1.3t-2.

0t Three-wheel Electric Counterbalanced Forklift

CPDS13/15/16/18/20-AC3/AC3-F
CPDS13/15/16/18/20-AC4/AC4-F
CPDS13/15/16/18/20-AC5/AC5-F
CPDS13/15/16/18/20-AC6/AC6-F
CPDS13/15/16/18/20-AD3/ AD4
CPDS13/15/16/18/20-AD5/ AD6
CPDS13/15/16/18/20-AZ3/ AZ4
CPDS13/15/16/18/20-AZ5/ AZ6
CPDS13/15/16/18/20-AC6-NA
CPDS13/15/16/18/20-AC4-I
CPDS16/18/20-AD4-I
CPDS16/18/20-AD6-I
CPDS16/18/20-AC6-I

Service Manual

Original Instruction

03 / 2022
 Foreword
Thanks for purchasing Hangcha three-wheel Electric Counterbalanced Forklift Truck
Three-wheel electric forklift truck is a new product with a small turning radius, an
attractive design, a small and compact structure, a low centre of gravity, good stability,
dual motor front wheel drive, steering and lifting by the same pump as well as superior
performance.
This manual is brief introduction and correct use to three-wheel Electric
Counterbalanced Forklift Truck. Relevant people should read and comprehend this
manual well.
Due to the continuous update and improvement of our products, there may be minor
discrepancies between your forklift truck and this manual.
For any questions, please contact Hangcha or your nearest dealer.
Three-wheel electric forklift trucks have been passed CE certification.
Left driven Right driven Pump Rated capacity(t)/ Load
Model
controller controller controller center(mm)
1.3/500，1.5/500，1.6/500，
CPDS13～20-AC3 Curtis 1234 Curtis 1234 Curtis 1253
1.8/500，2.0/500
1.3/500，1.5/500，1.6/500，
CPDS13～20-AC4 Curtis 1234 Curtis 1234 Curtis 1234
1.8/500，2.0/500
1.3/500，1.5/500，1.6/500，
CPDS13～20-AC5 Curtis 1234 Curtis 1234 Curtis 1253
1.8/500，2.0/500
1.3/500，1.5/500，1.6/500，
CPDS13～20-AC6 Curtis 1234 Curtis 1234 Curtis 1234 1.8/500，2.0/500

ACS48S-23P ACS48S-35P Curtis 1.3/500，1.5/500，1.6/500，

CPDS13～20-AD5
Inmotion Inmotion 1253-4801 1.8/500，2.0/500

ACS48S-23P ACS48S-35P ACS48S+-35P 1.3/500，1.5/500，1.6/500，

CPDS13～20-AD6
Inmotion Inmotion Inmotion 1.8/500，2.0/500

ACE2 ACE2 Z-S HP 48/350 B

1.3/500，1.5/500，1.6/500，
CPDS13～20-AZ3 36-48V/350A 36-48V/350A C/CAN
1.8/500，2.0/500
ZAPI ZAPI ZAPI
ACE2 ACE2 ACE2
1.3/500，1.5/500，1.6/500，
CPDS13～20-AZ4 36-48V/350A 36-48V/350A 36-48V/350A
1.8/500，2.0/500
ZAPI ZAPI ZAPI
ACE2 ACE2 Z-S HP 48/350 B
1.3/500，1.5/500，1.6/500，
CPDS13～20-AZ5 36-48V/350A 36-48V/350A C/CAN
1.8/500，2.0/500
ZAPI ZAPI ZAPI
ACE2 ACE2 ACE2
1.3/500，1.5/500，1.6/500，
CPDS13～20-AZ6 36-48V/350A 36-48V/350A 36-48V/350A 1.8/500，2.0/500
ZAPI ZAPI ZAPI
1.3/500，1.5/500，1.6/500，
CPDS13～20-AC6-NA Curtis 1234 Curtis 1234 Curtis 1234 1.8/500，2.0/500
1.3/500，1.5/500，1.6/500，
CPDS13～20-AC3-F Curtis 1234 Curtis 1234 Curtis 1253
1.8/500，2.0/500
 1.3/500，1.5/500，1.6/500，
CPDS13～20-AC4-F Curtis 1234 Curtis 1234 Curtis 1234
1.8/500，2.0/500
1.3/500，1.5/500，1.6/500，
CPDS13～20-AC5-F Curtis 1234 Curtis 1234 Curtis 1253
1.8/500，2.0/500
1.3/500，1.5/500，1.6/500，
CPDS13～20-AC6-F Curtis 1234 Curtis 1234 Curtis 1234
1.8/500，2.0/500
ACS48S-350C- HP48V/350A B 1.3/500，1.5/500，1.6/500，
CPDS13～20-AD3 ACS48S-23P
35P C/CAN 1.8/500，2.0/500

ACS48S-350C- ACS48S+-450C- 1.3/500，1.5/500，1.6/500，

CPDS13～20-AD4 ACS48S-23P
35P 35P 1.8/500，2.0/500

Curtis Curtis Curtis 1.3/500，1.5/500，1.6/500，

CPDS13～20-AC4-I
1234SE-6321 1234SE-6321 1234SE-6321 1.8/500，2.0/500

CPDS16~20-AD4-I ACS80S-23P ACS80S-23P ACS80S-35P 1.6/500，1.8/500，2.0/500

ACS48S-350C-3
CPDS16~20-AD6-I ACS48S-23P ACS48S-23P 1.6/500，1.8/500，2.0/500
5P

CPDS16~20-AC6-I 1232SE-5321 1232SE-5321 1232SE-5321 1.6/500，1.8/500，2.0/500

© 03/2022 HANGCHA GROUP CO., LTD

 Content
Foreword
1 Driving System.....................................................................................................................1
Reduction gearbox.................................................................................................................1
Disassembly and installation of drive axle.......................................................................6
Disassembly and installation of the Transfer.................................................................. 8
2 Steering system.................................................................................................................33
Steering device.....................................................................................................................33
Steering axle.........................................................................................................................34
3 Brake system......................................................................................................................37
Braking principle diagram..................................................................................................37
Service brake........................................................................................................................37
Pedal structure..................................................................................................................... 37
Parking brake........................................................................................................................40
Trouble diagnoses and corrections................................................................................. 41
4 Hydraulic system.............................................................................................................. 42
Structure of hydraulic system........................................................................................... 42
Working Principle of Hydraulic System.......................................................................... 42
Main component of hydraulic system............................................................................. 43
Main relief valve pressure adjustment............................................................................48
5 Lifting system.....................................................................................................................55
Data.........................................................................................................................................56
Fault diagnoses and corrections......................................................................................57
Tilt cylinder............................................................................................................................ 58
Lift cylinder............................................................................................................................ 61
Mast disassembly and installation...................................................................................63
6 Electric System..................................................................................................................68
AC motor................................................................................................................................68
DC motor................................................................................................................................70
Controller............................................................................................................................... 74
Electrical Schematic Diagram...........................................................................................96
1 Driving System
Driving system is composed of drive motor, reduction gearbox and tires etc. Please refer to the
figure 1.1 Driving system diagram.
Front wheel adopts dual-motor drive, that the left/right driving wheel is driven by one AC motor
respectively.
Reduction gearbox is a two-stage reducer, of which one is a couple of cylindrical helical gears and
the other is planet gear at the wheel rim which contributes to its small structure.
Service brake and parking brake share one wet brake, which lies in the reduction gearbox.

Traction motor

Reduction box

Tire

Fig.1.1 Driving system diagram

Reduction gearbox
Data
CPDS13/15/16/18/20-AC3/AC4/AZ3/AZ4
CPDS13/15/16/18/20-AC4-I
CPDS13/15/16/18/20-AC5/AC6/AC6-NA -2022.04
CPDS13/15/16/18/20-AD5/AD6/AZ5/AZ6 -2022.04

Item Parameter

Weight(Excluded oil) About 40 kg

Oil capacity One side about 0.35 L

Oil type DEXRON Ⅲ

Brake Fluid DOT3 or DOT4

Control pressure （6-8） MPa

Foot brake
Normal pressure(maximum-continuous) 8 MPa

Max. pressure 10 MPa

1
 Brake fluid volume in the cylinder(normal
1.71cm3
condition)
Brake fluid volume in the
3.71 cm3
cylinder(Maximum wear condition)
Hand brake handle pull 100 N

Hand brake Travel 6 mm

Wear limit travel 13 mm

CPDS13/15/16/18/20-AC5/AC6/AC6-NA 2022.04-
CPDS13/15/16/18/20-AD5/AD6/AZ5/AZ6 2022.04-

Specifications for the overall product Data

Weight with oil up to 78 kg

Minimum storage temperature +5°C (+41°F)
Maximum storage temperature +40°C (+104°F)
Maximum operating temperature +80°C (+104°F)

Ambient temperature in operation -30 to +40°C

-30°C～+40°C
Gearbox
Gear ratios available 14.0 to 26.6
Maximum static wheel load 2850 kg (8818 lb 8 oz)
Maximum input speed 5000 rpm
Maximum output torque 1320 Nm
Wheel
Wheel dimensions Rim 6.5 F-10
Wheel 200/50-10
Rim 4.33 R-8
Wheel 18x7-8
Lubricant
Gearbox oil type
acc. to ZF lubricant list TE-ML17C
Gearbox oil quantity approx. 0.35 l

2
 Trouble
CPDS13/15/16/18/20-AC3/AC4/AZ3/AZ4
CPDS13/15/16/18/20-AC4-I
CPDS13/15/16/18/20-AC5/AC6/AC6-NA -2022.04
CPDS13/15/16/18/20-AD5/AD6/AZ5/AZ6 -2022.04

Condition Probable cause Corrective action

Too much gear clearance Adjust

Great impact sound when
running and reversing
Too much gear wear Replace

Too low oil level in the gear box Refill gear oil

Gear noise during running Too much gear clearance Adjust

Too much gear wear Replace

Unable to move or
Friction plate damage Replace
insufficient braking force

CPDS13/15/16/18/20-AC5/AC6/AC6-NA 2022.04-
CPDS13/15/16/18/20-AD5/AD6/AZ5/AZ6 2022.04-

Noises：

Type of noise Possible cause Rectification

High-pitch hitting Teeth of spur gear stage Check gear teeth of input pinion and spur
noise (depending damaged when mounting gear for damage （ Replace a damaged
on rpm) motor input pinion; if the spur gear is damaged,
you may carefully refile the gear teeth
using a diamond file。 ）

High-pitch,singing noise Mechanical engine Check motor dimensions and motor

connection defective motor connection and if necessary retighten
bearing defective input pinion to hub

Dull, grinding noise Defective wheel bearing Inspect wheel bearing, replace if
Incorrect bearing pretension necessary
of wheel bearing Check bearing pretension,correct if
necessary
Defective teeth in
Inspect planetary stage gear set and
planetary gear
wheel bearing, replace if necessary

3
 Leaks, leaky points：

Location Possible cause Rectification

Bleeder Oil level too high Check oil level, correct if necessary

Housing cover Bolts not tightened to Check tightening torque, retighten bolts if
specified torque necessary
Gear shaft Radial shaft sealing ring Check radial shaft sealing ring, replace if
damaged or worn necessary

Brake lever Defective sealing ring Check sealing ring, replace if necessary

Screw plugs Screw plugs not tightened to Check tightening torque, if necessary
specified torque Incorrect orretighten bolts.
defective sealing ring
Remove screw plugs and use genuine ZF
mounted
sealing rings

Motor connection Defective motor O-ring Remove motor and replace O-ring

Motor Worn radial shaft sealing ring If necessary replace motor

on motor shaft

Drive with limited or no function

Location Possible cause Rectification

Defective connecting cable/loose

Replace/tighten connecting cable/
Carbon brushes (if fitted)
Motor Replace carbon brushes
fretted/worn
Replace motor
Insulation burned through
Replace motor/gearbox
Blocked motor/gearbox
Drive unit Carry out maintenance/repair to service
Service brake blocked
brake

Inadequate brake response

Location Possible cause Rectification

4
 Air in hydraulic system
Worn brake discs
Foot brake
Worn axial slide bearing
Ruptured brake cable
Bleed or top up brake fluid
Replace brake discs
Replace axial slide bearing
Replace brake cable

Braking connection part

CPDS13/15/16/18/20-AC3/AC4/AZ3/AZ4 CPDS13/15/16/18/20-AC5/AC6/AC6-NA
CPDS13/15/16/18/20-AC4-I CPDS13/15/16/18/20-AD5/AD6/AZ5/AZ6
No.1 Part：Head connector of hand brake cable, its wear limit is 13mm, replace once exceed this
limit.
No.2 Part：The connector of service brake pipe, replace once the brake cylinder leaks.
No.3 Part：Bleeder plug, screw off the plug to deflate after adding brake fluid; when testing the
brake, use bleeder plug to get rid of the gas in the brake pipe and brake. Detailed procedure:
When testing, first tighten the bleeder screw, then step on the brake pedal continuously until you
feel hard to step on, at this time, keep the brake pressed, release the bleeder screw to deflate,
stop when bubble is given off, and then screw down the bleeder screw and release the pedal.
Repeat the above procedures until no bubbles appear. Both left and right brakes are operated
according to the above requirements.

Oil plug and oil change of reduction gearbox

1.Oil filler plug 2.Oil level plug 3. Oil level plug 4.Drain plug 5.Breather plug
Procedures：

5
1. Jack-up the forklift, place a solid block under the truck frame, and screw off the tire nut and
take down the tire assembly.
2. Place a container under the reduction gearbox, screw off drain plug 4, and discharge the old
oil.
3. Clean the dirt in the reduction gearbox with clean oil of the same specification.
4. Screw down drain plug 4, add clean oil of the same specification through oil filler plug 1, until
the oil level plug 2 overflows.
5. Screw down drain plug 1 and oil level 2, and clean the overflowing oil on the reduction
gearbox.
6. Install tire assembly, screw down the tire nut symmetrically in twice, and the tightening torque
is 157Nm~176 Nm.

Disassembly and installation of drive axle

1. Support front of the forklift, support the truck frame with block and get the front tires off the
ground.
2. Dismantle forks and mast.
3. Remove the brake pipe and reduction gearbox connected nut; dismantle the brake cable on
the hand brake lever; dismantle wires on the motor.

Caution：
 Insert plug to the brake pipe to avoid brake fluid overflow.
4. Lift the reduction gearbox with lifting appliance slightly, prevent reduction gearbox falling down
after dismantling the truck fame connected bolt.
5. Dismantle rim nut, take down rim and tire.
6. Dismantle reduction gearbox and truck frame connected bolt.

6
7. Lift out the reduction gearbox and motor.
8. Dismantle reduction gearbox and motor connected bolt, remove reduction gearbox and motor
horizontally.
9. To install the drive axle, reverse the order of disassembly, but pay attention to the followings：
─ When installing the motor, apply some lubrication grease on the motor spline, send the
motor to the mounting position carefully, get through the bolt assembly(Apply LOCTITE
242 (222) LOXEAL to the meshing part of rear bolt), and screw down the bolt in twice in
diagonal order.
─ Discharge the contaminated oil in the reduction gearbox, add clean gear oil with the same
specification until oil overflows at the oil plug.

7
Disassembly and installation of the ○
7 in the case of changing.

Transfer
Disassembly of the Transfer
CPDS13/15/16/18/20-AC3/AC4/AZ3/AZ4
CPDS13/15/16/18/20-AC4-I
CPDS13/15/16/18/20-AC5/AC6/AC6-NA
-2022.04
CPDS13/15/16/18/20-AD5/AD6/AZ5/AZ6 5. Remove six hexagon socket bolts ○
3
-2022.04
1.Remove the adapter ○1 (M6×1) which concludes a transfer cover ○
2

At the time of the reassembly,change with a transfer case ○

1 .

bearings,O-rings,piston seals,oil seals,friction Put a transfer cover in the bottom.

plates and mating plates for a new article as a After having removed two hexagon socket
general rule. bolts ○
3 (M6×1)from the transfer case
side,remove a transfer case ○
1 .

2. Remove the hub cap ○

2 .

Return the caulking of the lock nut ○

3

(M30×1.5),then remove the lock nut.

Attention :Be careful so that a thread is not
damaged.

1 .The planet gear ○

6. Remove the carrier○ 2 is

united with the carrier.

3. Remove the lock plate ○
4 and the O-ring
○
5 ,then remove the hub assy ○
6 .

7. Remove the snap ring ○

3 ,The thrust washer

○
4 (t=1),two thrust washers ○
5 (t=2),the
4.Remove the inner race of taper roller bearing planet gear ○
6 and the needle bearing ○
7

8
from the carrier ○
1 .(3 places in total)

In the case of the thrust washer ○

5

(t=2)measures thickness t less than

t=1.6,change it for a new article at the time of
the reassembly.

12. Remove the driven gear ○

3 (Z=88).When

the ball bearing ○

4 is changed,strike with two

holes of driven gear ○

3 and remove it .

8. Remove the thrust needle bearing ○

8 and
the thrust washer ○
9 (t=2.5).

9.Remove the inner race of tapper roller

13. Remove eight hexagon socket bolts ○
5
bearing ○
10 from the carrier ○
1 in the case of
(M6×1) and bearing retainer ○.
6

changing . Attention :Because return spring ○

7 (four) come

off,be careful to loss.

10. Remove the sun gear ○

1 .

14. Remove four return springs ○

1 ,three

friction plates ○
2 ,three mating plates ○
3 and

the pressure plate ○

4 .

11. Remove the snap ring ○

2 from the sun
gear ○
1 .

9
15. Remove the ball bearing with snap ring ○
1

which is united with the snap ring ○

2 ,the

spacer ○
3 and drive gear ○
4 (Z=22) from the

transfer cover .

20. Remove the brake rod ○

2 ,then remove the

O-ring ○
3 .

16. Disassemble the snap ring ○

2 ,the spacer

○
3 ,the ball bearing with snap ring ○
1 and the

drive gear ○
4 .

21. Remove the retaining ring ○

2 from the

transfer case ○
1 .

17. Remove the air breather ○

5 (R1/8).

22. Remove the ring gear ○

3 (Z=64),then
remove six flat key ○
4 .

18. Remove two stop rings ○

6 ,the brake pin

○
7 ,then remove the brake lever○
8 .

When the ring gear ○

3 is hard to move,remove

it while beating the side of the ring gear in the

long stick things such as drivers lightly from
the arrow side of the right figure.

19. Remove two hexagon socket bolts ○

1

（M5×0.8）.

10
Attention :Be careful not to touch the oil
seal .and be careful not to damage the tooth of 27. Remove four O-ring seal plugs
the ring gear. ○
4 ( G1/4),then remove four O-rings○
5 .

23. Remove the oil seal ○

5 in the case of
changing.

24. Remove the outer race of taper roller

bearing○
1 in the case of changing.
CPDS13/15/16/18/20-AC5/AC6/AC6-NA
Attention :Don’t damage the rolling contact 2022.04-
CPDS13/15/16/18/20-AD5/AD6/AZ5/AZ6
surface. 2022.04-
When changing the disc set in one
gearbox, the disc set of the gearbox on the
other side of the vehicle shall also be changed.
If this is disregarded,there may be a
pronounced difference in braking effect

25. Remove the outer race of taper roller between the left-hand and right-hand gearbox.

bearing○
2 in the case of changing. The difference in braking effect may lead to

Attention :Don’t damage the rolling contact longer braking distances or to the vehicle

surface . breaking out to the side.

1.Brake disc set

26. Remove the needle bearing ○

3 in the case

of changing.

11
 several times with enough
drive to pull out the cylindrical pin.

1.1 Remove the brake disc set from the

internal gear
3.2 Grooved nut
1.2 Unclamp the housing from the assembly
Undo the grooved nut from the wheel shaft
fixture
and remove manually.
2.Protective cap
2.1Release the protective cap from the wheel
shaft and remove manually

3.Cylindrical pin
3.1 Remove the cylindrical pin which secures
the grooved nut from the
wheel shaft . To do this, screw the thread of
Pinion-extractor with hammer stroke fully into 3.3 Place the housing on the press table with
the cylindrical pin. Slide the hammer upwards

12
the mating surface facing downwards.

4.3 Remove O-ring from planet carrier by

hand.。

4. Planet carrier
Caution ： Risk of accident and injury from
crushing. When pressing out the planet carrier,
do not place hands between the punch and the
tool.
4.1 Press the planet carrier out of the
housing.The punch of the hand lever press
and the tool shall be at right angles to each
Clamp the housing in the assembly fixture.
other.
Remove the spacers from the housing

5.Planetary gears
Clamp the planet carrier in a vice.

4.2 Remove the planet carrier from the

housing

13
Caution：it the jaws of the vice with protective
jaws (e.g. copper, aluminium or
brass) to prevent the surfaces from being
damaged.
Remove the 3 planetary gears
7.1 Remove the wheel shaft side taper roller
bearing from the wheel shaft . If necessary,
heat the taper roller bearing.
7.2 Remove the planet carrier side taper roller
bearing

6. Gear shaft
Drive the wheel shaft out of the housing .
8. Internal gear
Secure the drive against falling from below
Remove the 12 Torx bolts from the
with your hand.
internal gear，Remove the internal gear from
the housing.If the internal gear is damaged, it
shall be replaced as a complete unit.

7.Wheel shaft taper roller bearing

Caution ： If necessary, heat the taper roller
bearing to facilitate removal. Wear prescribed
protective equipment and use appropriate
tools.

9. Wheel shaft sealing ring

Drive the sealing ring downwards and

14
out of the housing by impacting it alternately
on opposite Sides.The shaft sealing ring is
destroyed in the process. During reassembly,
a new shaft sealing ring shall be used.

12. Wheel shaft sided sealing ring

Disassemble the sealing ring by using a
chisel.

10. Wheel shaft side bearing cup

Drive the wheel shaft side bearing cup of
the taper roller bearing downwards and out of
the housing by impacting it alternately on
opposite sides

The sealing ring is destroyed in the

process. During reassembly, a new sealing
ring shall be used.

11. Planet carrier side wheel shaft

Drive the planet carrier side bearing cup of the

taper roller bearing downwards and out of the
housing by impacting it alternately on opposite
sides

15
Reassembly of the Transfer Assy
CPDS13/15/16/18/20-AC3/AC4/AZ3/AZ4
CPDS13/15/16/18/20-AC4-I
CPDS13/15/16/18/20-AC5/AC6/AC6-NA
-2022.04
CPDS13/15/16/18/20-AD5/AD6/AZ5/AZ6
-2022.04
1. Install the ball bearing with snap ring○
2 ,the 4. Install the pressure plate ○
7 in the each

spacer ○
3 and the snap ring ○
4 to the drive gear clutch pin through a hole ○
8 .

○
1 (Z=22).

Attention :Be careful to the direction of the ball

bearing with snap ring.

5. Install the mating plate ○

1 in the each clutch

pin through a hole.

2. Install the ball bearing ○

2 which it put

together by the above.

6. Install the friction plate○

2 .

3. Drive four clutch pins ○

5 and two parallel

pins○
6 .

Perform the procedure 5 and procedure 6

mentioned above repeatedly,install three
mating plates ○
1 and three friction plates
○
2 .After install,confirm that there is the friction

Attention :Be careful to a direction of clutch plate in the top.

pins ○
5 .
7. Put four return springs ○
3 .

16
8. Match the bearing retainer ○
4 with the 11. Install it while engaging the driven gear
position of the clutch pin and the return spring with the drive gear.
and put it.Be careful to of the notched portion.
Attention :Perform tighten it while confirming
that four spring do not slip off.

12. Install the snap ring ○

2 in the sun gear ○
1 .

13. Install it while matching the sun gear

9. Tighten eight hexagon socket bolts ○
1 (M6×1) ○
1 with the spline of the friction plate.

by order of the placement in a diagonal.
Attention :After tightening,confirm that three
friction plates move smoothly and do not move
by letting air in form a supply opening of the
port.
Attention :Insert it while turning the sun gear
lightly,and don’t damage the spline of the
friction plate.

Confirm that the snap ring ○

2 is completely

inserted in the reentrant of the driven gear ○

3 .

Tightening Torque 11Nm~15Nm

LOCTITE#262 or
Adheshive
equivalent
10. Install the ball bearing ○3 in the driven
gear○
2 (Z=88).

14. Install the inner race of the taper roller

17
bearing ○
2 in the carrier ○
1 in the case of damage the rolling contact surface of the
changing. roller.

15. Install thrust needle bearing ○

8 ,thrust 18.Install the oil seal○
3 .

washer○
9 (t=2.5) in the carrier○
1 . Attention :Be careful to a direction.Be careful

Attention :A direction of the thrust needle not to damage a lip.

Liquid packing ThreeBond#1104 or equivalent
bearing ○
8 is on the side of the thrust
washer○
9 .

16. Install two thrust washers ○

5 (t=2),the 19. Reverse the transfer case ○
1 and install
planet gear ○
6 (Z=25),the needle bearing the Outer ring of the taper roller bearing ○
4 .

○
7 ,the thrust washer ○
8 (t=1) and the snap ring Attention :Be careful to a direction of the taper
○
9 in the carrier ○
1 .(three places in tatal). roller bearing ○
4 .Be careful not to damage the

Attention :Be careful so that a part of thrust rolling surface contact of the roller.
washer○
4 and washer○
3 do not come off.

Measure the thickness of the thrust washer

○
5 (t=2),and when the thickness is less than

1.6,change it for a new article.

20. Istall the ring gear ○

5 (z=64) in the transfer

case while matching each groove position ○

1 .

Attention :Be careful to a direction of the ring

gear.
17. Install the outer ring of the taper roller
bearing○
2 in the convex side of transfer case

○
1 .

Attention :Be careful to a direction of the taper

roller bearing ○
2 .In addition ,be careful not to

18
21. Install six flat keys ○
1 in the grooves of the
25. Drive two parallel pins ○
1 into the transfer

ring gear and the transfer case .

case.

22. Install the retaining ring ○

2 . 26. Install the carrier while engaging the planet
gear with the sun gear installed in the transfer
cover .

23. Install the needle bearing ○

3 .

Attention :Be careful to the direction .(the

stamp of the marker side ).Be careful not to 27. Apply liquid packing to the slanted line part
strike it with hammers directly. of the chart below of the transfer cover.

Liquid packing ThreeBond#1104 or equivalent

24. Install the O-ring ○

4 in four O-ring seal
plugs ○
5 (G1/4),then install four O-ring seal

plugs ○
5 in the transfer case . 28. Dock with the transfer cover while bringing
down the transfer case from the top.
Attention :Be careful not to touch the oil seal.

29. Apply the adhesive and tighten two

19
hexagon socket bolts (M6×1,L=35) from the
transfer cover side .Reverse the transfer assy
and apply the adhesive to six hexagon socket
bolts ○
1 (M6×1,L=20),(six)and tighten them
afterwards.
Tightening Torque 11Nm~15Nm
Adheshive LOCTITE#262 or equivalent 33. Install the O-ring ○
3 in a groove .

Attention :Insert completely the O-ring and be

careful not to protrude from a groove.

30. Install the inner ring of the taper roller

bearing ○
3 in the hub assy ○
2 with six hub 34. Install the lock plate ○
1 .The direction is

bolts. good in both.

31.Fill up grease between lips of the oil seal○

1 . 35. Do a temporary total of the lock nut
Industrial lithium-based ○
2 (M30×1.5),then hook a spring balancer ○
3
Grease
grease
on one of the six hub bolts and tighten the lock
nut so that the force of tangential direction
when the hub wheel begins to turn around
becomes 60N-88N.

32. Install the wheel hub ○

2 .

Attention :Be careful not to damage the lip of

the oil seal .After insert the wheel hub,confirm
that it turns around lightly .

20
 38. Install the O-ring ○
2 in the brake rod
○
1 ,then install the brake rod ○
1 in the transfer

cover.

Attention :Be careful to the directions (the

narrow path side goes out ).

39. Tighten two hexagon socket bolts

○
5 (M5×0.8) by order of the placement in a

diagonal.

36. Caulk the lock nut ○

1 a groove of the
carrier.
Attention :Caulk it surely to the groove bottom.

40. Set the brake lever ○

6 so that the hole of

the oval becomes it inward to the transfer

cover,then put the the brake pin ○
7 through
the hole of the transfer cover and the brake
lver ○
6 ,and install the two stop rings ○
8 .

Attention :Because installation places are

different,be careful with the for L.H. and the for
R.H.

37. Install the hub cap ○

2 .

21
 CPDS13/15/16/18/20-AC5/AC6/AC6-NA
2022.04-
CPDS13/15/16/18/20-AD5/AD6/AZ5/AZ6
2022.04-

Caution ： Be careful not to place your

hands or fingers between the punch and the
41. Install the adapter ○
9 .
tool when working with the hand lever press.
1.Wheel shaft sided sealing ring
1.1 Place the wheel shaft sided sealing ring
onto the transmission housing(see picture).
Make sure that the sealing lip is facing

42. Install the air breather ○

1 (R1/8). upwards.

Attention :Because installation places are

different,be careful with the for L.H. and the for
R.H.

Adhesive LOCTITE#572 or equivalent

1.2 Drive up the sealing ring into the

transmission housing against the block.

2.Shaft sealing ring

2.1 Place the shaft sealing ring (103.130)
into the tool 4 .

22
 the bottom.

2.2 Drive the shaft seal into the bore by using

an assembly mandrel. The shaft seal has
reached its correct position as soon as its
upper surface has reached at least the lower
end of the bore's chamfer.

3.3 Coat the inner lip of the shaft sealing ring

with multipurpose grease.

3. Wheel shaft side bearing seat

3.1Clean the wheel shaft side bearing seat
of the taper roller bearing in the housing

4. Planet carrier side bearing seat

Drive the planet carrier side bearing cup
of the taper roller bearing into the bearing
seat
3.2 Drive the wheel shaft side bearing cup of
the taper roller bearing into the bearing seat.
The inside of the bearing cup shall narrow to a
taper towards the bearing seat and the wide
edge of the bearing cup shall be positioned at

23
 5.2 The opening of the ring shall be visible
(see arrow)

Bolt on the internal gear with 12 Torx

bolts .
(1) Pretighten the bolts with a compressed-air
screwdriver in a crosswise pattern.
(2) Firmly tighten the bolts using a torque
wrench.

Caution ： The inside of the bearing cup shall Caution：When tightening the bolts, note the

narrow to a taper towards the bearing seat and tightening torque of 79 N·m.

the wide edge of the bearing cup shall be

positioned at the bottom. Drive in the bearing
cup until a dull metallic sound signals that the
bearing cup is resting
against the bearing seat.

5. Internal gear (Parts Kit available)

5.1 Manually slot the toothed disc into the 5.3 Check whether it is still possible to move
internal gear. the internal gear in a rocking motion after
tightening the bolts.
If it is possible, continue with work step

24
6.If it is not,Remove the internal gear again
6.4 Press taper roller bearing on gear wheel
and replace it or remove from the housing all
side onto gear shaft using lever press and tool
the parts which have so far been in- stalled
1
and replace the housing.
Plunger of lever press, tool and gear shaft
Caution:The rocking motion of the internal must align vertically with no offset.
gear is important for being able to compensate
for the oscillations generated by the planetary
gears.
Caution ： Risk of accident and injury from
6.Gear shaft
crushing. When pressing the taper roller
6.1 Coat the Nilos ring with multipurpose
bearing together with the gear shaft, do not
grease
place hands in area between plunger and tool.
6.5 Grease the taper roller bearing

6.2 Slide the Nilos ring onto the

wheel shaft
6.6 Place the wheel shaft on the press table so
that the wheel studs point downwards. The
wheel shaft shall stand on a suitable sleeve
and the wheel studs shall be clear of the table.
Unclamp the housing from the assembly
fixture.

6.3 Fit taper roller bearing on gear wheel side

to gear shaft by hand.

6.7Fit the housing perpendicularly onto the

wheel shaft.The mating surface of the housing

25
shall face upwards.
6.8 Place the taper roller bearing onto the seat
of the wheel shaft
6.9 Press the planet carrier side taper roller
bearing onto the wheel shaft.The punch of the
hand lever press, tool and taper roller bearing
shall be positioned vertically to each other.
Caution ： Risk of accident and injury from
crushing. When pressing the taper roller
26
bearing onto the wheel shaft, do not place
hands between the punch and the tool.
6.10 Clamp the housing in the assembly
fixture.
6.11 Check the wheel shaft for smooth
running.
（ 1 ） It shall be possible to move the wheel
shaft easily by hand.
（ 2 ） In order that the taper rollers can align
themselves correctly in the bearing races, a
soft head hammer should be used to tap at
various points around the wheel shaft.
If the taper rollers are correctly aligned,
continue with work step 7.If they are not ，
Remove the wheel shaft again. Check both
bearings (wheel shaft side and planet carrier
side) for any damage which may have
occurred during the press fitting procedure.If
damage is found, remove the bearings and
replace with new ones.
7.Measuring and adjusting
Measuring the distance between the
bearing surface of the taper roller bearing and
the surface of the wheel shaft
（1）Rest spacer on the mating surface of
the housing
 （2）Set the depth gauge onto spacer
8.Planet carrier
8.1 O-ring and press on planet carrier by hand.

Caution：It shall be ensured that the greatest

possible contact area of the depth gauge is 8.2 Coat the toothing of the planet carrier and
resting on spacer. the o-ring (103.180) with Klüberplex BEM
（3）Adjust the depth gauge to the surface 34-132 (Klüber Lubrication)or Optimol White
of the wheel shaft. Paste T.

（4）In the position, zero the depth gauge.

8.3 Blow out the seating of the planet carrierin
（5）Adjust the depth gauge to the surface of
the housing with compressed air and fit the
the taper roller bearing
planet carrier.
（6）Read off the difference between the
two settings.
（7）Repeat the measurement on the opposite
side.
Caution：The difference in measurement may
not exceed 0.5 mm.
（8）Select spacers
The thickness of the spacer set shall be
the same as the difference between the 8.4 Place the housing on the press table so

measurements. A preloading on the wheel that the wheel shaft is facing downwards. The

shaft is then achieved. The preloading on the wheel shaft shall stand on a suitable sleeve

wheel shaft shall be between 3 and 7 N·m. and the wheel studs shall be clear of the table.

27
 ease of movement in the Housing.It shall be
possible to turn the wheel shaft easily by hand.

8.5 Press the planet carrier into the wheel

shaft . 9.Grooved nut
9.1 Fit the grooved nut to the wheel shaft.Fit
tool 2 to the grooved nut.Slightly tighten the
grooved nut with a compressed-air
screwdriver.

（1）Make sure that the outer toothing of the

planet carrier and the inner toothing of the
wheel shaft mesh together correctly.
（2）The punch of the hand lever press,
tool and wheel shaft shall be positioned
vertically to each other without
deflection.

Clamp the housing in the assembly

fixture.
Caution：Risk of accident and injury from
crushing. When pressing in the planet carrier,
do not place hands between the punch and the
tool.

8.6 Manually check the wheel shaft for

28
 （3）Turn the wheel shaft with the torque
wrench.
（4）Read off the drag torque from the
torque wrench.

9.2 Fit tool 14 to the wheel shaft and lock in

place with the screws
Tighten the grooved nut to a tightening
torque of 535 N · m.
The drag torque shall be between 3 and 7 N
•m. If it is, continue with work step 10.2 ，If it is
not，Correct the spacers as follows:
a.Drag torque too high ： The spacers
chosen are too thick ， Remove parts back to
work step 6 and redetermine the correct
spacer thicknesses。
9.3 Remove tool 10 from the wheel shaft and b.Drag torque too low ： The spacers
check the wheel shaft for freedom of chosen are too thin ， Remove parts back to
movement. The wheel shaft shall be easy to work step 5 and redetermine the correct
turn in the housing spacer thicknesses.

10.2 Drive the collar of the grooved nut by

means of a chisel (edge of the chisel must be
a radius of approx. 2.0 mm) into the recesses
of the planet carrier.

10.Wheel shaft drag torque

10.1 Check the drag torque on the wheel
shaft
（1）Attach tool 11 to the wheel shaft.
（2）Attach the torque wrench with transition
piece.

29
Notice：Use a chisel with a rounded edge only.
13.Planetary gears ——(Parts Kit available)
A sharp edge may can damage the shoulder of
13.1 Place a planet gear with pre-assembled
the slotted nut.
cylindrical roller bearing straight onto one of
11.Cylindrical pin
the pins of the planet carrier
Insert the cylindrical pin into the wheel
shaft and drive it in.

Notice ： Do not tilt the planet gear. Face

upwards the identification mark of the planet
gear.
13.2 Drive in the planet gear including the
cylindrical roller bearing until reaching the limit
stop. Use a hammer and a striking mandrel
(tool 12). Drive in the remaining two
pre-assembled planet gears by using the
same method.
12. Protective cap
Fit the protective cap to the wheel shaft
and tap it lightly until it snaps into place.

30
 13.3 Apply a pining by using tool 13 to
lock the planet gears
Notice ： The pining is done correcly as
soon as the axial play of the planet gear's
cylindrical roller bearings on the bolts has
dissappeared completely

Special tools

Tool 1 Tool 2

Tool 3 Tool 4

Tool 5 Tool 6

31
 Tool 7 Tool 8

Tool 9 Tool 10

Tool 11 Tool 12

Tool 13 Tool 14

Tool 15 Tool 16

Tool 17
Swiveling
clamping fixture

32
 2 Steering system
The steering system consists of steering device, steering axle and wheels.
The steering device is composed of steering wheel assembly, steering tube device, locking handle
and the hydraulic diverter. See figure 2-1. Both the steering column and steering wheel can be put
forward and backward by an angle of 6°, which can meet the requirements of different operators.
The steering axle assembly is composed of the steering axle, steering knuckle, steering hub,
steering wheels and steering cylinders. See figure 2-2.

Steering device
It is composed of steering wheel, up shaft assembly, cardan joint, bottom shaft assembly, bearing,
circlip for shaft, bottom steering column, steering gear, priority valve, clamp lever and hydraulic
switch etc.; steering wheel can be put forward and backward as needed. Refer to fig.2-1 steering
device structure.

Fig. 2.1 Steering device structure

1. Steering wheel nut 2. Steering wheel assembly 3. Washer 4. Upside steering shaft 5. Circlip for hole
6. Bearing 7. Upper steering column 8. Snap ring 9. Bolt 10. Washer
11.Clamp lever 12.Clamp bolt 13. Washer 14. Bolt 15. Washer
16. Washer 6 17. Bolt 18.Sleeve 19. Bolt 20. Washer
21.Cardan joint 22. Bottom shaft assembly 23. Bearing 24. Circlip for shaft 25.Screw

33
26. Bottom steering column 27. Bolt 28. Washer 29.Hydraulic steering gear 30.Priority valve

Steering axle
Housing 12 is fixed at the rear part of truck frame, and the acting force from ground is supported
by back-up bearing 11, 13. Nut 16 is used to adjust the preload of bearing 11, 13; hydraulic oil from
priority valve flows to cylinder component 17, pushes the movement of piston 21, piston 21 drives
the movement of rack 18, and axle seat assembly that meshed with rack 18 turns left and right,
which realizes the truck left/right movement, and the maximum turning angle is 86°.

Fig.2-2 Steering axle structure

1. Axle seat
2. Seal ring 3.Oil seal 4.Bearing 5.Rim 6.Bearing 7.Washer
assembly
14.Cover
8.Locknut 9.Cover 10. Seal ring 11.Bearing 12.Housing 13.Bearing
plate
17.Cylinder
15.O-ring 16.Nut 18.Rack 19. Seal ring 20.Seal ring 21.Piston
component
24.Composition 25.Outer
22.Seal ring 23.Bolt
seal ring hexagonal plug

Use notice：
─ Cylinder leaks oil, check and replace seal ring 19, 20,22, and also check if the guide sleeve
and cylinder damage.
─ Check bearing 11, 13 and seal ring 10, 15 periodically; if damage, replace bearing and seal
ring timely; replace lubrication grease periodically.
─ Check bearing 4, 6 and oil seal 3 periodically; if damage, replace bearing and oil seal timely;
replace lubrication grease periodically.

34
─ Adjustment to preload of back-up bearing 11, 13: dismantle counterweight and its cover plate
etc., jack-up the rear part of the truck frame, screw down nut 16 until the kingpin cannot be
moved by hand, and then rotate nut 16 for 1/6～1/4 circles in opposite direction.

Condition Probable cause Corrective action

Damage or trouble of oil pump Replace

Failure to rotate
Priority valve is clogged or damaged. Clean or replace
steering wheel

Damaged hose or connector, block lines Replace or clean

Too low diverter valve pressure Adjust pressure

Air in oil lines. Exhaust air

Laborious operation
for steering The steering fails to turn to its natural position,
Replace spring flat
broken lock spring or insufficient spring pressure
Check piston for
Too much internal leakage in steering cylinder. sealing

Oil is not sufficient in oil tank. Refill oil

Steering gear shaft/ rack damage Replace

Abnormal noise Hub bearing or supporting bearing damage Replace

Insufficient lubrication Fill lubricating grease

Suction piping or filter clogged. Clean or replace

Steering cylinder seal ring or pipelines or

Replace
connectors damage
Oil leakage
Seal ring of hub bearing or supporting bearing
Replace seal ring
damage
Steering angle of
left/right drive wheel Incorrect controller parameter Adjust
mismatching

Disassembly and installation of steering axle

Disassembly
1. Jack-up the forklift, support the truck frame with blocks and get the rear wheel off the ground.
2. Dismantle the rear cover plate.
3. Dismantle the truck frame and counterweight connected bolt(if the space for bolt removal is
not enough, first lift out the battery), and then lift out the counterweight.
4. Unscrew the rim nut, and dismantle the tire.

35
5. Unscrew the oil pipe joint that connects the steering cylinder, block the pipe with piston to
avoid oil outflow. Dismantle wire.

6. Dismantle rubber plate and truck frame connected bolt, and remove the rubber plate.
7. Dismantle steering axle and truck frame connected bolt, hoist out the steering axle backward.
8. To install the steering axle, reverse the order of disassembly, but pay attention to the followings：
─ When installing tire, apply LOCTITE 222 glue to the thread, screw down the nut in three
times in symmetry cycle.
─ When installing the steering axle on the truck frame, get through the bolt from bottom to
top, apply LOCTITE 242 (222) LOXEAL to the final nut and thread meshing part, screw
down the bolt in twice.

36
3 Brake system
Brake system is composed of service brake and parking brake. Service brake depresses the brake
pedal by foot while parking brake is braked by applying the brake handle. Both service brake and
parking brake function together with the wet brake located in the reduction gearbox.

Braking principle diagram

（一 Schematic diagram of drum brake braking principle

Service brake
Service brake system is composed of pedal mechanism, brake master pump, brake piping and
wet brake etc.

Pedal structure

Fig.3.1 Pedal structure

37
Brake pedal adjustment：
1. Adjust brake light switch, make the pedal pad point P 125mm±5 from the front base plate and
screw down the nut;；

2. Adjust the length of brake master pump push rod, and make the spare travel of the point P to
point Q is 1～3mm, and lock the nut;

3. When depressing the brake pedal 10～20mm gradually, the brake light switch is completely
connected, and release the foot to this state, brake light switch should disconnect.

Brake master pump

The master pump contains a valve seat, check valve, return spring, primary cup, piston and
secondary cup, which are kept in place with stop washer and stop wire. The exterior of the cylinder
is protected against dust by means of a rubber dust cover. The piston is actuated through the push
rod by operation of the brake pedal. Once the brake pedal is depressed, the push rod pushes the
piston forwards. And the brake fluid in the front cavity of 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 pipelines to the wheel cylinder. Thus, each wheel cylinder piston is forced
outwards. It connects the brake shoes with the wheel drum which slows or stops the lift truck.
Meanwhile, the back cavity of 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 backward
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, which makes the fluid returning into the master pump (front
cavity of the piston) through the check valve. With the piston in original position, the fluid in the
cylinder flows into the reserve tank through the return port. Reset the pressure of the check valve
to keep it in proportion to a residual pressure of that in the brake lines and wheel cylinders in order
to make sure each wheel cylinder piston cup is securely seated to prevent oil leakage and
eliminates of vapor lock when the lift truck comes to an emergency stop.

38
 Fig. 3-2 Brake master pump
1.Locknut 2.Push rod 3.Dust cap 4.Locking steel wire 5.Lock washer 6. Auxiliary cup
7.Piston 8.Primary cup 9.Spring 10.Check valve 11.Valve seat 12.Pump body

39
Parking brake
Parking brake is composed of handle, cable and wet disc etc. When to stop or park the forklift,
apply the hand brake to avoid the accidental move of the forklift. Generally, service brake is
adopted to brake the forklift during travelling, only when emergency brake is needed but the
service brake fails, then the hand brake is applied to stop the forklift.
When pulling the hand brake lever backward, cable shrinks. With the action of cable force, No.3
brake rod swings to the truck around the fulcrum and the other end of brake rod ejects the brake
cylinder, the clamping of friction plate generates frictional resistance thus prevents the tire rolling.
When pushing the hand brake lever forward(if there is button on the lever, it needs press this
button and meanwhile push the lever upward), No.3 brake rod returns, with the action of spring,
brake cylinder piston shrinks, friction plates are loosened, then the frictional resistance disappears,
namely the parking brake force disappears.

1.Hand brake cable 2.Service brake oil pipe 3.Brake rod 4.Nut 5.Nut
Parking brake cable adjustment：
When pulling down the hand brake, braking force is insufficient, release No.4 nut, screw down
No.5 nut to reduction gearbox direction, properly shorten the cable length between springs, after
adjustment, screw down No.4 Nut.
When releasing hand brake, the forklift is still under the effect of parking brake force, release No.5
nut, screw down No.4 nut away from the reduction gearbox direction, properly lengthen the cable
length between springs, after adjustment, screw down No.5 Nut.

Caution
 It is forbidden to substitute parking brake for service brake in travel, otherwise the parking
brake damages easily.
 Make sure braking force on left/right brake is equal when adjusting the parking brake cable.

40
Trouble diagnoses and corrections
Condition Probable cause Corrective action

Oil leakage in brake lines Correct and replenish

Air in brake lines Remove air

Insufficient brake
force Improper functioning of master pump Correct or replace

Clogged oil lines Clean

Friction plate wear or deformation Replace

Improper brake adjustment Adjust

Brake friction plate wear Replace

Unequal braking Air or block in the brake pipe Remove air or clean
(forklift truck veers
to one side) Oil leak in the brake pipe Adjust or replace

Oil leak in the cylinder piston Replace

Improper adjustment of parking brake

Adjust
cable length

No free play of brake pedal Adjust

Faulty piston cup Replace

Weak or broken return springs Replace

Brake dragging
Clogged master pump returns port Clean

Clogged oil lines Clean

Friction plate deformation Replace

Brake noise Friction plate wear or deformation Replace

41
4 Hydraulic system
Structure of hydraulic system
Hydraulic system mainly consists hydraulic fuel tank, gear pump, priority valve, hydraulic steering
gear, control valve, steering cylinder, tilt cylinder, lift cylinders and hydraulic pipelines etc.

Working Principle of Hydraulic System

The high pressure oil from main oil pump divides to two parts by priority valve: one of them will be
distributed to control valve. The high pressure oil flows to the lift cylinders or tilt cylinders by way of
control valve. When the lifting and tilting valves are in the netrual position, there is no oil output
from the priority valve. When pulling the lift valve , the high pressure oil flows to the downside of
the piston which push the piston rod upward. When pushing the lift valve, the downside of piston of
lift cylinder is in connection with the low pressure and piston rod falls down by dead weight and the
load weight. The oil flowing out from the lift cylinder passes through the check valve where slows
down the falling speed. There is no oil output from the priority valve. When operating the tilting
valves, the high pressure oil flows to a cavity of tilt cylinder and the other cavity is in connection
with the low pressure which realise the tilting back and forward of the mast. The other oil line flows
to the steering gear which makes sure the steering operation always in priority.
转向油缸
Steering cylinder
升降油缸
倾斜油缸 Lift cylinder
A B Tilf cylinder
调整油缸 调整油缸
Adjustment cylinder Adjustment cylinder

A B

转向器 单向限速阀
Orbitrol Flow regulator valve

EF

T P

油泵
Pump

滤油器
Filter

油箱
Tank
多路换向阀（四联阀）
Contorl valve

42
Main component of hydraulic system
Gear Pump
DSG05 series hydraulic gear pump adopts double pump structure, asymmetrical gear, integral
pump body, DU bushing, powder metallurgy plate. It features in small pressure pulsation and low
noise.
Main parameter：

Type：DSG05C16F9H9-R Oil inlet

Rated displacement：16 ml/r Gear pump
Rated pressure：20.6 MPa
Max. pressure：22.6 MPa
Rated speed：2000 r/min
Min. speed：500 r/min Oil outlet
Max. speed：3000 r/min

Installation Instructions：
– Before installation, make sure the rotation direction of gear pump can meet the system
requirement.
– The coaxially between the gear pump axle and the motor axle must be less than 0.05mm.
– Connect the inlet and outlet connector, do not misconnect.
– Install the flanges and connectors. No bump, scratch or burr, in case of oil or gas leakage and
noise-producing.
– Avoid that there is no axial force or radial force on the gear pump axle. Install it smoothly
during the installation, no mounting or dismounting by force.
Operation and Maintenance：
– Always follow the Instruction, never overload.
– Hydraulic oil requirement: summer, L-HM32 or similar viscosity hydraulic oil; winter or
Refrigerator forklift, L-HV32 low temperature hydraulic oil;
– Starting for the first time, run without load to bleed the air in hydraulic system, until there is no
bubble.
– Keep the oil clean. Clean the oil tank and oil lines fully before refilling.
– Inspect the oil cleanliness and strainers periodically, replace as necessary.

Fault diagnoses and corrections：

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,
suction pipe or strainer plugged
replace

43
 Bearing worn, retainer or O-ring
Replace malfunctioning parts
damaged
Readjust to specified pressure using
Maladjusted relief valve.
pressure gauge
Low Retighten suction side pipe
discharge
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 hoses and clean
hose or plugged strainer. strainer
Air being sucked from loose suction
Retighten each joint
side joint.
Replace new oil with proper viscosity for
Oil pump
temperature at which pump is to be
noise Cavitation due to too high oil operated
viscosity.
To operate when oil temperature is
normal
Check for the cause of bubbles and then
Bubbles in hydraulic oil
take action
Faulty oil seal on pump, faulty
Oil leakage
O-ring or worn sliding surfaces on Replace faulty parts
from oil pump
pump.

44
Hydraulic steering gear
BZZ5 series steering gear is load sensing type, owns characteristics as easy operation, reliable
work, few fault, simple structure, easy allocation as well as manual steering in downtime etc.
Steering gear No.：423-7782-15
Displacement：500cc/r
Inlet relief valve：9 MPa
Overload valve：15 MPa
Rated flow：60L/min
Steering torque：1.3~2.2 Nm
Contamination level of oil：ISO 18/13
Priority valve No.：880-1550
Control pressure of priority valve ：
0.52MPa
Fault diagnoses and corrections
Trouble
Turning steering wheel slowly is
light and turning fast is heavy or
no power to steer
Steering wheel is heavy when
turning fast or slowly
Steering wheel swings and the
vehicle can not run straightly
The vehicle can not run
straightly
Hard to feel the terminal point of
the steering wheel
Steer inaccurate or crawl
Steering wheel can turn easily,
but the steering wheels keep still
or turn slowly
Large empty stroke of steer
wheel
Oil return pipe Steering device
Sensor
Connecting gear
pump pipe
Priority valve
Left steering pipe
Connecting
multiple valve pipe Right steering pipe
Probable cause Corrective action
The pressure of system relief valve is low Increase relief valve value
The pressure of relief valve of steering gear is low Increase relief valve value
or the valve core get stuck or replace
The oil of steering system returns unsmooth Clean and dredge
The damaged inlet non-return valve plugged the
Clean or replace
oil to the steering gear
The pipelines of load sensor have leakage, work
Replace or dredge
unsmooth
Steering gear has inner leakage or the steering
Repair or replace
non-return valve cannot reset
The steering lever bends Replace
The steering lever interferes with valve element
Test or replace
of the steering gear.
Low relief valve pressure Increase relief valve value
The mechanical resistance of steering gear itself Apply lubricating oil to the
is big steering part
Air in the steering system Exhaust air
Inner leakage of steering cylinder Replace sealing element
Trimmer valve or oil supply valve has large
Replace
leakage
One-way cylinder Check oil circuit fault
Trimmer valve or oil supply valve has large
Replace
leakage
The reset characteristics of steering gear is not
Replace spring
well due to damaged spring
Steering gear has large inner leakage Replace damaged part
The relief valve or double-way overload valve set
Stagger the valve value
the same pressure
Steering cylinder has large inner leakage Replace damaged part
Dredge oil circuit or
The returning pipe of priority valve plugged
replace damaged part
Air in the steering system Exhaust
Replace damaged part in
Steering cylinder has inner leakage
the cylinder
Trimmer valve or oil supply valve gets stuck Clean or replace
Replace damaged part in
Oil intermingle in steering cylinder
steering cylinder
Insufficient oil pressure in steering cylinder Increase relief valve value
The clearance of the contacts between steering
Decrease clearance
gear and steering column is big
Air in the hydraulic system Exhaust air
The reset characteristics of trimmer valve or oil Replace spring
45

Reset incorrect or heel Turn
Steering wheel turn itself
The steering wheel gets stall
The steering wheels make
reverse turning when turning the
steer wheel
Steering wheel is blocked
supply valve is not well
Spring leaf broke or lacks of elasticity Replace
The frictional resistance between axle head of Clean the rust and apply
valve core and front cover of steering gear is big lubricating grease
High oil return backpressure Decrease valve value
Check and correctly
Misconnection of oil pipe
connect the oil pipe
The sleeve of valve core gets stuck Clean or replace
Stator and rotor are stuck Clean
Plugged oil pipeline or faulty pipeline connection Clean or check pipeline
Steering column gets stuck Adjust
The inner parts of steering gear damaged Replace
Misconnection of left/right steering oil pipe Correctly connect the oil
pipe
The inlet check valve of steering gear damaged, Replace check valve
the oil flow back

Control valve（Standard）

Each control valve connector：

P: Oil inlet connector of control valve;
T: Oil return pipe connector of control valve;
A1, A2, B1, B2: Attachment pipeline connector;
A3, B3: Tilt pipeline connector;
A4: Mast lift cylinder connector, if truck equipped with lowering safety function device, it connects
to electronic control lifting manifold block.
Control valve parameter：

Nominal pressure 20.6 MPa

Nominal diameter 15 mm

Inlet flow 60 L/min

Permission backpressure 1.5 MPa

14.0±0.5 MPa (1.3t)
Set pressure of main relief valve 15.5±0.5 MPa (1.5t)
18.0±0.5 MPa (1.6~2.0t)
Working oil temperature -20℃～100℃

46
Fault diagnoses and corrections：

Trouble Probable cause Corrective action

Loose of pressure-adjust screw Readjusted and retighten

Distorted or damaged
Replace
Pressure of relief valve is pressure-adjust spring
not steady or cannot be
adjusted. Replace or clean for new
Worn or blocked relief valve core
assembling

Pump malfunction Examine and repair pump

Replace valve core and tilt

Mast tilts forward when Worn or damaged tilt lock valve lock valve as an assembly
tilt levers are applied
forward and backward Broken tilting lock spring Replace spring
while motor is off.
Damaged tilt valve plunger O-ring Replace O-ring

Mast is unstable when Replace tilt relief valve

tilting forward Malfunction of tilt relief valve
assembly
Clearance between valve body Replace valve rod with
and valve rod is too large specified clearance
Keep the lever be in the
Fork carriage descends Valve rod is not in center neutral
apparently when the lift
lever is in neutral
Cylinder seal abated Examine and repair cylinder.

Overload valve is worn or blocked

Replace or clean taper valve.
by dirt

Damaged or distorted
Replace spring.
reposition-spring
Dirt exists between valve body and
Clean
Reset failure spool valve.

Blocked control device. Adjust

Not coaxial parts at reposition Reinstall, be coaxial

Damaged O-ring Replace

Check and retighten. of the
Faulty seal of joint
relevant part

Leakage Clean seal plate and retighten

Loose seal plate.
blots.

Loose of lock-nut of relief valve

and connect-nut between plate Tighten
and plate
Control valve can’t move Control valve adjusting handle
Adjust
forward or backward interference

47
Main relief valve pressure adjustment
The main relieve valve has been adjusted before leaving the factory, , it is not allowed to adjust at
will in general condition. Adjusting way is as follows:
(1) Park the truck on solid and smooth road, place in neutral, pull up the hand brake handle, tilt the
mast backwards to the end, and drop the fork to the ground. The engine stops.
(2) Open front soleplate, release the pressure mouth bolt of oil inlet pipeline in the multi-way valve,
and put in clean place. If hydraulic oil outflows, please protect the environment.
-

(3) Connect the pressure gauge. Notice: a. Specification of gauge should be larger than 20Mpa. b.
taper thread at pressure mouth matches: Rc1/8R1/8; c. tightening torque is 20-22N•m.
(4) Start the engine, place the mast in vertical, and the fork is 300mm from the ground.
(5) Read out the indication in the pressure gauge, and judge is the main safety valve of multi-way
valve is in normal scope.
(6) 1.3t：14.0MPa，1.5t：15.5MPa，1.6t~2.0t：18.0MPa
(7) If the pressure is not in the normal scope, please release the main safety valve lock nut, and
adjust adjusting bolt.If the indication is smaller than the normal scope, inner hexagon spanner
the adjusting bolt in clockwise (+) to increase main safety valve pressure.If the indication is
larger than normal scope, inner hexagon spanner the adjusting bolt in counterclockwise (-) to
decrease main safety valve pressure.
(8) Stable the pressure in normal scope for 30’s.
(9) Release pressure gauge, install the bolt, and the tightening torque is 20-22N•m. Drop the mast
to the ground and tilt backward to end.
(10) Retighten the tightening nut, and fix it on the front soleplate.

48
Electro-magnetic proportional control valve（Option）
Structure

Code No. Part No. Part name Qty

1 11122373 Valve body 1
B 2 130037 CP100-3-B-0-005 1
G 3 131504 CP701-1-B-0-150 1
L 4 131643 CP308-1-B-0-0.1 1
K 5 131947.000 CP200-7-B-0-E-C-XXX 1
H 6 133577.200 CP208-4-B-0-E-C-200 1
C1-C3 7 133851 CP124-1-B-0 3
D1-D4 8 133853 CP104-2-B-0 4
9 321211(S80006-4) Plug (-4 SAE), tapered 7
10 321212(S80006-6) Plug (-6 SAE), tapered 1
11 545020140+463200060 Plug M10×1 2
12 545020190+463150530 Plug M20×1.5,DIN 908 4
J 13 83011831 PSVP12-NCR-24D-FL-B-00 1
E1, E2 14 850168819+171149919 PSV10-34-02-24D-FL-22-B-00 2
A 15 850168919+171149919 PSV10-34-05-24D-FL-22-B-00 1
M 16 850255919+171187719 PSV12-NC-80-24D-FL-B-00 1
F1, F2 17 860106519 CB10-HV-2-B-1-E-150-B-00 2
T 18 H140771 CV10-NP-0.3-B-00 1
19 Z8242005 Plug (8mm) 22

49
Schematic diagram

Schematic diagram of fourth electro-magnetic proportional control valve

50
Mast emergency lowering
Once there is failure in hydraulic system, mast and loads will stay in certain height, at this time,
lower the mast manually. Procedures:
– Turn off the switch lock and press the emergency stop switch.
– Take out the battery plug.
– Screw off the set screw of baseplate, take down the front baseplate and rear
baseplate(four-wheel forklift); screw off the set screw of valve cover, and take down the
control valve cover(three-wheel forklift).
– Slowly rotate the emergency lowering valve(13) in counterclockwise with socket head wrench,
lower the mast and loading part.
– Rotate the emergency lowering valve(13) clockwise with socket head wrench to stop position,
then the lowering is stopped.

Warning
 Operator must stand beside the forklift when using emergency lowering valve.
 Never use emergency lowering to lift the mast when loading parts in the goods shelf.
 Restart the forklift only after confirming and eliminating the failure.

51
Safety function device（Option）
Safety function device is a protective device of fork locking after power off. That the mast cannot
lift or lower after power off or operator leaves the seat.

Safety Lift cylinder

function
valve

Multiple
valve

Oil tank
Each connector of safety function device：
A：connect control valve; B: connect lift cylinder or the speed limit valve of lift cylinder；C: connect
solenoid valve；D: connect oil return pipe；E: stop valve.
When solenoid failure or other failure of the forklift causes the forks unable to lower, open E stop
valve, unload, and then forks lower under the action of gravity.

52
Steering cylinder
Pressure oil from steering gear enters cylinder component 17, pushes the movement of piston 21,
piston drives rack 18 to move, rack 18 meshes with the gears of axle seat assembly 1, axle seat
assembly 1 moves left and right, thus realizes the forklift steering.

1. Axle seat
2. Seal ring 3.Oil seal 4.Bearing 5.Rim 6.Bearing 7.Washer
assembly
14.Cover
8.Locknut 9.Cover 10. Seal ring 11.Bearing 12.Housing 13.Bearing
plate
17.Cylinder
15.O-ring 16.Nut 18.Rack 19. Seal ring 20.Seal ring 21.Piston
component
24.Composition 25.Outer
22.Seal ring 23.Bolt
seal ring hexagonal plug

Steering cylinder disassembly：

1. Dismantle steering axle and tire.

Caution：
 Unscrew the pipeline connector on both left and right ends of the steering axle, block the
pipeline with plug to avoid oil outflow.
2. Dismantle the potentiometer component on the steering axle, listed as following figure:

53
 1
1 螺栓M4×35 Bolt M4×35
2
2 垫圈4 Washer 4
3 5
4 6 3 电位器支架 Bracket
7
8 4 螺母M4 Nut M4

5 螺钉M6×10 Screw M6×10

6 垫圈6 Washer 6

7 电位器轴 Potentiometer shaft

8 螺母M6 Nut M6

3. Unscrew nut 16, disassemble cover plate 14 and seal ring 15, remove axle seat assembly 1 as
well as its bearing and seal ring.
4. Disassemble cylinder component 17 on both left and right ends of the cylinder, and take down
seal ring 19, 20.
5. Take out rack 18, screw off bolt 23, take down seal ring 22 and piston 21.
6. To install, reverse the order of disassembly, but pay attention to the followings：
─ Rack 18 is in the relatively middle position of housing 12, and gears on the axle seat
assembly 1 correctly mesh with gears on rack 18.
─ Adjustment to the preload of back-up bearing11, 13: screw down nut 16 until the steering
main shaft cannot be moved by hand, rotate the nut 16 for 1/6～1/4 circles to the opposite
direction.
Fault diagnoses and corrections
Trouble Probable cause Corrective action
Abnormal noise from the Gear wear Replace
steering axle Improper gear meshing Adjust
Deviate to one side when Adjust gears mounting position
Steering wheel returns but the
mounting gears
steering wheels deviate to one
Oil circuit blocking on the other Check, adjust or replace
side
side of wheel deviation
Oil leak or oil intermingle due Replace
to piston damage
Oil circuit blocking Check, adjust or replace
Wheels do not steer when Gear damage, deformation Replace
turning the steering wheel Improper gear meshing or Adjust
stuck
Too low oil pressure Adjust oil pressure control
valve
Steering cylinder seal ring
damage or pipeline or Replace
Oil leak connector damage
Seal ring on back-up bearing
Replace seal ring
or cylinder damage

54
5 Lifting system
The lifting system is mast, fork carriage, forks, load bracket, chain, lift cylinder, tilt cylinder and
pipeline. It is forklift truck work equipment, which performs loading and unloading. There are three
types for the fitted mast: duplex wide view mast, duplex full free lift mast and triplex full free lift
mast.
Mast type Basic mast height Optional mast height
Duplex wide view mast, 3.0 m 2.5~4.5 m
Duplex full free lift mast 3.0 m 2.5~4.0 m
Triplex full free lift mast 4.5 m 4.0~6.5m

Fig.5-1 Duplex wide view mast,

1. Outer mast 2. Inner mast 3. Load bracket 4. Fork carriage 5. Forks
6. Chain 7.Lift cylinder 8.Tilt cylinder

Fig. 5-2 Duplex full free lift mast

1. Outer mast 2. Inner mast 3. Chain 4. Free lift cylinder 5. Fork carriage
6. Forks 7. Lift cylinder 8. Load bracket 9. Tilt cylinder

55
 Fig.5-3 Triplex full free lift mast
1. Outer 2.Middle 3. Inner mast 4.Front cylinder 5. Free lift 6. Fork
mast mast chain cylinder carriage
7. Forks 8. Chain 9. Lift 10. Load bracket 11. Tilt cylinder
cylinder

Data
Inspection and adjustment
Repair clearance（mm）(no
Place Assembly clearance
parts changed)
Mast to roller mm 0.1～0.8 0.2～1.0

Shims mm 0.5 / 1.0 / 2.0

Mast to support guide plate mm 0.1～0.8 0.2～1.0

Shims mm 0.5 / 1.0 / 2.0

Inner mast to carriage side
mm 0.1～0.6 0.2～1.0
roller
Shims mm 0.5 / 1.0 / 1.5

Lifting chain deflection mm 25～30

Tightening torque of main component

Place Tonnage（t） Tightening torque（Nm）
127~157(M16), 245~314(M20 single
1.0t~1.8 t
chain)
Lifting chain locknut
2.0 t ~3.5 t 176～216(M18), 245～314（M20）

1.0 t ~1.8 t 89～118（M14）

Bearing cap of mast and drive axle
2.0 t ~3.5 t 176～216（M18）

Tilt cylinder locknut 1.0 t ~3.5 t 89～118（M8）

Lift cylinder bolt（upper end） 1.0 t ~3.5 t 76～107（M12）

56
 1.0 t ~1.8 t 22～29（M8）
Lift cylinder bolt（lower end）
2.0 t ~3.5 t 44～58（M10）

1.0 t ~1.8 t 14～18（M8）

Fixing bolt of lift cylinder（U type）
2.0 t ~3.5 t 29～39（M10）

Fault diagnoses and corrections

Trouble Probable cause Corrective action
Replace piston ring or tilting
Tilt cylinder and seal ring abraded excessively
Fork carriage or mast cylinder.
tilts automatically
The hydraulic control valve spring is inoperative. Replace it.

The fork carriage Caused by piston jamming or piston rod bent. Replace the faulty parts.
moves up and down
sluggishly. Too much dirt is accumulated in the cylinder. Clean

Adjust clearance with thrust metal

Carriage assembly out of adjustment.
and carriage side roller.
Insufficient clearance between rollers and mast
Adjust roller clearance
channel.
Fork carriage is lifted or
Foreign materials clamped against moving part. Remove foreign materials.
lowered unsmooth
Apply grease on contact surfaces of
Insufficient lubrication.
sliding parts.（butter）

Inner mast deflection or fork carriage bent Repair or replace.

Forks are lifted

Lift chains out of adjustable. Adjust lift chains.
unevenly

Grease stiffened or dirt accumulated on lift roller Clean and lubricate lift rollers.
Lift roller does not
rotate
Improperly adjusted lift roller. Adjust.

Insufficient lubrication. Lubricate.

Improperly adjusted lift roller, after extending Adjust roller, side roller adjusting
mast, descend to bump with mast channel shim
Excessive mast noise
Adjust shim and cushion, get the
inner mast first touch cushion when
Cushion under outer mast does not work on
inner mast drops, and then the
container forklift
piston rod in the cylinder can touch
the bottom of cylinder.
Excessive wear occurs between the oil pump Replace the worn parts or the oil
body and gears, causing too much clearance. pump.
The lift cylinder piston seal ring has worn, resulting in
Replace Y-ring.
Insufficient lift power or excessive inner leaks.
no lift movement. Springs of the multiple control valves and its
Replace new spring.
relief valve are inoperative.
Excessive wear occurs of the hydraulic control
Replace.
valve, resulting in excessive oil leaks.

57
 Oil leaks occur between the hydraulic control
valve sections.
Leakage occurs in the hydraulic pipe.
The hydraulic oil temperature is too high. Oil
viscosity is too low and the rate is insufficient.
The load carried is beyond the designed
capacity.
Dismantle for regrinding the joint
surfaces and reassemble the valve.
Tighten the joint nuts and inspect
the seal for damage.
Change the wrong hydraulic oil or
stop operation for reducing the oil,
find out the reasons for high oil
temperature
Lift according to requirement.

Tilt cylinder
Pressure oil from control valve flows into the tilt cylinder and pushes the piston rod to extend or
contract, thus realizes the mast going forward or backward.
Duplex wide view Duplex full free lift Triplex full free lift
Mast type
mast, mast mast
Mast
5.5°/6° 5.5°/6° 3.5°/5°
forward/backward

Tilt cylinder structure：

1.Oil cup 8. Scraper seal 15. Piston

2.Spherical
9.Guide sleeve 16.Seal ring
bearing

3.Bolt 10.U-RING 17.Guide ring

4.Gasket 11. Step seal 18.Nut

19.Cylinder
5.Nut 12.O-ring
body

6.Earing 13.O-ring 20.Pin

21.Spacer
7.Piston rod 14. O-ring
bush
Disassembly and installation of tilt cylinder
1. Tilt the mast backward, and fully lay down the fork carriage.
2. Fix the outer mast with steel wire rope. Prevent the mast falling after disassembling the
cylinders.
3. Screw out the bolts from the outer mast and pull out the pin.

58
4. Dismantle front baseplate, dismantle the pipeline connector on the tilt cylinder and the
connecting part with the truck frame, then take out the tilt cylinder.

5. To install, reverse the order of disassembly. After installment, add lubricating grease to the oil
cups at the pin and earring 6.

Caution：
Pay attention to the following notes when disassembling the tilt cylinder：
 Fix the outer mast with steel wire of crane. Prevent the mast falling after disassembling the
cylinders.
 Keep away from the truck. Never stand under the fork carriage when it’s fitted with forks.

Tilt cylinder parts disassembly

1. Retain the tilting cylinder with a jaw vice
2. Drain out the remaining fluid in the cylinder by way of pulling the piston rod back and forth
when both inlets and outlets are open.
3. Screw out guide sleeve 9, pull out the piston rod 7 and its piston, seal ring out of the cylinder
19 by way of earring 6.
4. Unscrew earring bolt 3, and screw out earring 6.
5. Pull out pin 20, screw out nut 18, and dismantle guide ring, seal ring, piston.

Caution：
 Dismantled scraper seal and seal ring must be replaced, never reuse.

Inspections on key components

– Check for deformation and the scratch and corrosion of the inwall. If the cylinder is badly
damaged or severely deformed, replace a new one. If the scratch or corrosion is not that

59
 serious, polish it with”00” abrasive paper and lubrication oil.
– Check for the deformation of the piston rod and see if it is dent or with pocking marks and
corrosion.
– Light scars on the internal surface of the guide sleeve do not impact its performance. But if the
unilateral abrasion loss reaches 0.2mm ～ 0.3mm, the seal rings fails to function. Replace
timely.
– Check for the scars, cracks on the piston and check if the seal groove is damaged or not.
Keep the fit clearance of cylinder and piston between 0.10mm ～ 0.15mm. The maximum
clearance should not exceed 0.2mm. Otherwise replace the piston.
– If any seal ring is found overworn, aged or scratched or flaw lip, replace them timely.

Installation and adjustment of tilt cylinder

– Clean up every part with gasoline and dry up with compressed air before installation. Smear
some hydraulic fluid on the cylinder inwall, piston and piston rod surfaces and the surfaces of
seals. (Hydraulic fluid should be the same type as the working oil.)
– Follow the reverse sequences of the disassembly to assemble the cylinder. Keep an eye on
the installing direction of the seals. When the lip of seal ring passes through the inlet an outlet,
press it gently with a smooth pole, in case the chamfer edge of the inlet and outlet lip
damages the lip.
– After the piston is put in the cylinder, the movement in a whole stroke should be smooth and
no obstruction and not jammed.

Inspection and adjustment of the mast tilting angles

– Keep the truck fully loaded and the mast in a vertical direction.
– Lift the forks 300～500mm off the ground. Leave the range quadrant on the tangent plane of
the inner mast and read the angle.
– Tilt the mast forward to the end. Value of the quadrant angle is the forward tilting angle. Tilt the
mast backward to the end. Value of the quadrant angle is the backward tilting angle.
– If the angle is big or small, turn the earring on the top of the piston to reset and fasten with
bolts and nuts.

60
Lift cylinder
Pull backward the lift lever, pressure oil from control valve or electronic control lift manifold block
enters into the lower end of lift cylinder, pushes the piston rod to extend upward, thus drives the lift
of mast and fork carriage. Push forward the lowering lever, pressure oil from the lower end of
cylinder returns to oil tank through speed limit valve, and mast lowers under the effect of gravity.
The mast lowering speed is controlled through the flow limit by speed limit valve.
Lift cylinder structure：

2 7
3 8
5 9
4 10
11
12
13

16
14
15

2. Dustproof 5.Guide 6.Cylinder

1. Piston rod 3. Seal ring 4. O-ring
ring sleeve body
7. Steel cable 12.Valve
8. Piston 9.Support ring 10.Guard ring 11. Seal ring
baffle ring pocket
13. Steel cable 14. Nipple
15. O-ring 16.Sleeve
baffle ring component

61
Lift cylinder disassembly
Procedures：
– Tilt the mast forward to the end in order to
dismantle lift cylinder easily.
– Lower the lift cylinder to the end to
compress the oil back to the tank. Close
the electric switch.
– Dismantle the lower end rigid tube and
upper end hose of the lift cylinder.
– Remove the cylinder fixed U bolt from the
outer mast.
– Dismantle the cylinder piston rod and
mast connected bolt.
– Dismantle the chain on the mast.
– Lift the inner mast with steel wire and take
away the left and right lifting cylinders.
Lift cylinder parts disassembly
1. Screw out the guide sleeve 5 with a
hookwrench and take down scraper seal
and seal ring.
2. Pull out piston rod 1 and its piston parts.
3. Remove the steel cable baffle ring 13,
valve pocket 12, seal ring 11 off the piston
8.
4. Dismantle nipple component 14 and seal
62
ring 15 on the lift cylinder.
Caution：
 Replace the scraper seal and seal rings
once they are removed.
Inspections on key components
– Check for deformation and the scratch
and corrosion of the inwall. If the cylinder
is badly damaged or severely deformed,
replace a new one. If the scratch or
corrosion is not that serious, polish it
with”00” abrasive paper and lubrication
oil.
– Check for the deformation of the piston
rod and see if it is dent or with pocking
marks and corrosion.
– Light scars on the internal surface of the
guide sleeve do not impact its
performance. But if the unilateral abrasion
loss reaches 0.2mm ～ 0.3mm, the seal
rings fails to function. Replace timely.
– Check for the scars, cracks on the piston
and check if the seal groove is damaged
or not.
– If any seal ring is found over worn, aged
or scratched or flaw lip, replace them
timely.
Installation and adjustment of lift
cylinder
– Clean up every part with gasoline and dry
up with compressed air before installation.
Smear some hydraulic fluid on the
cylinder inwall, piston and piston rod
surfaces and the surfaces of seals.
(Hydraulic fluid should be the same type
 as the working oil.)
– Follow the reverse sequences of the
decomposition to assemble the cylinder.
Keep an eye on the installing direction of
the seals. When the lip of seal ring passes
through the inlet an outlet, press it gently
with a smooth pole, in case the chamfer
edge of the inlet and outlet lip damages
the lip.
– After the piston is put in the cylinder, the
movement in a whole stroke should be
smooth and no obstruction and not
jammed.
– Conduct the exhaust and running tests
after truck is assembled. Check for oil
leakage and the loosening bolts.
– Observe if the left/right lift cylinder stay in
the same level and lift synchronously, or
adjust the shims between the piston road
and inner mast support.
Mast disassembly and installation
1. After screwing off the bolts from the middle
of the fork carriage and pulling out the fork
locating pin, move forks to gap portion in
the middle of carriage bracket.
 Keep hands and feet away from forks.
Remove and install forks carefully. Keep
feet and hands clear.
 Do not remove forks from the top of the
fork. Severe injury can result if the fork is
dropped.
3. Attach wire ropes to fork carriage
assembly and lift it with a lifting device.
4. Pull out the fork carriage connected chain
cotter, remove chain attaching nuts, and
detach chains from fork carriage.
5. Remove fork carriage assembly from inner
mast.
6. Remove the rubber hose connector that
enters the speed limit valve of lift cylinder,
and remove the oil return hose on the
upper end of left/right lift cylinder.
7. Lift the inner and outer masts with steel
wire.
8. Screw out bolt, pull out pin, take down
bearing, and separate the tilt cylinder and
outer mast.

2. Tilt the mast forward and lower the forks

until they are off the fork carriage, then
back up the truck.

Warning
9. Screw out the bolts and nuts on two ends

63
 that connects outer mast and drive axle.

10. Remove mast assembly.

11. To install mast assembly, reverse order of
removal: Forks directly face the truck and
place on the ground, lower the fork
carriage to the lowest, truck travels
forward slowly, aims at the fork slot with
– Slide the inner mast and disassemble the
beam and gap on the fork carriage, fully lift
lift cylinder.
the fork carriage, adjust the fork position
Take out the rollers
and lock it.
– Stretch out the inner mast from the bottom.

Warning Remove the retainer rings from the

 Be careful when removing and installing composite rollers and take away the side
the forks, carriage and mast, as they are rollers. Prepare two plectanes with about
heavy. 10mm thickness and diameter at Φ53 and
Φ58 respectively. Cover the roller holder
Spare parts disassembly with the two plectanes. Dismount the
Warning composite rollers and main rollers with a
 Be careful when disassembling the bearing puller.
masts as they are heavy. – If there is no bearing puller, unclench the

Disassemble the lift cylinder rollers carefully. (even unclenching power for
– Place mast on ground. Remove bolts from all directions). Otherwise, the rollers would
lifting cylinder piston, U-bolt and tighten be damaged.
screw from outer mast.

64
 adjust as follow

“L” dimension Unit：mm

Truck model or Class
tonnage Class II
Max lifting Ⅲ
height mm
1t～2.5t
3t
2500～3300 368 328
3600 388 348
Disassemble the inner mast
Tie up the inner mast with steel wire. Slide out 4000 418 378
the inner mast with a lifting equipment. 4500 443 403

Inspection
– Check for wear or damage of the roller,
roller holder and other involved parts. – Adjust the clearance A to 0.1mm～0.6mm.

– Replace the damaged parts as necessary.

Assembly and adjustment

Warning
 Be careful when assembling as the
inner and outer masts are quite heavy.

Install roller
Slide inner mast into outer mast and securely
attach lift rollers

Adjust the clearance between the roller and

mast channel
– Set the distance between the rollers on
inner mast and outer mast as L. And

65

– Keep the clearance of rolling channel flange
within 0.8mm ～ 1mm. Do not adjust the
clearance. If it is over worn, replace the
rollers.
– Smear some lubricating grease on the
connecting surfaces of inner and outer
mast and also on the rollers and channel
rail. But in some areas with strong wind
and sand, carefully decide whether to
smear grease or not. Avoid the sand
sticking on the surfaces.
Clearance between the guide plate and
mast channel
Adjust the clearance B between guide plate
and inner mast column with a thin washer and
make it within 0.5mm ～ 1mm. Thin washer
might not be wanted as necessary. The
thickness of the washer should be around
66
0.2m.
Smear a layer of lubricating grease on the
guide plate and assemble the mast and lifting
cylinder on the forklift truck. Connect the oil
return tube and the high pressure tube.
Assemble the left and right cylinders and
adjust the cylinder position
– Install the left and right cylinders into the
mast. Insert the locating pin to the location
hole which is on the bottom beam of the
outer mast.
– Set the upper end of the piston rod into
the cylinder holder of the inner mast.
Make all directions evenly positioned. If
there is height difference on left and right
sides, apply a washer between the
cylinder holder hole and the upper end of
the piston rod and adjust. Screw up the
bolts that connect mast and piston rod.
Adjust the lifting chain
Install the fork carriage into the inner mast and
mount the chain. Screw two bolts on each side
of the chain. Make the mast in a vertical
direction and lower down to the end. Adjust the
nuts on the bottom of the chain and make the
lower end of the fork carriage about 74mm off
the ground.
 B、Bˊ、B" of rollers on fork carriage and
side roller of the composite roller
respectively.
– Calculate the difference values between A
and B, A and Bˊ, A and B" respectively.
Each difference value is the clearance
between the roller and inner mast

In order to adjust the tension of the chain, channel.

lower the lifting cylinder until the forks is on the Evenly adjust the washers of each side roller

ground. Adjust the chain nut (three nuts at on left and right. Adjust the clearance to the

each end) till length of C reaches to the rated following range：

value when the finger presses the central part A-B = 0.2 mm～1mm
of chain. A-B' = 0.1mm～0.8mm
The length of “C” is around 25mm~30mm. A-B" = 0.1mm～0.8mm

Rubber cover

Thin adjusting washer：0.5mm, 1mm.

– Use equal quantity of washers on left and
Adjust the clearance of rollers on the fork
carriage assy. right sides.
– Measure the distance A between the two – After the clearance is set. Slide the fork
channels of the inner mast. Collect the carriage on the inner mast upward and
value on the top, central part, central downward. Check if it is smoothly
beam of the inner mast and the bottom operated.
respectively.
– Measure the space from left and right side

67
6 Electric System
Electric system is composed of motor, controller, DC-DC converter, fuse, battery, lamp and
harness etc.

AC motor
Motor parameter

Model Rated Rated Rated Rated Insulation Frequency Phase

Type Duty
power voltage current speed grade
kW V A r/min Hz

Traction S2-60mi
HPQ4.75-4HC 4.75 33 115 1975 H 68.5 3
motor n

Traction
XYQ-4.75A 4.75 33 115 1975 H 60min 68.5 3
motor

Traction S2-60mi
HPQ4.75-80HC 4.75 55 69 1975 H 68.5 3
motor n

Pump
HPB9.5-4HC-C 9.5 3
motor

Pump
HPB9.75-80HC 9.75 55 153 1600 H S2-5min 53 3
motor

Caution
 AC motor does not have commutator and brush. No maintenance. But it needs regular
inspection and dusty clearing.

AC Motor maintenance

1. Motor must be maintained well so as to guarantee safety work and extend service life.
2. Motor installation and each fastener should be reliable.
3. Power cable should be correctly and firmly connected, no protrusion, no oil stain on the
insulation part, and keep dry.
4. Idle motion should be quick.
5. If there is any abnormal phenomenon, stop immediately, such as overheating or abnormal
noise. Operate until malfunction is corrected.
6. Do not disassemble the motor arbitrarily, follow the rules of Caution of Motor Disassembling;
7. Clean the surface of motor regularly, replace the grease of the motor bearing annually(working
temperature of grease is -40℃~+200℃)
8. Washing the motor case with high pressure liquid is strictly prohibited, in case of case
deformation.

68
9. To protect the motor shift, do not remove the motor by putting ropes on motor shift, during the
disassembling and assembling process.

Caution of AC motor disassembling：

1. Be careful of the outer coder, no strike and protect the connector of both signal wire. Do not
knock against coder gear when disassembling and inspecting the coder. Clear the gear before
assembling
2. Clear rust and other stain fully before assembling.
3. No part damages during the assembling
4. Wire connection should be correct and secure. No cutting-edge protrusion, no stain on
insulation, and keep dry
5. The motor rotor can rotate easily by hands.
Common fault and corrections：

Trouble Probable cause Corrective action

Inspect the voltage of battery, switch, wire line, contact
Power failure terminal, motor connect terminal. Find out the causes and
correct
Check for the reason of fuse burnout and correct. Reinstall
Fuse burnout
a new fuse according to the motor capacity
Check for the connection of control circuit according to
Faulty connection of control circuit
electric schematic. find out the causes and correct
Inspect the coil by using multimeter, tramegger or indicator
Stator or rotor coil open circuit lights. If there is an open circuit, find out the open place
and reconnect.
Check for equilibrium of motor there phases, Check for
Short circuit or earth connection of
Motor fail earth connection of coil, find out the disorder place and
stator coil phases
to start correct
Recalculate the load, select the proper motor or lighten the
Overloaded or mechanical part gets
load, check if mechanical transmission mechanism gets
stuck
stuck and correct
Improper thermorelay or thermorelay
Select proper thermorelay and readjust according to motor
is adjusted small, or overflow relay is
rated electric current
adjusted small
Faulty connection of motor Δ to Ｙ ,
causing the motor fail to start on Reconnect the motor according to the motor nameplate
heavy load
Recheck the head or tail port of stator coil, connect
Faulty connection of stator coil
correctly
Inspect the power line, motor connect terminal, fuse,
Starts on single phase switch, contact terminal, Find out the disconnection and
correct
The sectional area of fuse is too
Fuse was Rematch and replace a new fuse.
small
burned
A coil phase is shorten to the ground Disassemble and repair the motor coil
out, when
motor Overloaded or mechanical part gets Adjust the load to the rate value, and eliminate the
starts stuck mechanical failure
shorten circuit of connecting wires
Repair after finding out the shorten place
between battery and motor
The starting resistance of motor with Eliminate the shorted circuit or increase the starting
coils rotor is too small or shorted. resistance
Motor fails Check for the voltage of power, ask power supply
Lower voltage of power
to start department for helps

69
 Trouble Probable cause Corrective action
and gives Inspect the voltage of power, contactor, switch, one phase
Phase lack of power
out disconnection ,find out the causes and correct
buzzing The head or tail port of motor is Power DC to the stator coil inspects the polarity of the coil.
noise after misconnected or inner connection of Check the correct connection of the head or tail port of
power on coil connects contrary coil, and reconnect.
Misconnect △to Y connection Change Y to △connection
Find out the open circuit place and repair, check the
contact condition of brush of coil rotor and collecting ring.
Coil of stator or rotor is shorted
Check open circuit of the staring resistance or big
resistance
Overloaded or mechanical part got Release the load, eliminate the mechanical failure or
stuck replace the motor
Tight installation or hard grease Reinstall, and replace the grease
When polarity changing and
Select proper coil type and pitch. Lathe the rotor diameter
rewinding, the match of wedge and
improperly, Recalculate the parameters of coil
groove select improperly
Misconnection of power wire and
Eliminate the fault connection, motor shell should connect
ground wire. Badly earth connection
to the protective ground wire securely
of the motor
Charged
Wet coil and insulation aging Dry the coil and replace the insulation aged coil
motor
shell Lead wire and terminal box interfere
Pack up or replace the extension line
with the ground
Top end of the coil is connected to Find out the grounded place, pack up, insulate and paint,
the ground and add insulator into the end cover
When the Cage rotor broken bar or break
Check broken bar or break welding place, and repair
motor runs welding
with or One phase brush of cage rotor is Adjust the stress of brush, increase the contact surface of
without poor contacted brush and collecting ring
load, the Collecting ring short circuiting device
current of cage rotor type motor contact Inspect and maintain or replace short circuiting device
keep poorly
unsteadily One phase open circuit of coiled
Find out the open place and correct
rotor

DC motor

Rated Rated Rated Rated

Type Excitation Insulation Quota Weight
Model power voltage current speed
way class (min) （Kg）
kW V A r/min

Pump motor XQD-8.6-2H-7 8.6 45 248 1600 In series F 5 47

Pump motor XQD-8.6-2H-8 8.6 45 248 1600 In series F 5 47

70
DC motor fault diagnosis

Fault Probable cause

All copper sheet blacken ·Pressure of the brush is not right

·Short circuit of commutator segments

Commutator segments blacken in
group according to certain ·Short circuit of armature coils
sequence ·The welding of commutator segments and armature coils
is not good or short circuit.
·Center line shift of the commutator
Commutator segments blacken,
but without sequence
·Rough, un-round of the commutator surface

·Motor vibrate

·Gap between brush and brush box is too large

·The distance between brush box and commutator working
Wear, color change and fracture surface is too long
of brush
·The mica between commutator segments extrudes.

·Brush material is not good.

·Trade mark of brush is not right

·Overloaded of motor

·Commutator is not clear

·Commutator is not smooth or round

·Mica plate or part commutator segment extrude

·Brush does not grind well

Large spark
·Brush pressure is not large enough

·Incorrect brush trade mark

·Brush locked in the brush box

·Brush carrier loosen or vibrate

·Incorrect pole polarity and sequence

·Large brush spark

Brush and brush wire overheat ·Electrical brush and flexible conductor have bad contact

·Small flexible conductor area

Noise in the brush ·Uneven commutator surface

71
Motor outlet cable or pile head label, mode of connection

A1 Armature winding head

A2 Armature winding end
Series excited motor
D1 Series winding head
D2 Series winding end
A1 Armature winding head
A2 Armature winding end
Separately excited motor
F1 Separately excited winding head
F2 Separately excited winding end

Mode of connection：
Series excited motor
Commutator rotation direction

Separately excited motor

DC motor use and maintenance

Commutator end has four inspection windows for observing and maintaining commutator and
changing brush. There is four uniformly distributed poles in motor seat, pole coil is rolled with F
grade copper wire and immerse F grade insulating varnish, stator parts and brush neutral position
has adjusted at test station, so users should not dismantle and adjust at will.
─ Check if motor rotates flexibly or abrades.
─ Check if motor outlet(or terminal) connection is correct or reliable.
─ Brush should slide easily in the brush box.
─ Check if commutator segments are clean, if necessary, clean the minor groove of commutator
segments and carbon powder on the commutator surface with soft clean white cloth, when
there is grease on the surface, immerse the cloth in alcohol to wipe(park).
─ Check if all fasteners are tight.
─ Brush carrier should be tight and no loose. If it needs to turn or remove the brush carrier, only
mark can loosen the end cap bolt.
─ Aim at marker line to tighten screw when brush carrier reset to keep the brush in neutral

72
 position.
─ Check the coil insulation resistance regularly, when close to working temperature, it should
not be lower than defined data, otherwise dry.
─ Open the shutter regularly and check if the inner parts deformation or reversing part is normal.
─ Often clean sand and other adhesion on the motor in order not to affect its heat dissipation.
─ Check the motor at least once half year according to the following way：
- Check the outer part and clean dust on the motor;
- Clean and replace bearing, listen if there is abnormal noise during running;
- Check brush abrasion and replace if necessary.

Brush abrasion：
─ When replace brush, use 00 type abrasive
cloth to polish, pull abrasive cloth to left or
right when polishing.
─ After polishing abrasive cloth and cleaning
commutator, motor should work under
limited speed to ensure safety until the
brush working surface polishes.

73
Controller
The ZAPIMOS chopper family represents ZAPI’s answer to the needs of the 21rst’ century’s. To

ensure that products remain on the market, without running the risk of becoming technically

obsolescent, the ZAPIMOS family offers the following features:

– Advanced technology.

– Economical costs.

– Maximum safety.

– Maximum flexibility.

– Open to future technical innovations.

– Optimum level of protection.

The design has been derived from：

– High Frequency Mos Technology.

– Real time control over the internal and external components that influence the behavior of the

machine, with self diagnosis of the checking circuits themselves.

– Stored Program Machine (SPC), where the hardware is completely separate from the

functions to be configured. The programmer is parametric and can easily be modified by the

end user.

– Various chopper configurations can be selected by the user, without the need for hardware

modifications.

– Future technological updates are made easy for the user.

– The communication protocol will continue to evolve, thereby offering increased possibilities of

interaction and expansion. For this reason, the Zapimos family offers a standard dialogue

mode with external systems. This allows interfacing with commercially available systems, and

its price will be different with the different performance.

– electrical controller can meet the requirement of IP51, and offer good protection function,

which can protect from dust and liquid such as water, acid and so on coming inside. Its control

logical can be easily open and it is allowed to do simply change.

74
Potentiometer of steering angle sensor：
– Front double-wheel drive. A steering angle sensor helps to measure the steering angle to

make the controller differential the front two wheel.

– Using “SET STEER MIN” and ” SET STEER MAX” functions it is possible to acquire .The

voltage value corresponding to the two limits of the steering potentiometer’s stroke.

SAFETY & PROTECTION FEATURES

– Reverse Polarity of the battery：Electrical Circuit diagrams must be consulted in order to avoid

damage to the power unit. A Line (Main Contactor), managed by the logic unit, is necessary

for protection against reverse battery polarity.

– Connection errors：All inputs are protected against connections errors. Contactor drivers are

suitable for loads up to 2 Amps, and are protected against overload.

– Thermal protection：If the controller temperature exceeds 85°C, the maximum current reduces

in proportion to the thermal increase. The temperature can never exceed 95°C.

– Low Battery charge ： When the battery charge is low, the maximum current is reduced

proportionally to the battery discharge.

– External Agents ： The chopper is protected against dust and spray of liquid to a degree of

protection meeting IP51.

– Protection against accidental Start Up：A precise sequence of operations is necessary before

the machine will start. Operation cannot commence if these operations are not carried out

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

– Protection against uncontrolled movements.

– The Main Contactor will not close if:

- The Power Unit is not functioning .

- The Logic Unit is not operating correctly .

- The output voltage of the accelerator does not fall below the minimum voltage value stored,

with 1Volt added .

- Running micro-switch in closed position.

75
OPERATIONAL FEATURES
– Speed Control.

– Optimum sensitivity at low speeds.

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

– Regenerative Braking based on deceleration ramps.

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

– Speed Control during descent: the motor speed follows the accelerator. The chopper

automatically brakes if the motor speed overcomes the accelerator set point. This provides

optimum performance on a gradient.

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

– Programmable Anti Roll Back: When the Key Switch is closed, if the motor is rotating, the

chopper controls the speed and automatically brakes This keeps the motor at a very low

speed during descent on a gradient. This is a very useful safety feature and is not driver

dependent.

– Electro-brake management (optional)

– Output for hydraulic steering with adjustable delay.

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

Display).

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

– Internal Hour Meter that is displayed on the Console.

– Memory of the last 5 Alarms, with relative Hour meter count and chopper temperature all

displayed on the Console.

– Test Function within Console for checking main parameters.

– See the specific Description.

– Internal Contactor Coil Suppression.

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

– Presence of a second microprocessor for safety that monitors the CPU that controls the

motor.

Maintenance of controller
Controller does not have spare parts, do not try to open, repair or change controller, if users do

76
these, it will damage controller, and guarantee repair is invalid; keep controller clean and dry.

Clean controller outside at regular intervals, it may avoid corrosion or other dirt, dust and

electronic control fault chemical caused.

Clean as the following steps:

– Remove power supply plug;

– Connect controller B+ and B- (for example contactor circle or horn) with load to recharge

capacitance in controller.

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

– Airing controller before fixing power plug.

77
CURTIS 1234-XXXX controller fault code chart
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 battery, or is severely

Neither LED illuminated
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.
3. Controller defective.
1. Leakage to vehicle frame from phase U, V, or W (short in motor stator).
1,3 Current Sensor Fault
2. Controller defective.
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.
5. See 1311 menu Monitor » Battery: Capacitor Voltage.
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.
4. See 1311 menu Monitor » Battery: Capacitor Voltage.
1. Controller is performance-limited at this temperature.
Controller Undertemp
2,1 2. Controller is operating in an extreme environment.
Cutback
3. See 1311 menu Monitor » Controller: Temperature.
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.
5. See 1311 menu Monitor » Controller: Temperature.

78
 PROGRAMMER LCD
CODE POSSIBLE CAUSE
DISPLAY
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.
6. See 1311 menu Monitor » Battery: Capacitor Voltage.
7. Blown B+ fuse or main contactor did not close.
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
5. See 1311 menu Monitor » Battery: Capacitor Voltage.
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.
1. Open or short on driver load.
3,1 Main Open/Short 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
1. Open or short on driver load.
3,2 Coil2 Driver Open/Short 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
1. Open or short on driver load.
3,2 EM Brake Open/Short 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
1. Open or short on driver load.
3,3 Coil3 Driver Open/Short 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
1. Open or short on driver load.
Coil4 Driver
3,4 2. Dirty connector pins.
Open/Short
3. Bad crimps or faulty wiring.

79
 PROGRAMMER LCD
CODE POSSIBLE CAUSE
DISPLAY
1. Open or short on driver load.
3,5 PD Open/Short 2. Dirty connector pins.
3. Bad crimps or faulty wiring.
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
2. Bad crimps or faulty wiring.
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.
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

80
 PROGRAMMER LCD
CODE POSSIBLE CAUSE
DISPLAY
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.
3. Bad crimps or faulty wiring.
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.

81
CURTIS 1253-XXXX Pump controller fault
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 ¤¤¤ ¤¤¤¤ loose.
or is not close.
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 ¤¤¤¤ ¤¤¤ or too low.
（over-/under-temp）
2.Temperature sensor works abnormal.

82
 Inmotion controller error alarm code
Serial error
Analysis description Solution
number code
1 10 Operation sequence fault Reset all the traction controller switch
2 13 HPG CONTROLLER EEPROM KO Reset key
Incorrect start Accelerator pedal Release pedal switch
3 20
switch active before key on
Incorrect start Forward switch or Turn off the direction switch
4 21
reverse switch active before key on
Forward switch and reverse switch Direction switch fault
5 22
active at the same time
Throttle fault or analog need to be
6 23 Throttle analog value out of range
calibrated
Throttle fault or analog need to be
7 24 Throttle analog fault
calibrated
HPG CONTROLLER BATTERY HPG CONTROLLER BATTERY VOLTAGE
8 30
VOLTAGE LOW LOW NEED CHARGE
Traction controller CAN Check CAN wire of controller and display
9 31
communication fault
10 32 BDI level is too low Need charge
11 33 DC MOTOR VOLTAGE HIGH RESET KEY
12 34 CPU fault Reset key
More than one pump functions are Reset all the pump speed mode switchs
13 35
active at the same time
Incorrect start Tilt switch active
14 36 Reset tilt switch
before key on
Incorrect start Side switch active
15 37 Reset side switch
before key on
Incorrect start Attachment switch
16 38 Reset attachment switch
active before key on
Incorrect start Lift switch active
17 39 Reset lift switch
before key on
18 40 Lift analog value out of range Lift analog fault or need to be calibrated

19 43 Steer analog value out of range Steer analog fault or need to be calibrated
1、Vehicle speed is too high alarm
20 44 Traction controller speed protection
2、Traction motor encoder fault
1、Traction controller encoder fault
21 45 Traction controller encoder fault
2、Traction motor speed sensor connection

83
Serial error
Analysis description Solution
number code
wire is open
DC MOTOR OPERATING CURRENT IS 1、HPG CONRTOLLER SENSOR FAULT
22 49
ZERO 2、Pump motor Open
1、Check power wiring
23 51 Slave traction controller short
2、Controller enable before contactor pull
DC bus voltage of Slave traction Battery need charge
24 52
controller is low cut back
1、HPG CONRTOLLER OVER CURRENT
25 53 HPG CONRTOLLER OVER CURRENT
2、Pump motor fault
1、Vehicle overload or Mechanical clamping
26 54 Slave traction controller over current
2、Slave traction motor speed sensor fault
DC bus voltage of Slave traction DC bus voltage of Slave traction controller
27 55
controller is high cut back is high cut back
DC bus voltage of Slave traction DC bus voltage of Slave traction controller
28 56 controller is high cut back(Hardware is high cut back(Hardware monitoring)
monitoring)
Slave traction controller precharge Replace the pre charge resistance
29 57
failed
1、Slave traction motor temperature is high
Slave traction motor temperature is need cool
30 58
high cut back 2、Slave traction motor temperature sensor
fault
Slave traction controller temperature Slave traction controller temperature is
31 59
is high cut back high need cool
Slave traction controller temperature Slave traction controller temperature
32 60
sensor fault sensor fault
change the Slave traction motor encoder
33 61 Slave traction motor controller fault
AB
HPG CONTROLLER TEMPERATURE HPG CONTROLLER TEMPERATURE HIGH
34 62
HIGH NEED COOL
1、Slave traction motor temperature sensor
Slave traction motor tenperature is fault
35 63
sensor fault 2、Slave traction motor temperature sensor
connection wire is open
Open drain of Slave traction output Check the wire of open drain of Slave
36 64
open or short traction output open or short
37 65 Slave traction Internal power supply Slave traction motor temperature sensor or

84
Serial error
Analysis description Solution
number code
error speed sensor connection wire is open
HPG CONTROLLER BATTERY LOW NEED
38 66 HPG CONTROLLER BATTERY LOW
CHARGE
Slave traction motor encoder fault
39 67 Slave traction motor encoder fault Slave traction motor speed sensor
connection wire is open
40 74 HPG CONTROLLER DRIVER SHORTED HPG CONTROLLER DRIVER SHORTED

41 76 HPG CONTROLLER COIL SHORTED HPG CONTROLLER COIL SHORTED

42 78 HPG CONTROLLER VACC NOT OK HPG CONTROLLER VACC NOT OK

HPG CONTROLLER INCORRECT HPG CONTROLLER INCORRECT START

43 79
START
Traction controller temperature is low
44 81 Traction controller temperature is low
alarm
Traction controller temperature is Traction controller temperature is high
45 82
high alarm
Traction controller temperature Traction controller temperature sensor
46 83
sensor fault fault
1、Traction motor temperature is low
47 84 Traction motor temperature is low 2、Traction motor temperature sensor is
fault
1、Traction motor temperature is high
48 85 Traction motor temperature is high 2、Traction motor temperature sensor is
fault
1、Traction motor temperature sensor is
Traction motor tenperature sensor fault
49 86
fault 2、Traction motor temperature sensor
connection wire is open
1、Traction motor encoder fault
50 87 Traction motor encoder fault 2、Traction motor speed sensor connection
wire is open
DC bus voltage of traction controller 1、DC bus voltage high
51 88
is high 2、The ramp is too steep
DC bus voltage of traction controller
52 89 Need to charge or check power wiring
is low
The default value of the traction
53 90 Reset key
controller is updated

85
Serial error
Analysis description Solution
number code

54 91 Traction drive limit Battery low vehicle speed limit

Open drain of traction output open or Check the wire of open drain of traction
55 97
short output open or short
Traction controller over current or
56 98 Check power wiring
short
1、Check power wiring
57 101 Traction controller short
2、Controller enable before contactor pull
Traction controller temperature is high
Traction controller temperature is
58 102 need cool
high cut back

1、Traction motor temperature is high need

Traction motor temperature is high
59 103 cool
cut back
2、Traction motor temperature sensor fault
1、Vehicle overload or Mechanical clamping
60 104 Traction controller over current
2、Traction motor speed sensor fault

61 105 Traction controller precharge failed Replace the pre charge resistance

DC bus voltage of traction controller

62 110 Battery need charge
is low cut back
DC bus voltage of traction controller DC bus voltage of traction controller is high
63 111
is high cut back cut back
DC bus voltage of traction controller
DC bus voltage of traction controller is high
64 112 is high cut back(Hardware
cut back(Hardware monitoring)
monitoring)
Traction controller Internal power Traction motor temperature sensor or
65 114
supply error speed sensor connection wire is open
66 121 Pump controller temperature is low Pump controller temperature is low alarm
67 122 Pump controller temperature is high Pump controller temperature is high alarm
Pump controller temperature sensor Pump controller temperature sensor fault
68 123
fault
1、Pump motor temperature is low
69 124 Pump motor temperature is low
2、Pump motor temperature sensor fault
1、Pump motor temperature is high
70 125 Pump motor temperature is high
2、Pump motor temperature sensor fault

86
Serial error
Analysis description Solution
number code

1、Pump motor temperature sensor fault

71 126 Pump motor temperature sensor fault 2、Pump motor temperature sensor
connection wire is open

1、Pump motor speed sensor fault

72 127 Pump controller encoder fault 2、Pump motor speed sensor connection
wire is open
DC bus voltage of pump controller is DC bus voltage of pump controller is high
73 128
high
DC bus voltage of pump controller is
74 129 Check power wiring
low
The default value of the pump
75 130 Reset key
controller is updated
76 132 Pump drive limit Battery voltage low need charge

Open drain of pump output open or Check the wire of open drain of pump
77 137
short output open or short

78 138 Pump controller over current or short Check power wiring

79 141 Pump controller short
Pump controller temperature is high
80 142 Pump controller temperature is high alarm
cut back
Pump motor temperature is high cut
81 143 Pump motor temperature is high alarm
back
Pump controller current calibration
82 144 Reset key
error
83 145 Pump controller precharge failed Replace the pre charge resistance
84 148 BMS fault, Parking BMS fault，Check the battery
85 149 BMS secondary fault
DC bus voltage of pump controller is DC bus voltage of pump controller is low
86 150
low cut back cut back
DC bus voltage of pump controller is DC bus voltage of pump controller is high
87 151
high cut back cut back
DC bus voltage of pump controller is DC bus voltage of pump controller is high
88 152
high cut back(Hardware monitoring) cut back(Hardware monitoring)
1、Reset key
89 153 Pump controller CPU fault 2、Pump motor temperature sensor or
speed sensor connection wire is open
90 154 Pump controller speed control fault 1、Pump speed is too high alarm

87
Serial error
Analysis description Solution
number code
2、Pump motor encoder fault
BMS Temperature Warning，Reduce
91 156 BMS fault，Check the battery
Power
92 157 BMS Temperature Protection, Parking BMS fault，Check the battery
BMS Voltage Warning, Reduce
93 158 BMS fault，Check the battery
Power
94 159 BMS Voltage Protection，Parking BMS fault，Check the battery
CHECK DISPLAY AND CONTROLLER CAN
95 161 DISPLAY CAN FAULT
CONNECTION
96 163 BMS Current Warning，Reduce Power BMS fault，Check the battery
BMS Feedback Current Protection，
97 164 BMS fault，Check the battery
Parking
Seat switch off after a period of time,
98 165 Reset direction switch
the direction of the request to reset
99 168 BMS indicates Limit Current alarm BMS indicates Limit Current alarm

100 169 BMS indicates cutoff Current alarm BMS indicates cutoff Current alarm

DC bus voltage of Slave traction

101 170 Need to charge or check power wiring
controller is low
DC bus voltage of Slave traction 1、DC bus voltage high
102 171
controller is high 2、The ramp is too steep
The default value of the Slave traction
103 172 Reset key
controller is updated
1、Slave traction motor temperature is low
Slave traction motor temperature is
104 173 2、Slave traction motor temperature sensor
low
is fault
1、Slave traction motor temperature is high
Slave traction motor temperature is
105 174 2、Slave traction motor temperature sensor
high
is fault
Slave traction controller temperature Slave traction controller temperature is low
106 176
is low alarm
Slave traction controller temperature Slave traction controller temperature is
107 177
is high high alarm
Slave traction controller speed 1、Vehicle speed is too high alarm
108 178
protection 2、Slave traction motor encoder fault
109 180 BMS indicates brake Current alarm BMS indicates brake Current alarm
110 181 BMS CAN Error BMS CAN Error

88
Serial error
Analysis description Solution
number code
111 182 BMS Fault Check BMS
Open drain of slave traction output Check the wire of open drain of slave
112 185
open or short traction output open or short
113 200 Proportional valve error Proportional valve error
114 201 Steer controller short Check power wiring
Steer controller temperature is high Steer controller temperature is high need
115 202
cut back cool
1、Steer motor temperature is high need
Steer motor temperature is high cut
116 203 cool
back
2、Steer motor temperature sensor fault
117 205 Steer controller precharge failed Replace the pre charge resistance
DC bus voltage of Steer controller is
118 206 Battery need charge
low cut back
DC bus voltage of Steer controller is DC bus voltage of Steer controller is high
119 207
high cut back cut back
1、Steer motor encoder fault
120 210 Steer motor encoder fault 2、Steer motor speed sensor connection
wire is open
1、Steer motor temperature sensor is fault
121 211 Steer motor tenperature sensor fault 2、Steer motor temperature sensor
connection wire is open
Steer controller temperature sensor
122 212 Steer controller temperature sensor fault
fault
Steer controller Internal power supply Steer motor temperature sensor or speed
123 214
error sensor connection wire is open
Open drain of Steer output open or Check the wire of open drain of Steer
124 217
short output open or short
1、Steer motor temperature is low
125 218 Steer motor temperature is low
2、Steer motor temperature sensor is fault
1、Steer motor temperature is high
126 219 Steer motor temperature is high
2、Steer motor temperature sensor is fault
127 220 Steer controller temperature is low Steer controller temperature is low alarm
128 221 Steer controller temperature is high Steer controller temperature is high alarm
DC bus voltage of Steer controller is
129 222 DC bus voltage high
high
DC bus voltage of Steer controller is
130 223 Need to charge or check power wiring
low

89
Serial error
Analysis description Solution
number code
Steer Controller Internal power Steer motor temperature sensor or speed
131 234
supply error sensor connection wire is open
CHECK CAN WIRE OPEN AND CAN SPEED
132 241 HPG CONTROLLER CAN BUS KO
RATE
HPG CONTROLLER BATTERY OVER HPG CONTROLLER BATTERY OVER
134 242
VOLTAGE VOLTAGE
133 243 HPG CONTROLLER KEY SHORTED HPG CONTROLLER KEY SHORTED
HPG CONTROLLER WATCHDOG
134 244 HPG CONTROLLER WATCHDOG ERROR
ERROR
135 245 Attachment switch status error Reset attachment switch status
HPG CONTROLLER WAITING FOR TURN OFF THE PUMP CONCTACTOR
136 246
MAIN CONTACTOR PARAMETER

90
ZAPI controller
Italian ZAPI controller is reliable and high efficient, with great speed control. On the instrument is
state of charge, speed, total run time. If malfunctioned, cause of failure can be quickly and
efficiently determined by fault code or fault module part number. Operator can choose four
operation mode for different working conditions by using the instrument buttons.
Walking controller delivers excellent speed control and reliable regenerative braking performance.
– The motor velocity is controlled by the accelerator. Regenerative braking system will be
activated if speed increases above the default;
– Braking system (electric braking on the slope) will be activated if parked on a slope for a
preset time;
– Regenerative braking system for speed reducing on a slope;
– Regenerative braking system for accelerator pedal release (slowing down);
– Regenerative braking ratio can be adjusted to proportionally by analog input;
– High sensitivity at low speed;
– Longer driving torque (with current control) when started or overloaded.
– Electric braking system will be activated by the inverter;
The oil pump controller is designed for electric forklifts to improve better controller control. It
consists of “lift”, “forward/backward”, “power-assisted steering”, “side shifting(forward)” control
levers. It guarantees the speed while it has the characteristics as stably, safety, precision, bottom
noise, no arc spark, no large current impact to the battery when started.
Cautions：
1. No reverse of the battery polarity of the controller assembly.
2. Battery nominal voltage shall be no more than controller assembly nominal voltage.
3. No inversely connected U, V, W phase wires.
4. No connection between the charging circuit and the controller when charging.
5. Take safety measures during assembly, test run and maintenance, especially when galloping,
high current arc and battery liquid splashing.

91
ZAPI Fault code
Microcontroller Vehicle
Restart the
fault list Error Description Function status after
program
code test
Main contactor is not
FLASH checksum closed, Key switch
MDI mode allarm Program detects the fault electromagnetic brake Start restart the
71 starts, traction/lifting system
stop
Main contactor
Analog disconnects,
Analog channel, no reading Traction/lifting
MDI mode allarm electromagnetic brake Start, run
update request
96 starts, traction/lifting
stop
Main contactor is not
Difference between the key
closed,
switch voltage and battery Traction/lifting
Wrong set battery electromagnetic brake Start
nominal voltage is 20% larger request
starts, traction/lifting
than the standard voltage.
stop
Main contactor is not
Cpacitor charge closed,
Power capacitor voltage does not Traction/lifting
MDI mode allarm electromagnetic brake Start
increase request
60 starts, traction/lifting
stop
Main contactor is not
Coil shorted hw ko The main contactor or solenoid closed,
Traction/lifting
MDI mode allarm valve/short auxiliary coil is electromagnetic brake Start
request
76 damaged starts, traction/lifting
stop
Main contactor
disconnects(command
Driver shorted Main contactor drive circuit
has sent), start Start, stand Traction/lifting
MDI mode allarm shorted, unable to open the
electromagnetic by, run request
74 contactor
brake, traction/lifting
stop
Main contactor
disconnects(command
Solenoid valve/auxiliary drive
has sent), start Start, stand Traction/lifting
Aux driver shorted circuit shorted, unable to open
electromagnetic by, run request
the contactor.
brake, traction/lifting
stop
Main contactor
Safety in disconnects, Key switch
Safety input disconnect （ do not Start, stand
MDI mode allarm electromagnetic brake restart the
connect-BATT） by, run
86 starts, traction/lifting system
stop
Main contactor
disconnects,
Safety output drive circuit is Traction/lifting
Safety out electromagnetic brake Start
damaged （short or open）. request
starts, traction/lifting
stop
Main contactor
disconnects, Key switch
Watchdog#1 Incorrect status of watchdog Start, stand
electromagnetic brake restart the
MDI mode allarm 8 circuit signal #1 by, run
starts, traction/lifting system
stop

92
 Microcontroller Vehicle
Restart the
fault list Error Description Function status after
program
code test
Main contactor is not
closed, Key switch
Watchdog #2 Incorrect status of watchdog Start, stand
electromagnetic brake restart the
MDI mode allarm 8 circuit signal #2 by, run
starts, traction/lifting system
stop
Main contactor is not
Keyoff shorted closed, Key switch
Cut off the circuit low logic signal
MDI mode allarm electromagnetic brake Start restart the
at startup
76 starts, traction/lifting system
stop
Main contactor is not
closed,
Logic failure#1 Detect too low or too high voltage Start, stand Traction/lifting
electromagnetic brake
MDI code alarm 54 signal by, run request
starts, traction/lifting
stop
Main contactor is not Traction/lifting
Logic failure #3 closed, request
High current protection circuit is
MDI mode allarm electromagnetic brake Start
damaged
17 starts, traction/lifting
stop
Main contactor is not Traction/lifting
Power mos shorted closed, request
MDI mode allarm MOS tube shorted electromagnetic brake Start
89 starts, traction/lifting
stop
Main contactor is not
closed,
Start, stand Traction/lifting
VMN high Overhigh motor output voltage electromagnetic brake
by request
starts, traction/lifting
stop
Main contactor
VMN low disconnects,
Traction/lifting
MDI mode allarm Too low motor output voltage electromagnetic brake Start, run
request
72 starts, traction/lifting
stop
Main contactor is not
In the standby condition (no
Stby I high closed,
motor supply current), current Traction/lifting
MDI mode allarm electromagnetic brake Start
feedback value exceeds the request
53 starts, traction/lifting
allowable range
stop
Main contactor is not
closed,
Wrong 0 voltage Feedback value of motor phase Traction/lifting
electromagnetic brake Start
MDI code allarm 53 voltage is out of range request
starts, traction/lifting
stop
Main contactor is not
Contactor closed closed,
Traction/lifting
MDI mode allarm LC contactor blocked electromagnetic brake Start
request
75 starts, traction/lifting
stop
Main contactor is not
Watchdog circuit emitted fault Key switch
closed,
Hardware fault 20 signal cannot close MOS driver Start restart the
electromagnetic brake
circuit. system
starts, traction/lifting

93
 Microcontroller Vehicle
Restart the
fault list Error Description Function status after
program
code test
stop

Main contactor is not

The main contactor or solenoid closed, Key switch
Hardware fault 21 valve/short auxiliary coil is electromagnetic brake Start restart the
damaged starts, traction/lifting system
stop
Main contactor is not
Watchdog circuit emitted fault closed, Key switch
Hardware fault A1 signal cannot close main electromagnetic brake Start restart the
contactor driver circuit. starts, traction/lifting system
stop
Main contactor After the
Coil shorted MC disconnects, main
Traction/lifting
MDI mode allarm Main contactor coil shorted electromagnetic brake contactor is
request
76 starts, traction/lifting closed, start,
stop stand by, run
Main contactor After the
Coil shorted EF Solenoid valve/ auxiliary coil disconnects, main
Traction/lifting
MDI mode allarm shorted electromagnetic brake contactor is
request
68 starts, traction/lifting closed, start,
stop stand by, run
Main contactor After the
Contactor open disconnects, main
Main contactor coil is activated Traction/lifting
MDI mode allarm electromagnetic brake contactor is
but not closed request
77 starts, traction/lifting closed, start,
stop stand by, run
Main contactor
disconnects(command
Logic failure#2
Feedback circuit of motor phase has sent), start Stand by, Traction/lifting
MDI mode allarm
voltage is damaged(fail to close) electromagnetic run request
55
brake, traction/lifting
stop
Main contactor
disconnects(command
Contactor driver
Main contactor drive circuit is has sent), start Stand by, Traction/lifting
MDI mode allarm
damaged(fail to close) electromagnetic run request
75
brake, traction/lifting
stop
Main contactor
Solenoid valve/ auxiliary drive disconnects,
Stand by, Traction/lifting
Aux Driver Open circuit is damaged( fail to start the electromagnetic brake
run request
solenoid valve) starts, traction/lifting
stop
Main contactor
disconnects,
Encoder Error Traction/lifting
Encode reading error electromagnetic brake Run
MDI code allarm 82 request
starts, traction/lifting
stop
Main contactor
Program detected that the
Wrong Ram disconnects, Key switch
registration information of
Memory electromagnetic brake Continue restart the
memory can be erased and find
MDI code allarm 71 starts, traction/lifting system
the error value
stop

94
 Microcontroller Vehicle
Restart the
fault list Error Description Function status after
program
code test
Accelerator / lifting potentiometer
Vacc not OK value is greater than the Traction/pump motor Start, stand Traction/lifting
MDI code allarm 78 minimum record value, while the stop by, run request
direction / enable switch is off
Incorrect start Traction/pump motor Start, stand Traction/lifting
Incorrect start sequence
MDI code allarm 79 stop by, run request
Accelerator input signal is beyond
the scope of the minimum
Vacc out of range acceleration signal value - the Traction/pump motor Start, stand Traction/lifting
MDI code alarm 85 maximum acceleration signal stop by, run request
value, the range is set by the
parameter PROGRAMM VACC
Linear decrease of the
The controller temperature
current value of
Temperature reaches 85 ℃ at maximum
traction controller from Continue
MDI code allarm 62 current, and forms speed
maximum(85 ℃) to 0A
reducing condition
（105 ℃）
Motor temperature sensor is
Maximum current
Motor temperature disconnected (if it is a digital
halved and speed Continue
MDI code alarm 65 sensor) or exceed 150 ℃
reduced
threshold (if analog sensors)
In the case where the request No function, only
without the hand brake, the brake display fault signal Traction/lifting
Brake run out Continue
potentiometer input signal is the through handheld request
maximum value. programmer
Traction request signal and the
Stand by, Traction/lifting
Handbrake hand brake input signal are Traction motor stop
run request
effective at the same time
The maximum current gain
Current Gain parameters is factory defaults, Controller worked but
Start, stand
MDI code allarm indicating the maximum current lower than maximum
by
92 adjustment program is not current
implemented
Sens mot temp KO Output signal of motor Maximum current
MDI code allarm temperature sensor is out of halved and speed Continue
65 range reduced
Thermic sens Ko Output signal of controller Maximum current
MDI code allarm temperature sensor is out of halved and speed Continue
61 range reduced
Slip profile
Wrong Slip profile parameter Traction/pump motor Traction/lifting
MDI code alarm Continue
setting stop request
99
EEPROM KO Controller used
MDI code allarm Eeprom error parameter is the Continue
71 default one
Forward+Backward Walking command is effective in Start, stand Traction/lifting
Traction stop
MDI code alarm 80 forward and backward directions by, run request

95
Electrical Schematic Diagram

CPDS13/15/16/18/20-AC3、CPDS13/15/16/18/20-AC5
CPDS13/15/16/18/20-AC3-F、CPDS13/15/16/18/20-AC5-F
Electrical Schematic Diagram

96
 CPDS13/15/16/18/20-AC4、CPDS13/15/16/18/20-AC6
CPDS13/15/16/18/20-AC4-F、CPDS13/15/16/18/20-AC6-F
Electrical Schematic Diagram

97
CPDS13/15/16/18/20-AZ3, CPDS13/15/16/18/20-AZ5
Electrical Schematic Diagram

98
CPDS13/15/16/18/20-AZ4, CPDS13/15/16/18/20-AZ6
Electrical Schematic Diagram

99
CPDS13/15/16/18/20-AC6-NA Electrical Schematic Diagram

100
CPDS13/15/16/18/20-AC4-I Electrical Schematic Diagram

101
 BC

CPDS16/18/20-AC6-I Electrical Schematic Diagram

102
 1.5mm215A
24V
DC-DC 1.5mm215A FU4
DC
转换器 后
DC- FU3 警 大
80V B- 闪 灯光开关（示宽） 灯 灯
HT 光 制 开 开
器 SA1-2
1.5mm215A 动 关 关
方向开关（倒车） 灯 SF1 JK1 JK2
SA2-2 开
喇 灯光开关（转向）
关
叭 SA1-1
JDQ1 继
电 大
器 灯
继
JDQ2
电
RC1 器
SB2 SB1 HH

EL1-3 H1-3 EL2-3 H2-3 EL1-2 H1-2 EL2-2 H2-2 EL1-1 EL2-1 H1-1 H2-1 HU H1-4 H2-4 HF EL3
扶 喇 电
手 叭 喇
喇 按 叭
叭 钮
按
钮

左 左 右 右 左 左 右 右 左 右 左 右 倒 左 右 警 后
前 后 前 后 前 后 前 后 前 前 倒 倒 车 制 制 灯 大
转 转 转 转 示 示 示 示 大 大 车 车 蜂 动 动 灯
1.5mm215A
向 向 向 向 宽 宽 宽 宽 灯 灯 灯 灯 鸣 灯 灯
灯 灯 灯 灯 灯 灯 灯 灯 器

35mm2145A

103
FU2
T3 KM1 KM2
S1 P1
KSI
T28 HIGH SIDE IN HIGH SIDE OUT T29 KSI
KSI
1.5mm215A SA5 互锁开关 主接触器 KM1 P19 HIGH SIDE OUT B+
T12 T4
Di1 Drain 1 主接触器 P2 FU7
SA4-1 SS7 手刹开关 T18 T16 下降电磁阀 Drain 1
Di5 Drain 2 SLAVE KM2
前进开关 T19 ZF U TRACTION ACS 80S U
Di2 PUMP
SA2-1 ACS 80S MOTOR -220C-23P
后退开关 T23 B+ MOTOR
FU1 Di3 B+ -220C-23P
FU5 FU6 V P9 PUMP V
SF2 制动开关 SM CAN 120Ω PM
T11 S15 SLAVE P15
Di4 CAN L CAN L
ENCODER
ENCODER

2mm220.9A SS1 起升高速 S23 W P23

T30 CAN H TRACTION CAN H W
Di6 ACS 80S S8 P8 CAN
SS2 起升低速 T35 CAN GND GND
Di9 -220C-35P
B- B-
XL2-1 SS3 倾斜开关 T34
Di8 MASTER T32
GND
GND
PH A

+12V
PH A
PH B
Temp
PH B

SS4 侧移开关 T2 TRACTION +5V RV2

Di10 T9
属具 转角定位器
S16
P16 Temp

SS5 Ain2
S3
S4
S5
S6
S17 GND
P3 +12V
P4
P5
P6
P17 GND

T31
SS6 下降开关 T1 GND
XL1-1 Di11

T17
Di7
MAIN RV1
U T32
TRACTION +5V 加速器
MOTOR T20 0-5V
Ain1 踏板开关

CPDS16/18/20-AD4-I Electrical Schematic Diagram

V T31
MM GND

ENCODER
锂电池 3A1 KSI
T10 CAN-T
80V W CAN GND 3A12
SA4-2 T21 CAN-L IDD-43C
CAN L 3A23
BC T33 CAN-H 智能仪表
CAN H 3A35
GG YB
B- 3A2 BATT-

Temp
PH B
PH A
GND
+12V

SA3

T26
T6 GND
T8
T7
T6
T5

编程插口
CAN H
CAN L

35mm2145A
XL1-1 XL2-1
 1.5mm215A
24V
DC-DC 1.5mm215A FU4
DC
转换器 后
DC- FU3 警 大
48V B- 闪 灯光开关（示宽） 灯 灯
HT 光 制 开 开
器 SA1-2 动 关
1.5mm215A 关
方向开关（倒车） 灯 SF1 JK1 JK2
SA2-2 开
喇 灯光开关（转向）
关
叭 SA1-1
JDQ1 继
电 大
器 灯
JDQ2 继
电
RC1 器
SB2 SB1 HH

EL1-3 H1-3 EL2-3 H2-3 EL1-2 H1-2 EL2-2 H2-2 EL1-1 EL2-1 H1-1 H2-1 HU H1-4 H2-4 HF EL3
扶 喇 电
手 叭 喇
喇 按 叭
叭 钮
按
钮

左 左 右 右 左 左 右 右 左 右 左 右 倒 左 右 警 后
前 后 前 后 前 后 前 后 前 前 倒 倒 车 制 制 灯 大
转 转 转 转 示 示 示 示 大 大 车 车 蜂 动 动 灯
1.5mm215A 向 向 向 向 宽 宽 宽 宽 灯 灯 灯 灯 鸣 灯 灯
灯 灯 灯 灯 灯 灯 灯 灯 器

35mm2145A

FU2
T3 KM1 KM2
KSI S1 P1
T28 HIGH SIDE IN HIGH SIDE OUT T29 KSI
KSI
1.5mm215A SA5 互锁开关 主接触器 KM1 P19 HIGH SIDE OUT B+
T12 T4
Di1 Drain 1 主接触器 P2 FU7
SA4-1 SS7 手刹开关 T18 T16 下降电磁阀 Drain 1
SLAVE

104
Di5 Drain 2 KM2 ACS 48S
前进开关 T19 ZF U TRACTION U PUMP
SA2-1 Di2 ACS 48S MOTOR
后退开关
-350C-23P MOTOR
T23 B+ B+
FU1 Di3 -350C-23P PUMP
SF2 制动开关 FU5 FU6 V SM P9
CAN 120Ω
V
T11 S15 SLAVE P15 PM
Di4 CAN L CAN L
ENCODER
ENCODER

2mm220.9A SS1 起升高速 S23 P23

T30 CAN H TRACTION W CAN H W
Di6 ACS 48S S8 P8 CAN GND
SS2 起升低速 T35 CAN GND
Di9 -350C-35P
倾斜开关 B- B-
XL2-1 SS3 T34 MASTER
Di8 T32
GND

GND
+12V
PH A
PH B

PH A
PH B

SS4 侧移开关 T2 TRACTION +5V RV2

Di10 T9
属具 Ain2 转角定位器
S16 Temp
P16 Temp

SS5
S3
S4
S5
S6
S17 GND
P3 +12V
P4
P5
P6
P17 GND

下降开关 T31
XL1-1 SS6 T1 GND
Di11

T17
Di7
MAIN RV1
TRACTION U T32
+5V 加速器
MOTOR T20 0-5V
Ain1 踏板开关
V T31
MM GND

ENCODER
锂电池 3A1 KSI
T10 CAN-T
48V W CAN GND 3A12
SA4-2 T21 CAN-L IDD-43C
CAN L 3A23
BC T33 CAN-H 智能仪表
CAN H 3A35

CPDS16/18/20-AD6-I Electrical Schematic Diagram

GG YB
B- 3A2 BATT-

PH B
PH A
GND
SA3 +12V

T26 Temp
T6 GND
T8
T7
T6
T5

编程插口
CAN H
CAN L

35mm2145A
XL1-1 XL2-1
 Pre charger

Oil pump contactor

.. Emergency stop
Main contactor
. .
. .
ACS ACS
Pre charger
On-board
15A
15A

On-board
Fuse Fuse

. Key switch
.
. 3
key B+ HIGH_SIDE_IN
28
1
key B+
. Seat switch 12
Di1 HIGH_SIDE_OUT 29
. Forward switch 19
Di2
Open_Drain_Out_1 4
Main contactor coil 48V Open_Drain_Out_1
2

. Reverse switch 23
Di3
Open_Drain_Out_2 16
Lower lock solenoid 24V Open_Drain_Out_2
10

. Foot brake switch 11

Di4 25 Oil pump contactor coil 48V

. Hand brake switch 18

Di5 24

Oil pump
Di6

Left traction
27
Right traction

HP-48V
Di8 13

350A
Di9

Right traction motor

Left traction motor

Battery

26 16
Lower switch / safety belt switch Di10 Temperature sensing + 2 Temperature sensing + 2
. 1
Di11
Temperature sensing GND
1
Temperature sensing GND 17
1

ACS 23P
ACS 35P

encoder 12V
5 encoder 12V 3
1 1
7 5
encoder A 2 encoder A 2
Acceleration switch
8 6
Fs3 17 encoder B 3 encoder B 3 CAN high
Di7
encoder GND 6 . 4 encoder GND 4 4
Common

.
switch

32 Analog power supply (5V)

CAN low
Accelerated analog 20
Ain1 U U
Steering analog 9
Ain2 V V
. . 31
AGND W W

CAN high
33
. 23
CAN high
22

CAN low
21 . . 15
CAN low
14

B-
CAN_GND
10
. 8
CAN_GND
B-
7

Programming interface
CAN_120
9 3 2 7 6
. CAN high . .
CAN low .
CAN_GND
.
1 B+
23 CAN low
43C 12
CAN high
35
B-
2

. .
CPDS13/15/16/18/20-AD3 CPDS13/15/16/18/20-AD5 Electrical Schematic Diagram

105
 ACS 35P ACS 23P
48V 48V

ACS 23P
48V

IDD-43C DISPLAY

CPDS13/15/16/18/20-AD4 CPDS13/15/16/18/20-AD6 Electrical Schematic Di

106
 Maintenance record

Date Repair or maintenance items Serviceman

107
108