Service Manual

Electrical Forklift Truck
（Electric four-wheel Forklift Truck）
CPD10/15/18/20/25/30-A
CPD10/15/18/20/25/30/35-AC3
CPD10/15/18/20/25/30/35-AC3F
CPD10/15/18/20/25/30/35-AC4
CPD10/15/18/20/25/30/35-AC4F
CPD10/15/18/20/25/30/35-AD2
CPD25-ALC3 CPD25-ALC3F
CPD25-ALD2
SERVICE MANUAL
HANGCHA GROUP CO., LTD.

01 / 2015
FOREWORD
Thanks for your purchasing our electric four-wheel forklift truck.
A series electric four-wheel forklift truck is our company’s new product. It has the character of small
turning radius, beautiful shape, small dimensions, low gravity.
This service manual is about the structure,working principles and maintenance etc. To ensure
safety and exert the truck’s potential, all the personnel that in charge of maintenance and
management must read this manual thoroughly before starting work with the forklift.
This manual is about 1.0 ~ 3.5 t A series of four support battery counterbalance forklift truck
structure, working principle and maintenance etc. In order to ensure safety and give full play to you
buy the forklift truck performance, relevant operating personnel, equipment management and
maintenance personnel, should carefully read this manual.
Forbid repairing the truck if you haven’t been trained.
Our product design will update and perform better, so the content in this manual may be not the
same as the forklift you owned.
If you have any questions please keep touches with HANGCHA GROUP CO., LTD. sales
department or let the agents know.
A series four-wheel
Driven controller Pump controller Rated capacity(t)/ Load Center(mm)
forklift truck
1.0 / 500，1.5 / 500，1.75 / 500
CPD10~30-A Curtis1244 Curtis1253
2.0 / 500，2.5 / 500，3.0 / 500
CPD10~18-AC3(F) Curtis 1234 Curtis 1253 1.0 / 500，1.5 / 500，1.75 / 500
CPD35-AC3(F) Curtis 1238 Curtis 1253 3.5 / 500
CPD20~25-AC4(F) Curtis 1236 Curtis 1234 2.0 / 500，2.5 / 500
Kollmorgen Kollmorgen
CPD10~18-AD2 1.0 / 500，1.5 / 500，1.75 / 500
ACS48S-35P ACS48S-23P
CPD20~25-AD2 2.0 / 500，2.5 / 500
ACS48M-35P ACS48M-23P
CPD30~35-AD2 3.0 / 500，3.5 / 500
CPD25-ALC3(F) Curtis 1236 Curtis 1253 2.5 / 500
CPD25-ALC4(F) Curtis 1236 Curtis 1236 2.5 / 500
CPD25-ALD2 2.5 / 500
© 01/2015 HANGCHA GROUP CO., LTD.

CONTENT
FOREWORD
1. DRIVING SYSTEM .............................................................................................. 1
Motor .................................................................................................................... 1
Gear box .............................................................................................................. 8
Driving axle ........................................................................................................ 10
2. STEERING SYSTEM ......................................................................................... 16
Steering device ................................................................................................... 16
Steering axle ...................................................................................................... 17
3. BRAKE SYSTEM .............................................................................................. 21
Master cylinder ................................................................................................... 21
Foot brake .......................................................................................................... 22
Hand brake device ............................................................................................. 24
4. HYDRAULIC SYSTEM ...................................................................................... 25
Main pump ......................................................................................................... 27
Control valve ...................................................................................................... 28
5. LIFTING SYSTEM ............................................................................................. 30
Data .................................................................................................................... 30
Fault ................................................................................................................... 31
Mast ................................................................................................................... 32
Lifting cylinder .................................................................................................... 34
Tilting cylinder .................................................................................................... 34
6. ELECTRICAL SYSTEM .................................................................................. 35
Controller ............................................................................................................ 35
Electrical system principle diagram .................................................................... 49
1. Driving system
Drive system is composed most components such as electrical engineering, gear box, driving axle
detent tyre and wheel rim.
Gear box is two grades reduce speed gear, one grade straight gear and one grade planet gear. So
the gear box is very small.
Detent is a hoof detent, if you need know the particular content, you can see relevant portion of
the trig system.
Motor
Model Drive motor Pump motor
CPD10/15/18-A XQ-5-3A XQD-8.2-3D-1
CPD20/25-A XQ-7A XQD-8.6-3D-1
CPD30-A XQ-10.2 A XQD-10-3D-1
CPD10/15/18-AC3 HPQ8-4HC-A XQD-8.2-3D-1
CPD10/15/18-AC3F HPQ8-4HC-A XQD-8.2-3D-1
CPD20/25-AC3 HPQ11-4HC-A XQD-8.6-3D-1
CPD20/25-AC3F HPQ11-4HC-A XQD-8.6-3D-1
CPD25-ALC3 HPQ15-4HC-A HPB10-4HC
CPD25-ALC3F HPQ15-4HC-A HPB10-4HC
CPD30/35-AC3 HPQ15-4HC-A XQD-10-3D-1
CPD30/35-AC3F HPQ15-4HC-A XQD-10-3D-1
CPD10/15/18-AC4 HPQ8-4HC-A HPB8.6-4HC
CPD10/15/18-AC4F HPQ8-4HC-A HPB8.6-4HC
CPD20/25-AC4 HPQ11-4HC-A HPB8.6-4
CPD20/25-AC4F HPQ11-4HC-A HPB8.6-4
CPD25-ALC4 HPQ15-4HC-A HPB10-4HC
CPD25-ALC4F HPQ15-4HC-A HPB10-4HC
CPD30/35-AC4 HPQ15-4HC-A HPB10-4HC
CPD30/35-AC4F HPQ15-4HC-A HPB10-4HC
1
Model Drive motor Pump motor
CPD10/15/18-AD2 HPQ8-4HC-A HPB8.6-4HC
CPD20/25-AD2 HPQ11-4HC-A TSW112/4-195-T-48V
CPD20/25-ALD2 HPQ15-4HC-A HPB10-4HC
CPD30/35-AD2 HPQ15-4HC-A TSW112/4-195-T-80V
2
DC motor
Rated Rated Rated Rated Max. Excitations Insulation Cooling Protecting Ration Weight
Power Voltage Current Speed Speed Mode Grade Mode Grade
Model
kW V A r/m r/m min kg
Series
XQ-7A 7.0 45 180 1400 2400 F IC01 IP20 60 112
excitation
Series
XQ-10.2 A 10.2 75 162.5 1500 2400 F IC01 IP20 60 120
excitation
Separated
XQD-8.6-3D-1 8.6 45 248 1600 3000 F IC01 IP20 5 47
excitation
Separated
XQD-10-3D-1 10.0 75 160 2000 3000 F IC01 IP20 15 90
excitation
The marker, sign and connecting type of exceed cable or terminal of motor
A1：Motor armature's head
A2：Motor armature's end

Series excitation motor
D1：Shunt excitation's head
D2：Shunt excitation's end
A1：Motor armature's head
A2：Motor armature's end

Separated excitation motor
F1：Separated Excitation excitation's head
F2：Separated Excitation excitation's end

Connection mode：
Series excitation motor
Separate excitation motor
3
Height above sea level No exceed 1200m
Environment temperature
400C/-25℃
Electromotor highest/lowest
applied range
Relative temperature Until on the surface of motor dew 100%
Cooling air Must not contain volatile gas
Three times of rated current ,admit time is one

Most work Tractor motor minute
current of the
motor One point eight times of rated current,admit time is
Lifting motor、steering motor
one minute
Admit temperature Rolling bearing （ Environment
95℃
temperature not exceed 40℃）
From brush box catadrome side to surface of the
2～4mm
commutation
Cooling insulation resistance（When it approach work < 45V 0.5MΩ
temperature, please measure by 250Vmegohmmeter）。 45V～110V 1MΩ
Brush Metal plumbagin brush trade J201 chart No 5CZ、578
4
DC motor failure diagnosis
Failure phenomenon Possible cause

All of sheet copper
Brush’s pressure is wrong
nigrescence
Parts is short circuit
Parts of commutator according
Armature coil is short
to a certain order nigrescence
Parts of commutator is not fasten to armature coils open circuit
Parts of commutator are Commutator’s center line location change

nigrescent, but without definite
rule Commutator’ s surface is rough, out of round
Motor vibration
Clearance between brush and box is bigger.

Working surface distance between the box and commutator is
Brush wear and tear, change bigger
colors and break
Mice between parts of commutator extrude
Material of the brush is bad
Trademark of the brush is wrong
Motor overload
Commutator is unholy
Commutator is rough or out of round
Mica or parts of commutator extrude
Brush seat grinding is bad

Sparkle strong
The pressure of brush is not enough big
Trademark of the brush is wrong
The brush lock in the box
The brush frame is loose or vibrational
The polarity and tactic order of magnetic pole is wrong
The sparkle of brush is strong
The brush and wire heat The brush is not contacted with the cable
The cable is thinner
The brush have noise The surface of the commmutator is rough
5
DC motor of the use and maintain
The commutator has four check windows, with which you can observe and maintain the
commutator and brush. There are four average distributing magnetic poles in seat. The magnetic
pole coil is made of F state copper thread, dipping with F state insulating varnish. Parts of stator
and neutral position of brush have been adjusted; users mustn’t unpack and adjust randomly.
– Check armature for rotation and void frictionize.
– Check outgoing line of electric machine for connection.
– Brush should slide freely in the brush hold box.
– Check reverse chip for neatness, if need be，clear canaliculus between the reverse chip or the
commutator surface of powder, can used cleanly calico of soft and no thread downy , maybe
surface had oil ,calico can dip alcohol when wiping (stop process).
– Check all fasteners whether fastened.
– Brush’s shelf must reliable fastened, can’t become flexible. If need running or disassembly
brush’s shelf， must make out marker，can become flexible bolt. When the brush’s shelf
reposition, aim at marker line, screw down bolt, in order to keep brush in the former neutral
location.
– Winding isolating resistance should check of fix a date, when near work’s temperature, under
rule data, otherwise should put up dry.
– Fix a date open window shutter, check inside part whether transmutation and reverse partial
circs whether up to snuff.
– You should often clean bed load and other dirt on the motor’s shell, in order to giving out heat
quantity best.
– Every half year check motor one time as follow:
a. Inspect exterior and clean the dust for the motor；
b. Clean or replace bearing, during running it is permitted to giving off abnormal noise for
bearing；
c. Inspect the brush’s abrasion, if necessary replace it.
Burnishing for brush：
– When replaces the brush, using “00” thin emery
cloth to burnishing it. During burnishing you can
haul the emery cloth leftward or rightward.
– After burnish the brush and clean the
commutator with emery cloth, the motor should
lowered voltage and limiting speed to running
under load, in order to safety, till the brush’s
working face is shined.
6
AC motor
Rated Rated Rated Rated Max. Insulation Cooling Protecting Duty Weight
Power Voltage Current Speed Speed Grade Mode Grade
Model
kW V A r/m r/m kg
HPB8.6-4 8.6 31 248 1600 3200 F IC00 IP44 S3-15% 65
HPB10-4HC 10 51 161.6 2000 / F IC01 IP44 S3-15% 80
HPQ11-4HC-A 11 31 305 1200 2000 F IC01 IP20 S2-15% 100
HPQ15-4HC-A 15 51 200 1200 / F IC01 IP20 S2-15% 100
CAUTION
 AC motor don’t have commutator and brush，not need maintain. You must check and
clear dust everyday.
7
Gear box
Gear box is two grades reduce speed gear, one grade straight gear and one grade planet gear. So
the gear box is very small.
1. Transmission gear box house 2. Bearing block 3. Locking piece 4.Bolt

5. Differential housing,R.H. 6. Differential housing,L.H. 7. Bolt 8. Pin
9.Gear shaft 10.Gear shaft 11.Washer 12. Half shaft gear
13.Planetary gear 14.Thrust washer 15.Big ring gear 16.Bearing
17.Double gear shaft 18.Bearing 19.Bearing 20.Bush
21.Adjustable pad 22.O-Ring 23.Bearing block 24.Washer
25.Bolt 26.Locknut 27.O-Ring 28.End cap
29.Bolt 30.Bearing 31.Double gear 32.O-Ring
33.Shaft 34.Bearing 35.Pinion 36.Pin
37.Tank cap 38.Washer 39.Bolt 40.Bolt
41. Locating plate 42. Bolt
8
Trouble Probably cause Method of troubleshooting
Gear clearance is too big. Adjust

When traveling or change direction
Too much worn of gear. Replace
Oil level is low. Add oil
Too much noise when traveling Gear clearance is too big. Adjust
Too much worn of gear. Replace
9
Driving axle
3.1 Data
Model 2.0-2.5 t 3.0-3.5 t

Full floating, axle and truck body direct
Driving axle type
install, front wheel driving
Tire pressure MPa 0.9
Wheel hub rotation starting torque at hub blot N 10～29
Axial play of wheel bearing mm less than 0.08
Weight kg 195-198 202-208
3.2 Trouble diagnoses and corrections
Condition Probable cause Corrective action
Loose driving axle and body connecting blots. Tighten
Loose wheel nut Tighten
Worn or damaged wheel hub bearing. Replace

Abnormal noises
Wheel hub bearing not properly adjusted. Adjust
Worn axle shaft spliner. Replace
Insufficient lubrication Lubricate
Loose wheel nut. Tighten
Deformed wheel. Replace
Worn or damaged wheel hub bearing. Replace

Unstable driving
Loose driving axle and body connecting blots. Tighten
Wheel hub bearing not properly adjusted. Adjust
Improper tire pressure. Adjust
Worn or damaged axle shaft oil seal. Replace
Oil leakage Final drive improperly installed. Replace gasket
Loose drain plug. Tighten.
10
1. Rim 2. Brake drum 3. wheel hub 4.Wheel nut 5. Wheel hub bolt
6. Bolt 7.Brake assy 8. Wash 9.Bolt 10. Half-axle nut
11. Half axle 12.Bolt 13. Oil seal 14. Taper roller bearing 15. Adjusting nut
16. Lock nut 17.Pin 18. Paper shim 19. Oil seal 20.Axle case
21. Supporter
Fig.3-1 Driving axle
Tighten torque: N.m
Axle shaft bolt○

A 73.5-88.3
Trig soleplate bolt○

B 118-147
nut connecting brake drum and hub○

C 324-373
Bolt and nut connecting support plate and truck body○

D 324-373
Tyre nut○
E 441-588
11
3.3 Driving axle assemble removal and installation
WARNING
 Be careful when removal and installation driving axle as it is heavy.
– Raise front end of forklift truck and support frame with wooden blocks.
– Remove mast assembles.
– Slightly raise axle with a hoist and place wooden blacks under differential gear carrier and
transmission case.
– After placing a pan under axle case, loose oil plug, drain oil from axle case.
– Disconnect brake nuts from left and right cylinders.(see fig.5-1）.
CAUTION
 Plug brake tube openings to prevent oil from flowing out.
– Disconnect brake cable at hand brake lever.
– Remove front wheels.
– Remove axle shaft.
– Support driving axle with wire ropes and lifting device.
– Remove bolts securing axle mounting bracket to frame.（see fig.5-2）.
– Remove nuts securing axle case to differential gear carrier.（see fig.5-3）.
– Remove driving axle assemble.
Fig.1-1 Fig.1-2 Fig.1-3

– Remove brake drum，remove wheel hub.
– Remove axle mounting bracket and brake component from axle tube.
– Remove oil seal from axle tube.
– To install driving axle assemble in the reverse order of removal. Observe the following:
a. When installing axle mounting bracket and brake component, apply a coat of calcium
grease to axle tube.
b. Apply 1/3～2/3 of volume of calcium grease to wheel hub，then install them on axle tube.
c. Install oil seal with its part number facing to the inside of forklift truck.
d. attach seal tape （PVC, white）to drain plug then installed after cleaned it.
e. Replenish axle case with gear oil. Tighten vent plug after clearing.
12
Gear oil GL-5 85W/90 3.2 L
CAUTION
 Vent plug should clear instantly to prevent pressure inside of wheel hub from rising.
13
3.4 Axle shaft and wheel hub
Remove
– Raise the front end of forklift truck and support frame with wooden blocks.
– Remove front wheel and axle shaft.
– Remove lock nuts, lock washers, snap ring, felt ring, adjusting nut. Use special tools.
– Remove brake drum（refer to Fig.5-4）；
– If brake drum is difficult to remove:
a. Remove adjusting hole plug. Then with flat-blade screwdriver extend adjusting hole, turn
adjusting ratchet wheel by 10 notches. To contract brake shoe lining(refer to Fig.5-5).
b. evenly tapping on brake drum with brass bar or wooden mallet.
Fig.1-4 Fig.1-5
– Remove wheel hub, be careful not to drop bearing inner race.
– Remove oil seal and inner bearing as an assembly by evenly tapping on periphery of seal with
a wooden mallet and brass bar.
– Remove bearing outer race from wheel hub by evenly tapping on its periphery with a wooden
mallet.
CAUTION
 Be careful not to damage oil seal and outer race.
Inspection
Stepped wear or cracks on axle shaft splines Replace
Seized, scratched, noisy or rusted bearing or improper rotation of rollers Replace
Cracked or damage wheel hub Replace
Damaged oil seal felt ring. Replace
Installation
Install reverse order of removal.
14
3.5 Bearing adjusting
– Lubricate on taper roller bearing.
– Tighten roller bearing lock nut in wheel hub until wheel hub can no longer be rotated with one
hand.
– From that position, turn back lock nut approx. 600.
– Turn back wheel hub two or three rotations so that bearing settles down.
– Again tighten lock nut until it can no longer be rotated with one hand; then turn back
approx.600.
– Install snap ring and settles down felt ring, install lock washer so as to set its hole in the pin of
snap ring. Screw lock nut.
– Turn wheel hub back and forth two or three rotations to see if rotation starting torque is within
specifications. Rotation starting force:10～29N（refer to Fig.1-6）.
– Measure axial play of wheel hub to see if it is within specification. Axial play is less than
0.08mm （refer to Fig.1-7）.
Fig.1-6 Fig.1-7
15
2. Steering system
Steering system include rear steering axle and steering device.
Steering device
It consists of steering wheel, upside steering column, downside steering column, bearings,
steering gear, priority valve, clamp bolt and hydraulic switch etc. You can adjust the steering angle
forward and backward by yourself. Refer to Fig. 2-1.
1. Steering wheel 14. Down side steering column

3. Upside steering column 17. Steering gear
8. Gimbal 18. Priority valve
10. Down side steering axle 19. Clamp bolt
12. Bearing 22. Clamp lever
13. Snap ring 26. Hydraulic switch
Fig. 2-1 Steering device
16
Steering axle
2.1 General specifications
Axle body
Center support, swing type
type
Vertical play（mm） 0-1
Inner wheel 80º
Turning
angle Adjusting shim for end
Outer wheel 55.7º shaft of axle thickness 0.5, 1.0, 1.6
（mm）
Tyre
0.8 MPa Part No. N163-220020-000
pressure
Kingpin wheel hub bearing
Kingpin axial play（mm） Less than 0.20 Tighten steering spindle nut
until drive wheel hub no longer
Pre-tighte rotates with one hand. Then
Kingpin adjusting washer loose 1/8～1/6 rotations.
n
Or wheel hub rotation starting
Thickness（mm） Part No.
torque at hub blot 10-29.8N
Axial
0.10, 0.30, 0.70 N163-220012-000 Less than 0.10
play(mm)
Truck type 2.0-2.5 t 3.0-3.5 t
Weight（kg） 96-99 98-100
2.2 Trouble diagnoses corrections
Loose wheel nut Tighten
Wheel bearing out of adjustment. Adjust

Unstable
driving
Improperly adjusted shims. Adjust
Faulty steering system. Refer to turning system section
Insufficient lubrication. Apply calcium grease
Loose bolts and nut. Tighten

Noises
Improperly adjusting shim for axle end Shaft. Adjust
Damaged joint bearing at two ends of rod. Replace
17
18
2.3 Remove
Wheel hub
– Jack up and support forklift truck body with wooden blocks.
– Remove tire.
– Remove hubcap.
– Remove steering spindle nut.
– Pull off hub assembles.
– Remove bearing inner race.
CAUTION
 Not to drop bearing inner race.
 Be careful not to damage oil seal.
2.4 Kingpin and steering spindle

– Remove rod.
– Loose lock bolts.（See fig.2-2）；
– Remove grease nipples on kingpin.
– Remove kingpin.
CAUTION
 Hold kingpin to prevent it from dropping. (See fig.2-3).
– Take off spindle, thrust bearing and shim.
Fig. 2-2 Fig. 2-3

INSPECTION：
– Replace spindle if cracked.
– Replace bearing if its rollers or roller surfaces are rusted or nicked.
– Replace steel sleeve if it distortion, out of round, cracked.
– Replace thrust bearing and dust cap if them damaged.
Installation
To install, reverse the order of removal. Careful observes the following.
– Always insert kingpin from lower side.
– Install thrust bearing, set the tighten-ring below the support and loosen-ring. Pack all grease
between dust proof inside, loosen-ring, and tighten-ring.
19
– Adjust axial play to specification with shims. Axial plays less than 0.15mm.
– The character of seal tape faces outside. Apple grease to roller of roller bearing, also apply
grease between lip and groove of seal tape.
– Pack all grease nipple with a sufficient.
2.5 Wheel bearing adjustment
– Slowly rotate hub. Tighten steering spindle nut until it can no longer be rotated with one hand.
– From that position, turn back steering spindle nut 1/6～1/4 rotation. Measure hub bolt force is
10～30N.
– Make sure that hub rotates smoothly and that its axial play is within specification. Axial play is
less than 0.10mm.
2.6 Steering cylinder
2
3
4
5
6
8
1
1. Piston rod 2. LBH wiper 3. O-Ring 4. ISI seal ring

5. O-Ring 6. Guide sleeve 7. Glay ring 8. Crock
图 2-4 Steering cylinder
20
3. Brake system
The brake system is the front two-wheel braking type consisting of a master cylinder, brakes and
brake pedal.
Master cylinder
The master cylinder contains a valve seat, check valve, return spring, primary cup, piston and
secondary cup, which are kept in place with stop washer and stop wire. The exterior of the cylinder
is protected from dust by means of a rubber dust cover. The piston is actuated through the push
rod by operation of the brake pedal. First, as the brake pedal, the push rod pushes the piston
forwards. The brake fluid in the cylinder flows back to the reserve tank through the return port until
the primary cup blocks up the return port. After the primary cup passes the return port, the brake
fluid in the cylinder is pressurized and opens the check valve, flowing through the brake lines to
the wheel cylinder. Thus, each wheel cylinder piston is forced outwards. This brings the brake
shoes into contact with the wheel drum and slows or stops the lift truck.. Meanwhile, the cavity
caused behind the piston is filled with brake fluid led through the return port and inlet port to
lubricate the piston. When the brake pedal is released, the piston is forced back by the return
spring. At the same time, the brake fluid in each wheel cylinder is pressurized by the force of the
brake shoe return spring, thus returning into the master through the check valve. With the piston in
its original position, the fluid in the cylinder flows into the reserve tank through the return port. The
brake fluid in the brake lines and wheel cylinders has a residual pressure proportioned to the set
pressure of the check valve, which makes each wheel cylinder piston cup securely seated to
prevent oil leakage and eliminates of vapor lock developing when the lift truck is sharply broken.
1. Lock nut 2. Rod 3. Duct cover 4. Stop wire

5. Stop washer 6. Secondary cup 7. Piston 8. Primary cup
9. Spring 10. Check valve 11. Valve seat 12. Cylinder body
图 3-1 Master cylinder
21
Foot brake
2.1 Brake
The configuration of the right detent can refer to fig 3-2.
1. Brake mount bracket 2. Wheel cylinder body 3. Cylinder return spring

4. Rubber cap 5. Piston 6. Cylinder dust cover
7. Push rod 8. Air bleeder cap 9. Air bleeder screw
10. Brake shoe assy (front) 11. Brake shoe assy (rear) 12. Guider
13. Adjuster cable 14. Adjusting bolt 15. Pawl
16. Spring 17. Brake shoe return spring 18. Return spring
19. Parking brake rod 20. Strut level 21. Spring
22. Bolt 23. Washer 24. Snap ring
25. Guider 26. Spring support rod 27. Spring bracket
28. Spring 29. Plug 30. Oil connector
31. Bush 32. Brake steel cable
Fig.3-2 forklift truck right brake assy
22
2.2 Replace brake shoe:
– Place the forklift truck on level concrete.
– Start engine and raise carriage about 100mm.
– Place chocks behind rear wheels to prevent movement of forklift truck.
– Loosen wheel nuts two or three turns each.
– Tilt mast fully backward, and place a wooden block under each side of outer mast.
WARNING
 Do not allow wooden blocks to touch front tires.
– Tilt mast forward until front tires are raised from surface.
– Support forklift truck by putting additional wooden blocks under each side of front-end frame.
– Stop engine.
– Remove wheel tire nuts and brake drum.
– Replace brake shoes with new ones.
– Install brake drum.
– Adjust shoe to drum clearance:
a. Remove adjusting hole plug on the bottom of the brake assemble.
b. Insert a flat-blade screwdriver to adjusting hole, turn adjusting ratchet wheel downward to
expand the brake shoes until wheel hub can not be turned by hand.
c. Move the ratchet wheel 2～3 notches to allow the wheel hub to be turned freely, slight
friction is allowed between the brake and shoe lining.
d. Replace the plug.
e. Install wheels.
f. Properly adjusting pedal stroke.
g. Remove blocks.
h. make sure no person or obstacle is around forklift, then operate forklift in reverse at 2 to 3
km/h, set foot on brake pedal 2～3 times.
23
Hand brake device
The hand brake device adopts a hand-pulling soft brake wire cable device. It makes use of
auto-assist pressure linings type brake together with foot brake. Only when parking truck, use the
hand brake. If it occurs for foot brake malfunction, use hand brake to stop the truck.
Oil leakage in brake lines. Correct and replenish
Air in brake lines. Bleed air

Insufficient
brake force Improper functioning of master cylinder or wheel
Correct or replace
cylinder.
Clogged oil lines. Clean
No free play of brake pedal. Adjust
Faulty piston cup. Replace
Brake
Weak or broken return springs. Replace
dragging
Clogged master cylinder returns port. Clean
Clogged oil lines. Clean
24
4. Hydraulic system
The high pressure oil from main pump goes to control valve and divide it to two parts by dividing
valve inside control valve: one of them goes to lifting cylinder or tilting cylinder, another part goes
to steering gear with invariable flow to control steering cylinder. When lifting and tilting spool is in
neutral, high pressure oil return oil tank directly from pass way. When pulling lifting spool, high
pressure oil goes by throttle valve and then push piston rod under lifting cylinder piston. When
pushing lifting spool, it is that bottom of lifting cylinder piston connects with low pressure line and
then piston rod drops by deadweight and weight of cargo. In this time, oil from lifting cylinder goes
by unidirectional speed limiting valve so as to control the falling speed. When operating tilting
spool, high pressure oil goes to front house of tilting cylinder and another connects with low
pressure line so as to make mast tilt forward or backward.
25
Fig.4-1 Hydraulic System Diagram
26
Main pump
Trouble Probable cause Corrective action
Low oil level in tank. Add oil to specified level.

No oil from oil
pump Clean oil line and tank. If oil is dirty,
Clogged suction pipe or strainer.
change.
Worn bearing damaged backup ring
Replace faulty parts.
and O-ring.
Readjust to specified pressure using
Maladjusted relief valve.
pressure gauge.
Low discharge Retighten suction side pipe.

pressure on oil
pump. Add oil in oil tank.
Air in oil pump.
Check pump oil seal.
Do not operate pump until bubbles in

tank disappear.
Cavitation due to crushed suction Adjust or replace crushed hose and
hose or clogged strainer. clean strainer.
Air being sucked from loose suction
Retighten each joint.
side joint.
Replace with new oil having proper
Noisy oil
viscosity for temperature at which pump
pump Cavitation due to too high oil is to be operate.
viscosity.
To operate when oil temperature is
normal.
Determine cause of bubbles and
Bubbles in hydraulic oil.
remedy.
Oil leaking Faulty oil seal on pump, faulty O-ring
Replace faulty parts.
from oil pump or worn sliding surfaces on pump.
27
Control valve
Trouble Probable cause Corrective action
Loose of pressure-adjust screw. Readjusted and retighten.
Distorted or damaged pressure-adjust

Pressure of relief spring. Replace.
valve is not steady
or too low. Worn or blocked relief valve core. Replace or clean.
Pump abated. Examine and repair pump.
Replace valve core and tilt lock

Worn or damaged tilt lock valve.
Fork tilt forward valve as an assembly.
when control lever
Broken tilting lock spring. Replace spring.
is used while
engine is off.
Damaged tilt valve plunger O-ring. Replace O-ring.
Mast is unstable
when tilting Malfunctioning tilt relief valve. Replace tilt relief valve assembly.
forward.
Valve body and spool valve is worn and Replace spool valve with specified
clearance between them is too great. clearance.
Lowering distance Spool valve is not in centre. Keep being in the centre.
of mast is big when
spool valve is in
the centre. Cylinder seal abated. Examine and repair cylinder.
Taper valve is worn or blocked by dirt. Replace or clean taper valve.
Damaged or distorted reposition-spring. Replace spring.
Dirt exist between valve body and spool

Spool valve is not valve. Clean.
return neutral
position. Blocked control device. Adjusted.
Not coaxial parts at reposition Reinstall.，be coaxial
Damaged O-ring. Replace.
Faulty seal of joint. Check and retighten.

Leakage
Clean seal plate and retighten
Loose seal plate.
blots.
Loosed lock-nut of relief valve and
Tighten.
connect-nut between plate and plate.
28
Adjusting the pressure of the main relieve valve
The pressure of the main relieve valve is all ready adjusted in the factory, and it can’t be adjusted
generally. The following is an example of 3t truck to specify how to adjust the pressure.
– Put 125 percent of the rated load (2000kg) on the forklift stable.
– Step the accelerated pedal to the end, control the lift pole, if the forklift can get the height of
300mm,the main relieve valve is all right. Otherwise, adjust it as step (3).
– If the forklift can’t work, enhance the pressure main relieve valve, remove the front soleplate,
loosen the tightening nut of the main relieve valve, screw the adjusting nut clockwise to
enhance the pressure of the main relieve valve. If the height of lift is higher than 300mm,
screw the adjust nut anti-clockwise to reduce the pressure.
– Step the accelerated pedal to the end to make the forklift in the height range of 0-300mm.
Otherwise, adjust it as step (3).
WARNING
 The load should be put stably.
 Don’t adjust if the pressure is already adjusted correctly.
29
5. Lifting system
Data
Inspection and adjustment
Assly clearance Repair clearance
Place
(mm) (mm)
Mast to lift roller 0.1～0.8 0.2～1
Shims 0.5～1
Mast to back up metal 0.1～0.8 0.2～1
Shims 0.5～1
Inner mast to carriage side roller 0.1～0.6 0.2～1
Lift chain deflection 25～30 mm
Tightening torque
Place N·m
Lift chain lock nut 176-216(M18) ; 245-314(M20)
Mast support cap blot 176-216（M18）
Tilt cylinder lock nut 89-118（M14）
Lift cylinder bolt(head) 76-107（M12）
Lift cylinder bolt（toe） 44-58（M10）
Lift cylinder fixing bolt（U type） 29-39（M10）
30
Fault
Fault Probable cause Corrective action
Tilt cylinder and ring abraded excessively Replace piston ring tilt cylinder.
Fork arm carrier or
mast tilt by itself. The hydraulic control valve spring is
Replace it.
inoperative.
The fork arms Caused by piston jamming or bent piston rod. Replace the faulty parts.
carrier moves up
and down
sluggishly. Too much dirt is accumulated in the cylinder. Strip it down and clean.
Adjust clearance with thrust metal and

Carriage bracket assembly out of adjustment.
carriage side roller.
Insufficient clearance between inner and outer
Adjust clearance with rollers.
masts or rollers and mast.
Forks are lifted or
lowered Biting foreign materials between moving part. Remove foreign materials.
unsmoothly.
Apply grease on contact surfaces of
Insufficient lubrication.
sliding parts.（butter）
Bent carriage bracket assembly. Repair or replace.
Forks are lifted

Lift chains out of adjustable. Adjust lift chains.
unevenly
Grease stiffened or dirt accumulated on lift
Clean and lubricate lift rollers.
Lift roller does not roller and mast sliding surfaces.
rotate
Improperly adjusted lift roller. Adjust.
Insufficient lubrication. Lubricate.
Improperly adjusted lift roller, side roller and

Excessive mast Adjust.
back-up metal.
noise
By adjusting shims and rubber pad,
Rubber pad on lower of outer mast is useless piston rod is in touch with bottom of
for container fork lift truck. cylinder body after inner mast is in
touch with rubber pad.
Excessive wear occurs between the oil pump Replace the worn parts or the oil
body and gears, causing too much clearance. pump.
The lifting jack piston Yx-ring has worn, resulting in
Replace Yx-ring.
excessive inner leaks.
Springs of the multiple control valve and its
Replace.
relief valve are inoperative oil leaks.
Excessive wear occurs of the hydraulic
Replace
control valve ,resulting in excessive oil leaks.
Insufficient lift
Oil leaks occur between the hydraulic control Dismantle for regrinding the joint
power or no lift
valve sections. surfaces and reassemble the valve.
movement.
Tighten the joint nuts and inspect the
Leakage occurs in the hydraulic pipe.
seal for damage.
Change the wrong hydraulic oil or stop
operation for reducing the oil
The hydraulic oil temperature is too high. Oil
temperature. Find out the reasons for
viscosity is too low and the rate is insufficient.
high oil temperature and eliminate the
trouble.
The load carried is beyond the designed
Observe the lifting capacity limit.
capacity.
31
Mast
Basic mast is 3m high, composed of inner and outer mast, fork arm carrier, fork arm, chain and
idler wheel, etc.
1.Outer mast 2.Inner mast 3.Back rest 4. Fork arm carrier

5.Fork 6.Chain 7.Left lifting cylinder 8.Right lifting cylinder
9.Tilting cylinder 10.Idler wheel
Fig5-1 Double lift mast with wide view
1. Outer mast 2. Inner mast 3. Chain 4. Free lifting cylinder

5. Fork arm carrier 6. Fork 7. Left lifting cylinder 8. Right lifting cylinder
9. Fork arms 10.Tilt cylinder
Fig5-2 Double full free lift mast
32
1. Outer mast 2.Inner mast 3. Chain 4. Free lifting cylinder
5. Fork arm carrier 6.Fork 7. Sideway cylinder 8. Left rise cylinder
9. Right rise cylinder 10. Fork arms 11.Tilt cylinder
Fig 5-3 Container truck mast
1. Outer mast 2. Inner mast 3. Chain 4. Free lifting cylinder

5. Fork arm carrier 6. Fork 7. Sideway cylinder 8. Left rise cylinder
9. Right rise cylinder 10. Fork arms 11.Tilt cylinder
Fig 5-4 Triple full free lift mast
33
Lifting cylinder
Plunger feeder lifting cylinder has dash control, configuration see fig 5-5
1.LBH dust proof 2. ISI ring 3. Plug screw 4. O Ring

5.Piston 6.Bolt 7.Guide 8.bush
9. Cylinder body 10.Piston 11. Snap ring 12. Piston
13. Support ring 14. Back up rings 15. OSI ring 16. Valve guide
17.Snap ring 18. Steel axletree 19.Blowout patch 20.Adjusting washer
Fig 5-5 Lifting cylinder
Tilting cylinder
1. Retaining ring 2. Knuckle bearing 3. Support 4. Lubrication nipple 5. Nut

6. Bolt 7. Dust proof 8. Cylinder 9. Guide 10.U ring
11.O-Ring 12.Piston rod 13. O-Ring 14.Thimble 15.U ring
16.Piston 17.Cylinder body 18. Washer 19.Nut 20.Pin
21.bolt 22.Nylon tray 23. Snap ring 24.Snap ring 25.Adjusting washer
Fig 5-6 Tilting cylinder
34
6. Electrical system
Controller
CURTIS 1244 Controller
Summarize
Curtis PMC 1244 MultiMode controllers are separately excited motor speed controllers designed
for use in a variety of material handling vehicles. These programmable controllers are simple to
install, efficient, and cost effective.
Typical applications include low lifts, stackers, fork lifts, reach trucks, personnel carriers,
counterbalance trucks, order pickers, boom trucks, and other industrial vehicles.
The 1244 MultiMode controller offers smooth, silent, cost effective control of motor speed and
torque. A four quadrant, full-bridge field
Winding control stage is combined with a two quadrants, half-bridge armature power stage to
provide solid state motor reversing and regenerative braking power without additional relays or
contactors. The 1244 controller can also be specified to be compatible with CAN Bus
communication systems.
These controllers are fully programmable by means of the optional handheld 1307 programmer.
Use of the programmer provides diagnostic and test capability as well as configuration flexibility.
Like all Curtis PMC motor controllers, the 1244 offers superior operator control of the vehicle’s
motor drive speed. Features include:
Full-bridge field and half-bridge armature power MOSFET design, providing: Infinitely variable
forward, reverse, drive, and brake control；Silent high frequency operation；High efficiency.
– Regenerative braking, providing longer operation on a single battery charge and reducing
motor brush wear and motor heating.
– Programmability through the 1307 handheld programmer
– Complete diagnostics through the 1307 programmer and the internal Status LED
– Two fault outputs provide diagnostics to remotely mounted displays
– Continuous armature current control, reducing arcing and brush wear
– Automatic braking when throttle is reduced from either direction; this provides a compression
braking feel and enhances safety by automatically initiating braking in an operator hands off
condition.
– Deceleration Rate, Load Compensation, and Restraint features prevent downhill runaway
conditions; speed is controlled to within approximately 20% of level surface value.
– MultiMode allows four user-selectable vehicle operating personalities
– Programmable to match individual separately excited motor characteristics
– Meets or exceeds EEC fault detect requirements
– Vehicle top speed is controlled and limited in each mode
Linear temperature and under voltage cutback on motor currents; no sudden loss of power
– under any thermal conditions
35
– High pedal disable (HPD) and static return to off (SRO) interlocks prevent vehicle runaway at
startup
– Creep speed adjustable from 0% to 25% in each mode
– Continuous diagnostics during operation, with microprocessor power-on self-test
– Internal and external watchdog circuits ensure proper software operation
– Programmable coil drivers provide adjustable contactor pull-in and holding voltages
– Hour-meter enable output is active whenever the controller is providing motor current
– Optional Electromagnetic Brake Driver provides automatic control of an electromagnetic
brake or other similar function.
36
Fault code
LED PROGRAMMER LCD

EXPLANATION POSSIBLE CAUSE
Code DISPLAY
1,2 HW FAIL SAFE1-2-3 Self-test or watchdog fault 1.Controller defective.
M-SHORTED Internal M- short to B- 1.Controller defective.
1.Motor field wiring loose.

FIELD OPEN Field winding fault
2.Motor field winding open.
1,3
ARM SENSOR Armature current sensor fault 1.Controller defective.
FLD SENSOR Field current sensor fault 1.Controller defective.
1.VSC input wire open.

2.VSC input wire shorted to B+ or B-.
2,1 SPEED CONTROL FAULT VSC signal exceed range
3.Throttle pot defective.
4.Wrong throttle type selected.
1.Improper seq. of direction and
throttle inputs.
2.Wrong START LOCKOUT type
2,3 START LOCKOUT Starting sequence wrong
selected.
3.Misadjusted throttle pot.
4.Sequencing delay too short.
3,1 CONT DRVR OC Cont. driver output over current 1.Contactor coil shorted.
1. Main contactor stuck closed.

3,2 MAIN CONT WELDED Welded main contactor
2. Main contactor driver shorted.
1. Controller defective.
Internal voltage too low at
3,3 PRECHARGE FAULT 2. External short, or leakage path to B-
startup
on external B+ connection.
1. Any contactor coil open or not
MISSING CONTACTOR Missing contactor
connected.
3,4
1.Main contactor missing or wire to coil
CONT DNC Main contactor did not close
open.
1. Battery voltage >overvoltage
shutdown limit.
2. Vehicle operating with charger
4,2 OVERVOLTAGE Overvoltage
attached.
3. Battery disconnected during regen
braking.
1.Temperature >85℃ or < -25℃.
2. Excessive load on vehicle.
4,3 THERMAL CUTBACK Over-/under-temp. cutback
3. Improper mounting of controller.
4. Operation in extreme environments.
37
Fault code
LED Programmer
Explanation Possible cause
Code Lcd display
NO voltage or controller is not

OFF
working, error (such as MCII
ON defective)
Controller work normally, no

0,1 ■¤ error
1.EEPROM miss data

2.EEPROM data check error ， use
1,1 ¤¤ EEPROM defective
programmer 1311 to change any
parameter can delete the error.
1.MOSFET short down.

1,2 ¤ ¤¤ Hardware defective
2.Motor circuit is an open circuit.
2,1 ¤¤ ¤ Low voltage 1.Battery voltage is too low.
1.The function of lifting lock of the

2,2 ¤¤ ¤¤ Lifting lock.
controller is touch off.
1.Any switch of SS1-SS4 closes earlier

2,3 ¤¤ ¤¤¤ Order fault（Startup lockout）
than KSI or INTERLOCK.
1.Main contact bonded。

3,2 ¤¤¤ ¤¤ Contact err 2.The set of parameter “CONTACT
CNTRL” is wrong.
1.Pre-charge circuit work with err.

3,3 ¤¤¤ ¤¤¤ Pre-charge fault
2.Motor short down.
1.The connection of main contact coil

Contact has not been installed
3,4 ¤¤¤ ¤¤¤¤ or is not close.
loose.
2.Main contact works abnormally.
The voltage of battery is lower than the set

4,1 ¤¤¤¤ ¤ Low -voltage protect.
value of “LOVOLT CUTBACK”
4,2 ¤¤¤¤ ¤¤ Over-voltage protect. The battery voltage is too high.
1.The temperature of controller is too high

Temperature protect
4,3 ¤¤¤¤ ¤¤¤ （over-/under-temp）
or too low.
2.Temperature sensor works abnormal.
38
CURTIS 1236/1238 Controller
Summarize
CURTIS company procreates controller ，adopt international advanced closed loop system and
advanced control technique。Designing large screen instrument，can clear display “electric
quantity”、“speed”、“total time of run ” and so on information。Designation adopt code plus
character manner，increase maintain efficiency。Four work models can be set through meter so as
to suitable for different condition.
（1）Actuating motor
Actuating motor adopt three-phase alternating current frequency conversion electromotor ，
increase conversion efficiency，not have commentator brush in order not to maintenance 。
（2）Lift motor
Lift motor JC1 is direct current motor, so is the motor of J series truck. Lift motor JC2 adopts
three-phase alternating electromotor，increase conversion efficiency，not have commentator brush
in order not to maintenance.
（3）SAFETY & PROTECTION FEATURES
– Reverse Polarity of the battery
– Connection errors
– All inputs are protected against connections errors.
– Current overload protection
– it have detecting element，control peak current.
– Thermal protection: If the controller temperature exceeds 85°C, the maximum current reduces
in proportion to the thermal increase. The temperature can never exceed 115°C; If the electric
machinery temperature exceeds 145°C, the maximum current reduces in proportion to the
thermal increase. The temperature can never exceed 165°C.
– Low Battery charge: When the battery charge is low, the maximum current is reduced
proportionally to the battery discharge.
– External Agents: Electric control is hermetical .The chopper is protected against dust and
spray of liquid to economy.
– Protection against accidental Start Up: A precise sequence of operations is necessary before
the machine will start. Operation can not commence if these operations are not carried out
correctly. Requests for drive must be made after closing the Key Switch.
（4）OPERATIONAL FEATURES
– Feedback control system make the vehicle speed follow accelerator ，whether low speed or
not high speed easy control .
– Two archives speed and acceleration design ，can apply to most situation.
39
– Regeneration technology make change direction of fork even smooth。
– Three regenerative braking mode ：
a. Acceleration pedal part release appear regenerative braking;
b. Direction reverse regenerative braking;
c. Ramp downslide appear regenerative braking，except increase security drive，reclaim part
of electric energy，prolong work time of every time .
– Control speed during downgrade： speed lie on accelerator 。if speed exceed set point，
controller may automatic braking，this give optimal ramp.
Notice:
– Maintain electric control ， must first cut off electrical source ， then hold 10-100ohmic
resistance join controller anode and cathode，release residual voltage in the capacitor, or else
you may meet tip-and-run danger.
– Magnetic and radiation have some effect to inverter，long time effect may mangle controller,
So need apart form magnetic and radiation.
40
Failure code
There are two LEDs including a yellow LED and a red LED. The two LEDs have four different
display modes, indicating the type of information they are providing.
DISPLAY STATUS
Controller is not powered on, has a dead
Neither LED illuminated
battery, or is severely damaged.
Yellow LED flashing Controller is operating normally.
Yellow and red LEDs both on solid Controller is in Flash program mode.
Red LED and yellow LED flashing alternately Controller has detected a fault.
PROGRAMMER LCD
CODE POSSIBLE CAUSE
DISPLAY
1. External short of phase U, V, or W motor connections.
1,2 Controller Overcurrent 2. Motor parameters are mis-tuned.
1. Leakage to vehicle frame from phase U, V, or W (short in motor stator).
1,3 Current Sensor Fault
1. External load on capacitor bank (B+ connection stud) that prevents the
1,4 Precharge Failed capacitor bank from charging.
2. See 1311 menu Monitor » Battery: Capacitor Voltage.
Controller Severe 1. Controller is operating in an extreme environment.
1,5 Undertemp 2. See 1311 menu Monitor » Controller: Temperature.
1. Controller is operating in an extreme environment.
Controller Severe 2. Excessive load on vehicle.
1,6 Overtemp 3. Improper mounting of controller.
4. See 1311 menu Monitor » Controller: Temperature.
1. Battery Menu parameters are misadjusted.
2. Non-controller system drain on battery.
3. Battery resistance too high.
1,7 Severe Undervoltage
4. Battery disconnected while driving.
6. Blown B+ fuse or main contactor did not close.
1. Battery Menu parameters are misadjusted.
2. Battery resistance too high for given regen current.
1,8 Severe Overvoltage
3. Battery disconnected while regen braking.
1. Controller is performance-limited at this temperature.
Controller Undertemp
2,1 2. Controller is operating in an extreme environment.
Cutback
1. Controller is performance-limited at this temperature.
2. Controller is operating in an extreme environment.
Controller Overtemp
2,2 3. Excessive load on vehicle.
Cutback
4. Improper mounting of controller.
1. Normal operation. Fault shows that the batteries need recharging.
Controller is performance limited at this voltage.
2. Battery parameters are misadjusted.
3. Non-controller system drain on battery
2,3 Undervoltage Cutback
4. Battery resistance too high.
5. Battery disconnected while driving.
7. Blown B+ fuse or main contactor did not close.
41
PROGRAMMER LCD
CODE POSSIBLE CAUSE
DISPLAY
1. Normal operation. Fault shows that regen braking currents elevated the
battery voltage during regen braking Controller is performance limited at
this voltage.
2,4 Overvoltage Cutback 2. Battery parameters are misadjusted.
3. Battery resistance too high for given regen current.
4. Battery disconnected while regen braking
1. External load impedance on the +5V supply (pin 26) is too low.
2,5 +5V Supply Failure
2. See 1311 menu Monitor » outputs: 5 Volts and Ext Supply Current.
2,6 Digital Out 6 Overcurrent 1. External load impedance on Digital Output 6 driver (pin 19) is too low.
2,7 Digital Out 7 Overcurrent 1. External load impedance on Digital Output 7 driver (pin 20) is too low.
1. Motor temperature is at or above the programmed Temperature Hot
setting, and the requested current is being cut back.
2. Motor Temperature Control Menu parameters are mis-tuned.
Motor Temp Hot
2,8 3. See 1311 menus Monitor » Motor: Temperature and Monitor » Inputs:
Cutback
Analog2.
4. If the application doesn’t use a motor thermistor, Temp Compensation
and Temp Cutback should be programmed Off.
1. Motor thermistor is not connected properly.
2. If the application doesn’t use a motor thermistor, Temp Compensation
2,9 Motor Temp Sensor Fault and Temp Cutback should be programmed Off.
3. See 1311 menus Monitor » Motor: Temperature and Monitor » Inputs:
Analog2.
1. Open or short on driver load.
3,1 Coil 1 Driver Open/Short 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
3,1 Main Open/Short 2. Dirty connector pins.
3,2 Coil2 Driver Open/Short 2. Dirty connector pins.
3,2 EM Brake Open/Short 2. Dirty connector pins.
3,3 Coil3 Driver Open/Short 2. Dirty connector pins.
Coil4 Driver
3,4 2. Dirty connector pins.
Open/Short
3,5 PD Open/Short 2. Dirty connector pins.
1. Motor encoder failure.
3,6 Encoder Fault 2. Bad crimps or faulty wiring.
3. See 1311 menu Monitor » Motor: Motor RPM.
1. Motor phase is open.
3,7 Motor Open
1. Main contactor tips are welded closed.
2. Motor phase U is disconnected or open.
3,8 Main Contactor Welded
3. An alternate voltage path (such as an external precharge resistor) is
providing a current to the capacitor bank (B+ connection stud).
1. Main contactor did not close.
2. Main contactor tips are oxidized, burned, or not making good contact.
Main Contactor Did Not
3,9 3. External load on capacitor bank (B+ connection stud) that prevents
Close
capacitor bank from charging.
4. Blown B+ fuse.
1. Throttle pot wiper voltage too high.
4,1 Throttle Wiper High
2. See 1311 menu Monitor » Inputs: Throttle Pot.
42
PROGRAMMER LCD
CODE POSSIBLE CAUSE
DISPLAY
1. Throttle pot wiper voltage too low.
4,2 Throttle Wiper Low
2. See 1311 menu Monitor » Inputs: Throttle Pot.
1. Brake pot wiper voltage too high.
4,3 Brake Wiper High
2. See 1311 menu Monitor » Inputs: Brake Pot.
1. Brake pot wiper voltage too low.
4,4 Brake Wiper Low
2. See 1311 menu Monitor » Inputs: Brake Pot.
1. Combined pot resistance connected to pot low is too low.
4,5 Pot Low Overcurrent
2. See 1311 menu Monitor » Outputs: Pot Low.
1. Failure to write to EEPROM memory. This can be caused by EEPROM
4,6 EEPROM Failure memory writes initiated by VCL, by the CAN bus, by adjusting
parameters with the 1311, or by loading new software into the controller.
1. KSI, interlock, direction, and throttle inputs applied in incorrect sequence.
2. Faulty wiring, crimps, or switches at KSI, interlock, direction, or throttle
4,7 HPD/Sequencing Fault
inputs.
3. See 1311 menu Monitor » Inputs.
1.Emergency Reverse operation has concluded, but the throttle, forward
4,7 Emer Rev HPD
and reverse inputs, and interlock have not been returned to neutral.
1.This is a safety fault caused by a change in certain 1311 parameter
settings so that the vehicle will not operate until KSI is cycled. For
4,9 Parameter Change Fault
example, if a user changes the Throttle Type this fault will appear and
require cycling KSI before the vehicle can operate.
1. VCL code encountered a runtime VCL error.
2. See 1311 menu Monitor » Controller: VCL Error Module and VCL Error.
6,8 VCL Runtime Error
This error can then be compared to the runtime VCL module ID and error
code definitions found in the specific OS system information file.
1. External load on the 5V and 12V supplies draws either too much or too
little current.
External Supply Out of
6,9 2. Fault Checking Menu parameters Ext Supply Max and Ext Supply Min
Range
are mis-tuned.
3. See 1311 menu Monitor » Outputs: Ext Supply Current.
7,1 OS General 1. Internal controller fault.
1. Time between CAN PDO messages received exceeded the PDO
7,2 PDO Timeout
Timeout Period.
1. Stalled motor.
2. Motor encoder failure.
7,3 Stall Detect 3. Bad crimps or faulty wiring.
4. Problems with power supply for the motor encoder.
5. See 1311 menu Monitor » Motor: Motor RPM.
Motor Characterization 1. Motor characterization failed during the motor characterization process.
8,7
Fault
1. Encoder characterization failed during the motor characterization
Encoder Characterization
8,8 process.
Fault
2. Motor encoder pulse rate is not a standard value (32, 48, 64, 80 ppr).
8,9 Motor Type Fault 1. The Motor type parameter value is out of range.
1. Vehicle movement sensed after the EM Brake has been commanded to
9,2 EM Brake Failed to Set set.
2. EM Brake will not hold the motor from rotating.
1. Limited Operating Strategy (LOS) control mode has been activated, as a
result of either an Encoder Fault (Code 36) or a Stall Detect Fault (Code
Limited Operating 73).
9,3
Strategy（LOS） 2. Motor encoder failure.
4. Vehicle is stalled.
1. Emergency Reverse was activated and concluded because the EMR
9,4 Emer Rev Timeout Timeout timer has expired.
2. The emergency reverse input is stuck On.
43
Kollmorgen Controller
Summarize
INMOTION company procreates controller ，adopt international advanced closed loop system and
advanced control technique。Designing large screen instrument，can clear display “electric
quantity”、“speed”、“total time of run ”，“work time of drive ”，“work time of lift ”and so on information。
Designation adopt code plus character manner，increase maintain efficiency。It also through meter
check periphery component to come true function of handset
(1) Actuating motor
Actuating motor adopt three-phase alternating current frequency conversion electromotor ，
increase conversion efficiency，not have commentator brush in order not to maintenance 。
(2) Lift motor
Lift motor adopt three-phase alternating electromotor ，increase conversion efficiency，not have
commentator brush in order not to maintenance.
(3) Safety & protection features
– Reverse Polarity of the battery
– Connection errors
– All inputs are protected against connections errors.
– Current overload protection
– It have detecting element，control peak current.
– Thermal protection: If the controller temperature exceeds 85°C, the maximum current reduces
in proportion to the thermal increase. The temperature can never exceed 115°C; If the electric
machinery temperature exceeds 145°C, the maximum current reduces in proportion to the
thermal increase. The temperature can never exceed 165°C.
– Low Battery charge: When the battery charge is low, the maximum current is reduced
proportionally to the battery discharge.
– External Agents: Electric control is hermetical .The chopper is protected against dust and
spray of liquid to economy.
– Protection against accidental Start Up: A precise sequence of operations is necessary before
the machine will start. Operation cannot commence if these operations are not carried out
correctly. Requests for drive must be made after closing the Key Switch.
(4) Operational features
– Feedback control system make the vehicle speed follow accelerator ，whether low speed or
not high speed easy control .
– Two archives speed and acceleration design ，can apply to most situation.
– Regeneration technology make change direction of fork even smooth。
– Three regenerative braking mode:
a. Acceleration pedal part release appear regenerative braking;
44
b. Direction reverse regenerative braking;
c. Ramp downslide appear regenerative braking，except increase security drive，reclaim part
of electric energy，prolong work time of every time .
– Control speed during downgrade： speed lie on accelerator. If speed exceed set point，
controller may automatic braking，this give optimal ramp.
Notice
– Maintain electric control ， must first cut off electrical source ， then hold 10-100ohmic
resistance join controller anode and cathode，release residual voltage in the capacitor, or else
you may meet tip-and-run danger.
– Magnetic and radiation have some effect to inverter，long time effect may mangle controller,
So need apart form magnetic and radiation.
45
warning and error handling for Kollmorgen
Code Type Error Cause
101 Err. Application ACCEL SWITCH ACTIVE AT KEY ON The acceleration switch is on when key on
102 Err. Application DIR. SWITCH ACTIVE AT KEY ON At least one of direction switches is on when key on
103 Err. Application DIR. SWITCH BOTH ON ERROR Both of the direction switches are on at the same time
104 Err. Application TRACT POT VALUE OUT OF RANGE The value of traction pot is out of range(<30 or >2800)
The acceleration switch is off but the value of traction pot is
105 Err. Application TRACT SWITCH OFF WITH LARGE POT
more than 30%
111 Err. Application CAN COMMUNICATION ERROR CAN communication error
114 Err. Application BATTERY LOW ERROR The battery is low. BDI value<25 warning, <15% slow the truck
115 Err. Application START UP ERROR ERROR Internal error when start up
116 Err. Application LIFT SWITCH ACTIVE AT KEY ON The lift switch is on when key on
117 Err. Application PUMP SPEED1 SWITCH ACTIVE AT KEY ON The pump speed1 switch is on when key on
121 Err. Application PUMP POT VALUE OUT OF RANGE ERROR The value of pump pot is out of range(<10 or >2800)
122 Err. Application LIFT SWITCH OFF WITH LARGE POT VALUE The lift switch is off but the value of pump pot is more than 30%
Driver left the truck but the direction switch is still on, turn off
124 Err. Application DRIVER LEFT WITH DIRECTION
direction switch , the error disappear
125 Err. Application MAIN CONTACTOR OFF ERROR Main contactor is off
301 Warn. Traction TRACT ACS TEMP LOW ACS temperature is lower than -20°C
302 Warn. Traction TRACT ACS TEMP HIGH ACS temperature is higher than 85°C
303 Warn. Traction TRACT ACS TEMP SENSOR ACS temperature sensor not connected or short circuit
304 Warn. Traction TRACT MOTOR TEMP LOW Motor temperature is lower than-35°C
305 Warn. Traction TRACT MOTOR TEMP HIGH Motor temperature is higher than145°C
306 Warn. Traction TRACT MOTOR TEMP SENSOR Motor temperature sensor not connected or short circuit
307 Warn. Traction TRACT SPEED SENSOR Speed sensor not connected or short circuit
For the 24V forklift truck, the ACS voltage is higher than 36V;
308 Warn. Traction TRACT HIGH VOLTAGE For the 48V forklift truck, the ACS voltage is higher than 68V;
For the 80V forklift truck, the ACS voltage is higher than 98V
For the 24V forklift truck,the ACS voltage is lower than 18V;
309 Warn. Traction TRACT LOW VOLTAGE For the 48V forklift truck,the ACS voltage is lower than 24V;
For the 80V forklift truck,the ACS voltage is lower than 60V
310 Warn. Traction TRACT DEFAULT PAR. LOADED Default parameters are loaded
46
311 Warn. Traction TRACT REDUCED POWER The ACS output power has been reduced
312 Warn. Traction TRACT DEFAULT CAL. PAR. CAL. Use default parameters
316 Warn. Traction TRACT CURR SENSOR DEFAULT Current sensor use default parameters
317 Warn. Traction TRACT OPEN DRIAN ERROR The open drain output is not connected
318 Warn. Traction TRACT MISC Other warnings
351 Err. Traction TRACT SHORT CIRCUIT There is a short circuit among B+,B-,U,V,W
352 Err. Traction TRACT ACS TEMP HIGH ACS temperature is higher than 125°C
353 Err. Traction TRACT MOTOR TEMP HIGH Motor temperature is higher than 180°C
354 Err. Traction TRACT CURR SENS. ERROR Current sensor error
355 Err. Traction TRACT CAP. NOT CHARGING ACS capacitor is not charged up to 85% in 10s
356 Err. Traction TRACT NOT RESPONDING ACS is no responde
357 Err. Traction SLAVE COMM. TIMEOUT Slave node communication timeout
358 Err. Traction TRACT SDO FAILURE SDO err in CAN
MASTER COMM.
359 Err. Traction Master node communication timeout
TIMEOUT
360 Err. Traction TRACT LOW VOLTAGE For the 48V forklift truck,the ACS voltage is lower than 18V;
361 Err. Traction TRACT HIGH VOLTAGE (SW) For the 48V forklift truck, the ACS voltage is higher than 68V;
362 Err. Traction TRACT HIGH VOLTAGE (HW) For the 48V forklift truck, the ACS voltage is higher than 68V;
363 Err. Traction TRACT PCB TEMP HIGH The ACS PCB temperature is higher than 125°C
364 Err. Traction TRACT MISC. Other errors
401 Warn. Pump PUMP ACS TEMP LOW ACS temperature is lower than -20°C
402 Warn. Pump PUMP ACS TEMP HIGH ACS temperature is higher than 80°C
403 Warn. Pump PUMP ACS TEMP SENSOR ACS temperature sensor not connected or short circuit
404 Warn. Pump PUMP MOTOR TEMP LOW Motor temperature is lower than -35°C
405 Warn. Pump PUMP MOTOR TEMP HIGH Motor temperature is higher than 145°C
406 Warn. Pump PUMP MOTOR TEMP SENSOR Motor temperature sensor not connected or short circuit
407 Warn. Pump PUMP SPEED SENSOR Speed sensor not connected or short circuit
408 Warn. Pump PUMP HIGH VOLTAGE
47
409 Warn. Pump PUMP LOW VOLTAGE For the 48V forklift truck,the ACS voltage is lower than 24V;
410 Warn. Pump PUMP DEFAULT PAR. LOADED Default parameters are loaded
411 Warn. Pump PUMP REDUCED POWER The ACS output power has been reduced
412 Warn. Pump PUMP DEFAULT CAL. PAR. CAL. use default parameters
416 Warn. Pump PUMP CURR SENSOR DEFAULT Current sensor use default parameters
417 Warn. Pump PUMP OPEN DRIAN ERROR The open drain output is not connected
418 Warn. Pump PUMP WARNING OTHERS Other warnings
451 Err. Pump PUMP SHORT CIRCUIT There is a short circuit among B+,B-,U,V,W
452 Err. Pump PUMP ACS TEMP HIGH ACS temperature is higher than 125°C
453 Err. Pump PUMP MOTOR TEMP HIGH Motor temperature is higher than 180°C
454 Err. Pump PUMP CURR SENS. ERROR Current sensor error
455 Err. Pump PUMP CAP. NOT CHARGING ACS capacitor is not charged up to 85% in 10s
456 Err. Pump PUMP NOT RESPONDING ACS is no responde
457 Err. Pump SLAVE COMM. TIMEOUT Slave node communication timeout
458 Err. Pump PUMP SDO FAILURE SDO err in CAN
459 Err. Pump MASTER COMM. TIMEOUT Master node communication timeout
460 Err. Pump PUMP LOW VOLTAGE For the 48V forklift truck,the ACS voltage is lower than 18V;
461 Err. Pump PUMP HIGH VOLTAGE (SW) For the 48V forklift truck, the ACS voltage is higher than 68V;
462 Err. Pump PUMP HIGH VOLTAGE (HW) For the 48V forklift truck, the ACS voltage is higher than 68V;
463 Err. Pump PUMP PCB TEMP HIGH
464 Err. Pump PUMP MISC Other errors
48
Electrical system principle diagram
CPD10/15/18/20/25/30/35-A
49
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
CPD10/15/18/20/25/30/35-AC3
CPD10/15/18/20/25/30/35-AC3F
50
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
CPD10/15/18/20/25/30/35-AC4
CPD10/15/18/20/25/30/35-AC4F
51
. . 1 5  /25W
. .
. 3
KE Y 28
1
KE Y
. 12
Di1
HI GH _SIDE _IN
29
.
HI GH _SIDE _OU T
19 2
Di 2 Open _Drain _Ou t_1
.
4
23 Open _Drain _Ou t _1 10
Di 3 Open _Drain _Ou t_2
.
16
11 Open _Drain _Ou t _2
Di 4
.
25
18 Open _Drain _Ou t _3
Di 5
.
24
30 Open _Drain _Ou t_4
Di 6
. 34
Di 8
Open _Drain _Ou t _5 27
.
13
35 Open _Drain _Out _6
Di9
2 26 16
Di1 0 Motor temp. 2 Motor temp. 2
ACS 23P
ACS 35P
1
Di11 1 Motor temp. 1 7 1
GND
5
Encoder 1 2V 1 Encoder 1 2V 3 1
7 5
Encoder Ch1 2 En coder Ch1 2
8 6
.
Fs3 17 Encoder Ch2 3 En coder Ch2 3
Di7
Encoder GND 6 4 Encoder GND 4 4
Common
switch
32 Analog
Suppl y(5V)
20
Ain1
9
Ain2
. . 31
AGND
33
. . 23
. .
C AN _H CAN _H
21 15
C AN _L CAN _L
CAN _GND
10
. 8
C AN _GND
C AN _1 20 15 9
CAN _1 20  
. .
9 3 2 7 6
C AN _H .
C AN _L
.
C AN _GND
.
1 B+
C AN _GND
3
C AN _L
OP T1 0 5
CAN _H
6
B-
2
CPD10/15/18/20/25/30/35-AD2
CPD25-ALD2
52
Maintenance record
Date Maintain content Maintainer

HANGCHA GROUP CO. , LTD.
■ Address For: OVERSEAS USERS
■ Address: 88 Donghuan Road, Lin'an Economic Development Zone,Zhejiang, China
■ Fax: 0086-571-88926789 0086-571-88132890 ■ ZIP:311305
■ Web: http://www.hcforklift.com ■ E-mail: sales@hcforklift.com

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What are the main components of the driving system?

What are the main components of the driving system?

What are the main components of the steering system?

What are the main components of the steering system?

Electrical Forklift Truck

（Electric four-wheel Forklift Truck）

HANGCHA GROUP CO., LTD.

© 01/2015 HANGCHA GROUP CO., LTD.

CPD10/15/18-A XQ-5-3A XQD-8.2-3D-1

CPD20/25-A XQ-7A XQD-8.6-3D-1

CPD30-A XQ-10.2 A XQD-10-3D-1

CPD10/15/18-AC3 HPQ8-4HC-A XQD-8.2-3D-1

CPD10/15/18-AC3F HPQ8-4HC-A XQD-8.2-3D-1

CPD20/25-AC3 HPQ11-4HC-A XQD-8.6-3D-1

CPD20/25-AC3F HPQ11-4HC-A XQD-8.6-3D-1

CPD25-ALC3 HPQ15-4HC-A HPB10-4HC

CPD25-ALC3F HPQ15-4HC-A HPB10-4HC

CPD30/35-AC3 HPQ15-4HC-A XQD-10-3D-1

CPD30/35-AC3F HPQ15-4HC-A XQD-10-3D-1

CPD10/15/18-AC4 HPQ8-4HC-A HPB8.6-4HC

CPD10/15/18-AC4F HPQ8-4HC-A HPB8.6-4HC

CPD20/25-AC4 HPQ11-4HC-A HPB8.6-4

CPD20/25-AC4F HPQ11-4HC-A HPB8.6-4

CPD25-ALC4 HPQ15-4HC-A HPB10-4HC

CPD25-ALC4F HPQ15-4HC-A HPB10-4HC

CPD30/35-AC4 HPQ15-4HC-A HPB10-4HC

CPD30/35-AC4F HPQ15-4HC-A HPB10-4HC

CPD10/15/18-AD2 HPQ8-4HC-A HPB8.6-4HC

CPD20/25-AD2 HPQ11-4HC-A TSW112/4-195-T-48V

CPD20/25-ALD2 HPQ15-4HC-A HPB10-4HC

CPD30/35-AD2 HPQ15-4HC-A TSW112/4-195-T-80V

A1：Motor armature's head

A2：Motor armature's end

D2：Shunt excitation's end

A1：Motor armature's head

A2：Motor armature's end

F2：Separated Excitation excitation's end

Separate excitation motor

Cooling air Must not contain volatile gas

Three times of rated current ,admit time is one

Brush Metal plumbagin brush trade J201 chart No 5CZ、578

Failure phenomenon Possible cause

Parts of commutator are Commutator’s center line location change

Clearance between brush and box is bigger.

Material of the brush is bad

Trademark of the brush is wrong

Commutator is rough or out of round

Mica or parts of commutator extrude

Brush seat grinding is bad

Trademark of the brush is wrong

The brush lock in the box

The brush frame is loose or vibrational

The polarity and tactic order of magnetic pole is wrong

The sparkle of brush is strong

The cable is thinner

The brush have noise The surface of the commmutator is rough

HPB8.6-4 8.6 31 248 1600 3200 F IC00 IP44 S3-15% 65

HPB10-4HC 10 51 161.6 2000 / F IC01 IP44 S3-15% 80

HPQ11-4HC-A 11 31 305 1200 2000 F IC01 IP20 S2-15% 100