam of the inner mast without shims.

(2) Ensure that two lift cylinders are lifted at the same time when the mast ascended the ultimately

stroke.

(3) If they not lifted synchronously, add shims between the upper beam of the inner mast and the

piston rod head which reaches the lift cylinder’s ultimately stroke in movement. The shims’

thickness is 0.2mm or 0.5mm.

(4) Adjust the tightness of lift chains.

The adjustment of lift cylinder also belongs to exalted maintenance. Please be careful.
Adjusting valve
Upper beam of
the mast

Lifting cylinder

Fig. 6-6 Adjust lift cylinder

6.6.2 Adjust lift bracket’s height

(1) The truck should be stopped on horizontal ground. And ensure the masts erect.

(2) Lower the forks on the ground, adjust the set nut of tie-in on the upper of chains to assure the

distance A = 19mm～20mm between main rollers and the lift bracket.

(3) Make the mast assembly tilt backward when forks descended to the ground, adjust the pulling

force of lift chains and let the tightness of lift chains be equal.

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 Fig. 6-7 Adjust lift bracket’s height

6.6.3 Replacing rollers of the lift bracket

(1) Place a salver on the forks and make the forklift stop on the horizontal ground.

(2) Make the forks and salver descend to the ground.

(3) Take down tie-in on top of the chains. And take out chains from sheave. (See Fig. 6-8)

(4) Make the inner mast rise.

(5) The forklift can be reversed when the lift bracket disengaged from the outer mast.

(6) Replacing main rollers

(a) Take apart all of snap ring from the lift bracket and take out main rollers.

(b) Fit the new main roller (the same type as the old one) on the lift bracket and fastened with

snap ring.

Fig. 6-8
6.6.4 Replacing rollers of masts

(1) Take apart the fork bracket from the inner mast, then replace the main roller follows the way as

6.6.3.

(2) Park the truck on the horizontal ground and lift up the front-wheel 250～300mm from the

ground.

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(3) Pull parking brake level fully, and use a wedge to make back-wheel stationary.

(4) Take apart bolts which fastened lift cylinders and the inner mast. Hang up the inner mast without

losing shims of the piston rod heads carefully.

(5) Take apart bolts which jointed lift cylinders and the bottom of outer mast and take apart the

oil-pipe between two lift cylinders without loosing the nipple.

(6) Main rollers on the upper outer mast will be showed on the top of the inner mast as soon as main

rollers were taken apart from bottom of the inner mast after laying down the inner mast.

(7) Replacing main rollers

a) Take apart the upper main rollers without losing shims.

b) Fit the new main roller and shims together on the outer mast.

(8) Hang up the inner masts and let all rollers in the inner mast.

(9) Assembly the lift cylinder and the lift bracket as disassembly contrarily.

169