OMM-A-2.0-X3.0-Rider Pallet Truck-202301-EN-CE

A Series
CBD20/30-AC1S-SU
ELECTRIC PALLET TRUCK CBD20/30-ABC1S-SU
CBD20/30-AZ3S-SU
CBD20/30-ABZ3S-SU
CBD20/30-AC1S-ISU
CBD20/30-ABC1S-ISU
CBD20/30-AC2S-SU
CBD20/30-ABC2S-SU
CBD20/30-AC2S-ISU
CBD20/30-ABC2S-ISU
OPERATION AND MAINTENANCE

MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.

5/2022
FOREWORD
Thank you very much for purchasing A series bodykit electric pallet truck of Hangcha Group.
A series bodykit pallet truck is a newly developed product for warehouse logistic and adopts
newest AC drive control technology, it owns characteristics as advanced performance, comfort
operation, safety and security, low maintenance cost, and is an ideal tool for handling goods in
warehouse, supermarket and workshop.
Before use the truck, relative persons must read and understand the manual, get to know how to
safely operate and maintain the truck.
Part one of this manual is about the brief introduction and correct operation of the electric pallet
truck, which will tell you how to operate safely and maintain preventively; part two will tell you the
structure, working principle and maintenance of the electric pallet truck. To ensure safety and exert
the truck’s potential, all the personnel that in charge of operation maintenance and management
must read this manual thoroughly.
Due to the continuous updating and improvement of our products, there may be minor
discrepancies between your forklift truck and this manual.
For any questions, please contact Hangcha or your nearest dealer.
© 5/ 2022 HANGCHA GROUP CO., LTD

Content
PARTⅠ OPERATION AND MAINTENANCE ................................................................................ 1
1 Notice for use ............................................................................................................................1
1.1 General ...................................................................................................................................... 1
1.2 Use as required ......................................................................................................................... 1
1.3 Approved application conditions ............................................................................................... 2
1.4 Cautions for the use of cold storage truck ................................................................................ 3
1.5 Cautions for the use of lithium battery truck ............................................................................. 3
1.6 Proprietor responsibilities ..........................................................................................................4
1.7 Attachment installation or modification to the truck .................................................................. 4
2 Truck introduction ......................................................................................................................5
2.1 General ...................................................................................................................................... 5
2.2 Main part introduction ................................................................................................................7
2.3 Display and control .................................................................................................................... 9
2.3.1 Instrument ................................................................................................................................11
2.4 Standard technical data ...........................................................................................................13
2.5 Labels and warning label ........................................................................................................ 19
3 Safety instructions ...................................................................................................................21
4 Lifting and transport ................................................................................................................ 24
4.1 Lifting by crane ........................................................................................................................ 24
4.2 Securing the truck during transport .........................................................................................25
4.3 Transport ..................................................................................................................................26
5 Battery- Servicing, Recharging, Replacement ....................................................................... 27
5.1 Battery safety precautions .......................................................................................................27
5.1.1 Safety precautions for using lead-acid batteries .................................................................... 27
5.1.2 Safety precautions for using lithium battery ........................................................................... 28
5.2 Battery maintenance ............................................................................................................... 30
5.2.1 Lead-acid battery maintenance .............................................................................................. 30
5.2.2 Lithium battery maintenance ...................................................................................................31
5.3 Dimension/Service Weight ...................................................................................................... 32
5.4 Battery operating temperature ................................................................................................ 33
5.5 Battery charging ...................................................................................................................... 34
5.5.1 Lead-acid battery charging ..................................................................................................... 34
5.5.2 Lithium battery charging ..........................................................................................................35
5.6 Replacing battery .....................................................................................................................38
6 During running-in .................................................................................................................... 39
7 Operation ................................................................................................................................ 40
7.1 Check before operation ........................................................................................................... 40
7.2 Starting up ............................................................................................................................... 42
7.3 Travelling ................................................................................................................................. 43
7.4 Steering ....................................................................................................................................43
7.5 Braking .....................................................................................................................................44
7.6 Picking up goods ..................................................................................................................... 45
7.7 Transporting goods ..................................................................................................................46
7.8 Setting down goods .................................................................................................................47
7.9 Parking the truck as required .................................................................................................. 48
8 Stop use and store the forklift .................................................................................................49
8.1 Store for a long period .............................................................................................................49
8.2 Recommissioning after storing for a long time ....................................................................... 49
9 Maintenance ............................................................................................................................50
9.1 Maintenance summary ............................................................................................................ 50
9.2 Periodic maintenance schedule .............................................................................................. 51
9.3 Truck lubrication ...................................................................................................................... 55
9.4 Replace the key safe parts periodically .................................................................................. 57
9.5 Tighten wheel nut .................................................................................................................... 57
9.6 Take down rear closure plate and hood ..................................................................................58
PARTⅡ STRUCTURE, PRINCIPLE AND MAINTENANCE......................................................... 60
1 Drive system ........................................................................................................................... 60
1.1 Reduction gearbox .................................................................................................................. 61
1.1.1 Working principle .....................................................................................................................62
1.1.2 Disassembly and assembly order ...........................................................................................63
1.1.3 Notice to installment and use ..................................................................................................63
1.1.4 Fault diagnosis and corrections ..............................................................................................63
1.2 Motor ........................................................................................................................................64
1.3 Electromagnetic brake .............................................................................................................72
1.3.1 Working principle .....................................................................................................................72
1.3.2 Install the brake .......................................................................................................................74
1.3.3 Adjust brake air gap ................................................................................................................ 76
1.3.4 Maintenance ............................................................................................................................77
1.3.5 Common fault and troubleshooting .........................................................................................78
1.4 Dismantle the driving system from the truck ...........................................................................79
2 Hydraulic system .....................................................................................................................80
2.1 Hydraulic system working principle .........................................................................................81
2.2 Hydraulic unit ...........................................................................................................................82
2.3 Dismantle the hydraulic unit from the truck ............................................................................ 85
2.4 Dismantle the lifting cylinder from the truck or replace .......................................................... 86
2.5 Hydraulic system fault diagnosis and correction .................................................................... 87
3 Electric system ........................................................................................................................88
3.1 Principles of electrical system .................................................................................................88
3.2 Controller ................................................................................................................................. 93
3.2.1 Maintenance ............................................................................................................................93
3.2.2 Diagnosis and troubleshooting ............................................................................................... 94
3.2.3 Controller fault diagnosis and correction ................................................................................ 96
Attachment：Table for bolt’s tightening torque ..............................................................................133
Related safety standards (for trucks exporting to Europe) ........................................................... 134
EC DECLARATION OF CONFORMITY ........................................................................................ 135
Maintenance Record ...................................................................................................................... 136
PartⅠ Operation and Maintenance
1 Notice for use
1.1 General
Truck in this manual is only for lifting and transporting loads.
It must be used, operated and maintained according to the information in this manual. Any other
uses are outside the design envelope and can lead to injury to persons or damage to equipment
and property.
1.2 Use as required

– Pick and place goods with trays.
– Transport goods with trays.
– Do not carry people.
– Do not over load.
– Do not push or pull loads.
– Do not work together on the same goods by multiple pallet trucks.
1
1.3 Approved application conditions
－ Used in specified area as factory, tourist attraction and recreation place.
－ Operation only on secure, level surfaces with sufficient capacity.
－ Operation only on routes that are visible and approved by the proprietor.
－ Use in specified rated load.
－ Average environment temperature under continuous operating condition +25℃.
－ The highest environment temperature in the short term (≤1h) +40℃.
－ The lowest environment temperature under normal indoor conditions when operation +5℃.
－ The lowest environment temperature under normal outdoor conditions when operation -20℃.
－ Altitude: ≤2000m.
－ Negotiating inclines up to a maximum of 6 %.
－ It is prohibited to travel crosswise or obliquely. When going uphill with loads, keep the loads in
front; when going downhill, keep people in front.
WARNING
 It’s prohibited to use the truck in the area of the explosion.
 Special equipment and authorisation are required if the truck is to be used in
extreme conditions (e.g. cold stores).
Cold-storage truck should meet the followings when working:

According to different grade of cold-storage truck, operate in cold storage based on standard
continuous working time. The recommended working times of our trucks are as follows:
－ Do not work continuously over 2 hours in the cold storage above -18℃;
－ Do not work continuously over 15 minutes/hour in the -18℃～-30℃cold storage.
Working condition for lithium battery:
－ Best operating temperature range: 15℃～35℃；
－ Charging temperature range: 0℃～40℃，No charging below 0℃.
－ Discharging temperature range: -20℃～55℃, discharge capacity at low temperature(-20℃～
0℃) is lower compared with normal temperature condition; battery can be used at 40℃～
55℃ temperature, but too high ambient temperature of battery may accelerate the aging of
inner battery material and shorten the battery service life;
－ Ambient humidity: HR≤85%, battery should be used under dry condition.
2
1.4 Cautions for the use of cold storage truck
－ Use special oil for cold storage, maintain and replace periodically.
－ All cold storage trucks cannot be shut down or parked in cold storage, or it may cause
damage of hydraulic system and electric system.
－ Before entering the cold storage, do necessary hydraulic and traction motion to the
cold-storage truck, and then enter the cold storage after temperature rises.
－ If there is condensate water on the truck surface after the truck left the cold storage, only after
the surface is dry or the condensate water is complete dry can the truck enters the cold
storage again.
－ Shorten the maintenance period of the lubricating point to avoid its premature wear.
－ Battery cannot be empty for a long time after discharging, charge in time to keep high
electrolyte proportion and avoid electrolyte freezing.
－ Different truck models with operations can improve each truck functions in the cold storage.
－ If the truck malfunctioned in the cold storage, remove it from the cold storage immediately and
repair in buffer zone or maintenance area.
1.5 Cautions for the use of lithium battery truck

－ Never charge below 0℃;
－ If the lithium battery needs to interrupt or suspend charging, do not hot plug, avoid current arc
to damage charging base;
－ Charge the lithium battery immediately after per discharge to avoid battery loss;
－ Never place the battery near high temperature heat source, such as fire and heater etc.;
－ Do not use the battery in a location where static electricity and magnetic field is great,
otherwise, the safety devices may be damaged, causing hidden trouble of safety.
－ Avoid using the battery under high temperature for a long time, otherwise, it may cause
overheat of the battery or function invalid or service life being shortened;
－ Do not operate the electric truck with lithium battery at the temperature above 55℃ or below
-20℃;
－ Do not dismantle the battery box under any circumstance;
－ Never drop or knock the battery box etc.;
－ Short circuit of the battery is prohibited, never put any other object or tool to avoid battery
short circuit;
－ Never wash battery box directly, prevent water getting into the battery and ensure the safety;
－ It's forbidden to mix batteries of different brands, volumes and types;
－ Battery should be kept in a cool and dry place and avoid direct sunlight;
－ Do not change the battery setting parameter at will without the permission of the
manufacturer;
－ If the lithium battery is not used for a long time, it is necessary to charge and discharge the
battery once a month.
3
1.6 Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” is defined as any natural or
legal person who either uses the industrial truck himself, or on whose behalf it is used. In special
cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with
existing contractual agreements between the owner and user of the industrial truck, is charged
with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose for which it is
intended and that there is no danger to life and limb of the user and third parties. Furthermore,
accident prevention regulations, safety regulations and operating, servicing and repair guidelines
must be followed. The proprietor must ensure that all users have read and understood these
operating instructions.
Failure to comply with the operating instructions shall invalidate the warranty. The same applies if
improper work is carried out on the truck by the customer or third parties without the permission of
the manufacturer.
1.7 Attachment installation or modification to the truck

Truck modification by user, which can introduce hazards or risk not considered by manufacturers,
will invalidate the existing truck risk assessments.
Truck modification outside Europe is subject to regional requirements (see ISO/TS 3691-8)
4
2 Truck introduction
2.1 General
The industrial truck described in the present operating instructions is a bodykit electric pallet truck,
designed for lifting, lowering and transporting loads with pallet.
This truck is stand-on type, and adopts electric power steering system.
Users can get relevant information as rated load from the product model.
Model Meaning
CBD Electric pallet truck
20 Rated load×100kg
A Product serial number
B base model
C1（Z3\C2） Controller type
S Stand-on type
I Lithium battery（Lead acid battery without I）
SU Panel guard
5
Safety device
– bodykit cab ensures the safety of operator.
– Turn automatic deceleration function as standard.
– Slope anti-slide function guarantees safety operation.
– Apply emergency stop button to cut all electric function in case of an emergency.
– Red emergency reverse button on the handle head can protect driver from injury in case of an
emergency.
Truck body system
– Beautiful and compact outline, concise and fluent line.
– The adopted high strength steel framed structure is sturdy and durable.
– Chassis adopts 5-wheel structure, including one central driving wheel, two lateral auxiliary
wheels as stabilization and two load wheels. It can make sure stable and safe driving.
– Battery side extraction as standard can replace battery quickly
Pedal
– Damping designed pedal improves operation comfort.
– Only when the driver stands on the pedal can start drive.
Driving system
– The adopted floating drive suspension system makes the whole structure compact and easy.
Steering control system
– New ergonomics designed control handle and operating element make operation easier.
– Electronic power steering as standard.
Hydraulic system
– Modularization hydraulic power unit owns low noise, low vibration, little pressure loss and
good reliability.
Electric system
– 24V Electric system.
– Latest CURTIS permanent magnetic control system.
– CAN-BUS adopted control handle owns easy circuit layout, rapid and easy communication.
– Four speed mode.
– Display truck running hours, battery capacity and fault message on the meter.
– Electric lift limited function as standard
6
2.2 Main part introduction
3
2
4 1
8
14
9
13
10 12
11 10
15
16
17
18
21
20
19
7
No. Designation No. Designation
1 Switch lock 12 Rear frame
2 Emergency stop switch 13 Front frame
3 Control handle 14 Load wheel
4 Right protection pad 15 Hood
5 Left protection pad 16 Small hood
6 Left panel 17 Battery cover
7 Rear closure plate 18 Fork
8 Right panel 19 Side door
9 Pedal 20 Instrument
10 Auxiliary wheel 21 Cup holder
11 Drive wheel
8
2.3 Display and control
26
27 27
28 28
25 25
24 3
22 23 2
20
1
9
No. Designation Symbol Function
Start the truck by connecting the control voltage. Take away

1 Switch lock the key to guarantee that the truck does no move
accidentally.
Press this switch, power is off and all electric functions
Emergency stop
2 stop. Press when emergency or no use. If re-start
switch
needed, pull upward.
Display battery charging status, running hours and fault
3 Instrument
information.
For stand-on operation. Only when the driver stands on
the pedal can start travelling, “lifting” and “lowering”
9 Pedal
function. If the diver leaves the pedal during travelling,
the truck will brake automatically.
20 Control handle Control truck steering
When touching this button during running, the truck
Anti-collision travels along fork direction for about 3 seconds, then
22
protection button braking is started. Only reset the switch to original place
can restart the truck.
Low speed Change between high speed mode and low speed
23
button mode.
Low speed When the indicator light is always on, it means the truck
24
indicator light is in low speed mode.
25 Travel switch Control travelling direction and speed.
When pressing the horn button, it will give out sound

26 Horn button
warning signal.
Raise lifting device. When the battery is consumed about
27 “Lifting” button
80%, lifting function will be locked.
28 “Lowering” button Lower lifting device.
10
2.3.1 Instrument The green LED indicator light being normal on
means that the timer is working, and the
minimum timing unit is 0.1hour.
LCD will display truck accumulated working
hours for each start, and this time is the basis
of periodical maintenance to the truck.
C2 controller meter
LCD 55% 55%

5.5 1 KPH
The LCD type is an 8-alphameric character,

dot matrix LCD, and can display truck fault The upper part of the instrument used by C2
code, battery residual capacity and controller shows the remaining battery power;
accumulated working hours. the lower part shows the operating time of the
LCD displays battery residual capacity when forklift when the forklift is stationary, in unit h;
truck is in normal operation. the driving speed is displayed when the
LED Fault indicator light (Red) vehicle is moving, in unit KPH.
When there is a fault, the red LED light is on
and the LCD will display the fault code. Fault D13L Display characteristics:
code displays alternately every two seconds  Wide voltage input range: 9V~60V;
when there is more than on fault. Relevant  Built-in anti-reverse circuit;

fault code and diagnosis information, please
 Beautiful appearance and unique alarm
refer to the Fault Code Table in this manual.
LED Low battery capacity indicator light indication design;
(Yellow)  Implement time-limited vehicle speed,
When the residual battery capacity is lower
power, hour meter, and fault;
than 20%, the yellow LED indicator light
flashes, issued an “energy depletion” warning,  Positive IP65 protection level, able to
meanwhile the LCD displays “20%” for one adapt to a variety of complex
second, and then change to “Low BDI”.
environments;
When yellow LED indicator light is flashing, the
lifting function is locked automatically, and the
travelling speed is reduced. Charge the truck
immediately.
Hour meter indicator light (Green)
11
Instrument graphic
Paramter
No. Description
name
The number shows the
current accumulated
working hours of the
1 Hour meter
vehicles, with a
maximum of 5 digits; unit:
h
Speed Display current vehicle
2
display speed in km/h
Battery
Display current battery
3 level
level;
display
Display the current fault
code, and display
4 Fault code
cyclically when multiple
faults occur;
2 3 1 Note
1) Speed display accuracy and unit: the
controller software supports speed unit
switching and decimal point measuring
function, D13L can realize corresponding
display;
2) When the battery level is lower than 20%,
the battery icon flashes;
3) When the hour meter is in the main
interface, it is always displayed;
4) Some models are not used, so the speed
is displayed as 0;
5) It is panel screen printing color around the
meter;
6) When there is a fault in one of the
4 controllers of the vehicle, the red

exclamation mark of the instrument
flashes, and the current fault code is
displayed on the interface. See the
corresponding part of the manual for the
specific fault code.
12
2.4 Standard technical data
The following technical data are all standard data. Our company reserves the right of alteration
and extension.
CBD20-AC1S-SU CBD30-AC1S-SU
Model
CBD20-ABC1S-SU CBD30-ABC1S-SU
Operator type Stand-on Stand-on
General
Rated capacity Q (kg) 2000 3000
Rated load center distance c (mm) 600 600
Wheel base y (mm) 1505 1505

880 920
Service weight(including battery) kg
(825) (880)
Tire type Polyurethane Polyurethane
Front tyre, size/ quantity mm Φ230×75 / 1 Φ230×75 / 1

Wheel and tire
Rear tyre, size/ quantity mm Φ85×80 / 4 Φ85×80 / 4
Additional wheels size/ quantity mm Φ125×50 / 2 Φ125×50 / 2
Thread, front b10 (mm) 575 575
Thread, rear b11 (mm) 370 370
Free lift h3 (mm) 125 125
Fork lowest height h13 (mm) 85 85
Overall length L1⑯(mm) 2372 2372
Platform height mm 175 175
Overall width b1 (mm) 800 800

Dimension
Fork dimension ISO2331 s/e/l (mm) 64/170/1150 64/170/1150
Distance between fork-arms b5 (mm) 540/680 540/680
Ground clearance, laden, below mast m1 (mm) 21 21
Min. right angle stacking aisle width 1000×1200(1200 cross forks) Ast (mm) 25041) 25041)
Aisle width for pallets 800×1200 lengthways Ast (mm) 25542) 25542)
Turning radius Wa (mm) 21343) 21343)

9.0/9.5 7.5/9.5
Travel speed, laden/unladen km/h
(6.5/7.0) (5.5/7.0)
Performance
Lift speed, laden/unladen m/s 0.047/0.064 0.036/0.053
Lowering speed, laden/ unladen m/s 0.075/0.071 0.060/0.058

8/16 8/16
Max. gradeability, laden/ unladen %
(5/16) (5/16)
2.2 2.2
Drive motor rating S2 60min kW
(1.5) (1.5)
Motor and battery
Lift motor rating at S3 15% kW DC 2.2 DC 2.2
Steering motor kW DC 0.2 DC 0.2

24/280 24/340
Battery voltage, nominal capacity K5 V/Ah
(24/240) (24/280)
Battery voltage, rated capacity, Optional V/Ah 24/340 24/340
Controller manufacturer/ type Curtis AC Curtis AC
Note：1）VDI 2198: +430mm.

2）VDI 2198: +236mm.
3）When fork lowered, +68mm
13
CBD20-AZ3S-SU CBD30-AZ3S-SU
Model
CBD20-ABZ3S-SU CBD30-ABZ3S-SU
General

880 920
(825) (880)

Wheel and tire

Dimension

9.0/9.5 7.5/9.5
(6.5/7.0) (5.5/7.0)
Performance

8/16 8/16
(5/16) (5/16)
2.2 2.2
(1.5) (1.5)
Motor and battery

24/280 24/340
(24/240) (24/280)
Controller manufacturer/ type ZAPI AC ZAPI AC
Note：1）VDI 2198: +430mm.

2）VDI 2198: +236mm.
14
CBD20-AC1S-ISU CBD30-AC1S-ISU
Model
CBD20-ABC1S-ISU CBD30-ABC1S-ISU
General

880 920
(825) (880)

Wheel and tire

Dimension
Aisle width for pallets 800×1200 lengthways Ast (mm) 2554 2) 25542)

9.0/9.5 7.5/9.5
(6.5/7.0) (5.5/7.0)
Performance

8/16 8/16
(5/16) (5/16)
2.2 2.2
Motor and battery
(1.5) (1.5)
Battery voltage, nominal capacity K5 V/Ah 24/200 24/200
Note：1）VDI 2198: +430mm.

2）VDI 2198: +236mm.
15
CBD20-AC2S-SU CBD30-AC2S-SU
Model
CBD20-ABC2S-SU CBD30-ABC2S-SU
General

880 920
(825) (880)

Wheel and tire

Dimension

9.0/9.5 7.5/9.5
(6.5/7.0) (5.5/7.0)
Performance

8/16 8/16
(5/16) (5/16)
2.2 2.2
(1.5) (1.5)
Motor and battery

24/280 24/340
(24/240) (24/280)
Note：1）VDI 2198: +430mm.

2）VDI 2198: +236mm.
16
CBD20-AC2S-ISU CBD30-AC2S-ISU
Model
CBD20-ABC2S-ISU CBD30-ABC2S-ISU
General

880 920
(825) (880)

Wheel and tire

Dimension
Aisle width for pallets 800×1200 lengthways Ast (mm) 2554 2) 25542)

9.0/9.5 7.5/9.5
(6.5/7.0) (5.5/7.0)
Performance

8/16 8/16
(5/16) (5/16)
2.2 2.2
Motor and battery
(1.5) (1.5)
Battery voltage, nominal capacity K5 V/Ah 24/200 24/200
Note：1）VDI 2198: +430mm.

2）VDI 2198: +236mm.
17
18
2.5 Labels and warning label
Labels and warning label, like nameplate, load curve and warning label, must be clear and
readable. Replace when necessary.
The following picture displays the rough position of each label. Before operation, please study the
meaning of each symbol.
WARNING
ELECTRIC PALLET TRUCK

MODEL-TYPE XX XX X X XX X
SERIAL NO. X X X X X X X RATED CAPACITY X X X X
LOAD CENTER X XX WEIGHT WITHOUT BATTERY XX X
BATTERY VOLTAGE XX MAX.ALLOWABLE BATTERY WEIGHT X X X
RATED DRIVE POWER XX MIN.ALLOWABLE BATTERY WEIGHT X X X
YEAR OF MANUFACTURE X XX X
H ANGCH A GR OUP C O.,L TD.
A dd : L in ' an E c on o mi c D ev el o pm e nt Z o ne ,Z h ej ia n g, C hi na Li c en se No . ：TS 2 51 00 0 2- 20 1 6
19
No. Designation
Product nameplate: The rated capacity on the label is the max. load capacity by the
29 label listed equipment. Any change to forklift or other equipment may change rated
capacity.
30 Hoist label: Fixed point when using the crane to handle equipment.
31 Switch lock label：”OFF” means being disconnected, ”ON” means being connected.
Emergency stop switch label: ”O” means being disconnected, “I” means being
32
connected.
33 Danger label: Mind your hands.
34 Manufacturer’s logo
Warning label:It is forbidden that the operator`s foot is not on the platform during
35
operation.
36 Hydraulic oil inlet
37 Series tonnage label: A series, rated capacity is 2.0t/3.0t.
20
check or clean the controller, connect
3 Safety instructions
load(like contactor coil or horn) between
1. Only trained and accredited operators are
controller B+ and B- to discharge the
permitted to operate the truck.
controller capacity.
2. Operators must wear a helmet, work

shoes and overalls.
8. Whenever you discover a fault, stop the

forklift, hang a "DANGER" or "OUT OF
ORDER" sign on it, remove the ignition
key and notify a manager. The truck may
only be used after the fault has been
eliminated.
3. Never carry people. – Arrange for immediate repair in the event
4. Without permission of the manufacturer, of a fault when lifting or driving uphill or
the vehicle shall not be modified. downhill, or a leakage of battery
5. The truck is not authorized for use in electrolyte, hydraulic oil or brake fluid.
areas at risk of explosion.
6. Inspect the truck at periodic intervals for
leaks, deformation, defects, etc. the life of
the truck will be shortened or an accident Dangerou
s
could occur.
– Make sure to replace the “key safety parts”
during periodical inspection.
– Wipe off oil, grease or water from the floor 9. Batteries generate explosive gases. Keep
board and foot and hand controls. sparks and open flames away from the
– Strictly prohibit smoking and spark near battery. Keep tools away from the battery
the storage battery when checking it. terminals to prevent sparks or
– Be careful do not be scalded when short-circuits.
inspecting the motor, controller and etc.

7. The controller equips with energy
accumulator, do not touch between B+
and B- to avoid electric injury. If you need
21
or body under the forks. Never stand on
the fork.
WARNING
10. The work ground of forklift shall be solid

and smooth concrete surface or similar
ones. Pre-check the ground condition of
19. Never place your head or body in
working site. Tidy the working site, clean
between the mast and overhead guard.
obstacle, sweep macadam, muddy sand
Risk of serious injury or death due to
and wipe off greasy dirt.
entrapment. It’s forbidden to put the head,
11. Do not overload. Before operation, first
hand, foot or body into the space between
know the curve chart on the load curve
fork and link mechanism.
plate well, which indicates the relation
between rated load and load center.
12. Before start, press the horn and make
sure no people around. WARNING
13. Off-center loads may fall easily when
20. Make the loads in front when climbing the
turning corners or driving on uneven
slope. It’s prohibited to turn on the slope,
surfaces and increase the risk of the
or there’s danger of tipping over. Avoid
vehicle tipping over.
working on the slope.
21. Do not use truck under the weather of
sand, snow, thunder, storm, typhoon, etc.
Avoid using the truck when the wind
speed is larger than 5m/s.
22. After
．．．．．power
．．．．．off,
．
．．．brake
．．．．．works
．．．．．and the
．．．．．．
truck
．．．．．can
．．．not
．．．be
．．．towed(dragged)
．．．．．．．．．．．．．.
．
14. Avoid sudden drive, stop or turn. 23. As to
．．．．stand-on
．
．．．．．．．．truck,
．．．．．stand
．
．．．．on ．．．firmly
．．．．．
15. Do not drive the truck when the forks in and
．．． hold
．．．
．．the
．． handle
．．．．．．．tightly.
．．．．．．． When
．．．．
high position. turning, the
．．．．．．．．．．． speed
．．．．． should
．．．．．． be lower
．．．．．．．
16. When handling bulky loads, which restrict than
．．．．3km/h
．．．．．
your vision, please operate the machine in 24. The labels and signs on the vehicle
reverse or have a guide. provide warnings and operating
17. Cause the wheels of pallet truck is small, instructions. During operation, adhere to
it is not allowed to run on the street, but the requirements of the manual as well as
drive in specified stacking place. the labels and signs on the vehicle.
18. It’s forbidden to put the head, hand, foot Inspect the labels and signs, and replace
22
any that are damaged or missing.
25. Fire extinguisher shall be equipped at the
work site. Users can choose truck
equipped with fire extinguisher. Driver and
manger should be familiar with the fire
extinguisher position and application
method.
26. Use tray when carrying small items, do

not place on the fork directly.
27. Do wash the inner of the truck, do not
place the truck outdoors and exposed to
the rain.
28. Before dismantle or repair the truck, pull
out the battery plug firstly.
29. The truck must only be operated in work
areas with sufficient lighting to avoid
danger to personnel and materials.
Additional equipment is necessary to
operate the truck in areas of insufficient
lighting.
30. Jump out from the pedal far-away from
the truck, When a stand-on end-control
truck to step off and away from the truck in
the event of a tip-over or off-dock accident.
23
4 Lifting and transport
4.1 Lifting by crane
Procedures：
– Park the truck
– Open the battery cover（17）. 17
– Fasten the crane tool on the fixed point.

Then the truck can be loaded by the crane.
WARNING
 Steel-wire rope and lifting device should be concrete enough to support the truck
safely.
 Do not stay under the truck when hoisting the truck.
 When hoisting or setting down, it should be stable and slow to avoid collision or
accident.
24
4.2 Securing the truck during transport
Procedures：
– Place the pallet truck on the long-distance transportation facility through loading platform or
hoisting device.
– Fix the belt (52) to the pallet truck and fully tightened, block the wheels if necessary.
Then the pallet truck can be transported.
52
WARNING
 Truck or the trailer must equip with fixing ring.
 Block the pallet truck
 Only use tension belt or fastening belt of good nominal strength.
25
4.3 Transport
The pallet truck is designed for short-distance material handling only and is inappropriate for
long-distance transportation. If needed, the truck must be transported by using lifting device or
platform to place it on truck or trailer. Before operation, fix the pallet truck firmly on the transport
vehicle with belt, and block the wheel to avoid relative motion during transportation.
How to move damaged truck

Brake of this truck is normally closed type, so when there is fault or damage during operation and
the truck cannot move, it is not allowed to drag the truck directly with the drive wheels touching the
ground, but place the truck on tray or raise the drive wheels off ground and then drag the truck.
WARNING
 It’s strictly prohibited to move or drag damaged pallet truck on the ground, otherwise
it may damage the brake system of the pallet truck.
26
5 Battery- Servicing, Recharging, Replacement
5.1 Battery safety precautions
5.1.1 Safety precautions for using lead-acid batteries
1) Users need to create a file for the battery in order to better maintain the battery.
2) When the battery is used for the first time, it may not reach the rated capacity of the battery.
After about 5 ~ 10 times of full charge, the battery will reach normal capacity after it is used
and discharged.
3) The battery is prohibited under the condition of power loss. To ensure the battery life, should
avoid the discharge depth of more than 80% of the rated capacity of the battery. Whether it is
partially discharged or fully discharged, the battery should be immediately charged.
4) The charger output voltage, current and the scope of application must be battery voltage and
capacity to match, otherwise it will seriously affect the battery capacity and life.
5) The charging process, the electrolyte temperature should not exceed 50 ℃, or should try to
cool down. If the temperature still does not drop, you should reduce the charging current or
suspend the charge, until the temperature decreases, and then continue to charge.
6) Charging area is strictly prohibited fireworks. When the battery is charged, it will produce
flammable and explosive gas. When charging, be sure to open the cover of the battery pack
and make sure there is no covering on the battery. At the same time, you must open the filling
cap of each single battery to keep good ventilation environment .
7) The battery must be charged with DC. The charging process must be complete, often
intermittent charge, will affect the battery capacity and life.
8) The battery should be used to avoid over-discharge and long-time high-current discharge,
otherwise it will affect the battery life, serious connection cable may cause overheating and
cause accidents.
9) The battery can not be placed on conductive items to prevent the battery short circuit, it is
strictly prohibited any impurities fall into the battery. Periodically clean the battery cover
surface to ensure that the battery surface is clean and dry.
10) During loading and unloading, proper spreaders should be used to lift the battery box
smoothly, avoid collision, tumbling and squeezing the battery box to prevent the battery from
damaging and electrolyte splashing out.
11) The battery electrolyte is corrosive. During operation, protective equipment such as goggles,
rubber gloves and rubber shoes must be worn. Do not wear watches, metal bracelets,
necklaces and other accessories.
12) It is forbidden to short-circuit or adjust the battery positive and negative, otherwise it will cause
sparks, burning or explosion. Avoid any metal or other conductive objects other than the
battery post compression bolts and ribbons from touching the positive and negative terminals
of the battery.
27
13) Battery is strictly prohibited liquid. Always check and promptly adjust the electrolyte level, so
that it is located between the lowest level and the highest level. If the liquid level is low, add
deionized or distilled water. Prohibition of adding acid in normal use!
14) Do not hit, throw or stampede battery. Do not use the batteries near high-temperature sources,
dangerous goods or dangerous materials, such as fires, heaters, corrosive chemicals,
hazardous machinery and equipment.
15) If the connection of the battery pole is found to be oxidized, wipe it with a dry cloth and polish
it with a fine sandpaper before use. Otherwise, it may cause poor contact and the function
fails.
16) Batteries containing sulfuric acid may cause burns when exposed to sulfuric acid. In case of
accident, first aid and see your doctor on the skin. Eyes: Rinse with water for 15-20 minutes.
Take off immediately; swallow: Drink plenty of water and milk.
5.1.2 Safety precautions for using lithium battery

1) Users need to create a file for lithium batteries in order to better maintain the lithium battery.
2) The new factory battery should not be discharged, it must be fully charged before use.
3) Lithium batteries have a special charger, may not be charged with other types of battery
charger, so as not to charge lithium batteries.
4) Do not open the lithium battery cover maintenance, lithium battery failure, timely contact with
the manufacturer.
5) The battery is not used at a loss of power. To ensure the battery life, should avoid the
discharge depth of more than 80% of the rated capacity of the battery. Whether it is partially
discharged or fully discharged, the battery should be immediately charged.
6) Do not operate the lithium battery vehicle in a temperature exceeding 55 ℃. When the
ambient temperature is below 0 ℃, please stop charging the lithium battery vehicle.
7) It is strictly prohibited to discharge the battery below the termination voltage, please charge it
in time after discharge. Avoid overcharging when charging.
8) The battery inspection and maintenance operations, to be wearing working clothes, wearing
gloves, non-wearing watches, metal bracelets, necklaces and other accessories. The
electrolyte inside the battery is highly corrosive and must be worn during operation.
9) Under no circumstances shall the battery be shorted to the positive and negative terminals,
and any metal or other conductive objects other than the battery post clamping bolt and the
conductive tape should be avoided from touching the positive and negative terminals of the
battery.
10) Do not hit, throw or trample on the battery, do not heat the battery, do not throw the battery
into the water.
11) Do not reverse charge the battery, a reverse charge can cause the battery voltage to zero,
scrapped in advance.
28
12) If the battery smells, heat, discoloration, deformation or use, storage, charging any anomalies,
the battery should be immediately removed from the device or charger and disabled, please
contact the relevant technical departments of manufacturing enterprises or After-sales service
department to get the treatment.
13) If the connection of the battery pole is found to be oxidized, wipe it with a dry cloth and polish
it with a fine sandpaper before use. Otherwise, it may cause poor contact and the function
fails.
14) Do not place the battery near the high temperature sources, dangerous goods or dangerous
materials, such as fire, heaters, corrosive chemicals, hazardous machinery and equipment,
etc. Use and retention; When not in storage, should be placed in a cool dry environment in.
15) Do not immerse the battery in water or other conductive liquids. This operation may cause
personal injury or property damage.
16) Prohibit the use of strong static electricity and strong magnetic field, otherwise easy to
damage the battery safety protection device, bringing security risks.
17) Do not use this series of products with other models or types of batteries in series or in
parallel; prohibit the entire system with lithium-ion battery protection circuit board or battery
management system, the power system in series or in parallel operation, if necessary, please
contact this Company technical department to obtain the correct technical support.
18) Prohibit the use of this series of products by children and other people who lack knowledge of
the safe use of lithium-ion batteries.
19) Do not disassemble, squeeze, puncture, high temperature shelving or baking the battery, to
avoid the battery was too high amplitude vibration, external impact, height drop and so on.
20) It is forbidden to charge the battery without a proper charge protection device (lithium-ion
battery protection circuit board, battery management system, etc.) or using a non-battery
manufacturer approved charging device (charger, DC power supply, etc.).
21) If there is a lot of dust, metal chips or other debris on the top cover and pole of the battery
pack, clean it with compressed air in time and avoid using water or wet objects.
22) When charging and discharging Try to avoid splashing water or other conductive objects on
the battery cover and pole, such as exposure to heavy rain.
23) Once inadvertently make some kind of conductor come into contact with the positive and
negative poles of a single battery or battery pack at the same time to cause a short circuit, be
sure to disconnect the circuit which causes the short circuit in the shortest time.
24) Once the battery has been destructively hit, a large amount of energy stored in the battery will
be released in an instant, the battery can be cooled using a dry powder fire extinguisher.
25) Evacuate persons in the danger area if the battery is cracked or ignited, and immediately
spray with water or soak a smoldering, smoldering battery in the water tank.
26) Risk of fire or smoke: LFP batteries can leak / evaporate or decompose and release
flammable electrolyte under the condition of 150 ℃ if they are improperly used or affected by
29
the environment. Hydrogen fluoride (HF) and phosphorus oxides may form during fire, and
chemical reactions between LIPF6 and water in the electrolyte will produce fluoride and
carbon dioxide.
27) Extinguishing Media: Spray water or smoke or fire-burnt batteries in water. Use type D fire
extinguishers, CO2, dry chemical, or foam fire extinguishers.
28) Swallowing: Ingestion of electrolyte may cause throat or respiratory tract infections,
swallowing, drinking plenty of water and getting medical attention immediately. Make sure the
infected person does not use emetic. Make sure mucus does not block the respiratory tract,
and do not eat other things to unconscious people.
29) Contact with eyes: Electrolyte inside the battery will cause eye irritation and inadvertent
contact. Please do not rub it. Rinse immediately with plenty of water for at least 15 minutes. If
necessary, please go to the hospital for treatment immediately. Otherwise it will hurt your
eyes.
30) Contact with skin: The electrolyte inside the battery may cause skin infections, inadvertent
contact, take off contaminated clothing and wash the infection with plenty of water and soap
for at least 15 minutes, do not rub the ointment.
31) Inhalation: When the battery is leaked or ruptured, the internal components of the battery may
cause mucus, edema and other respiratory tract problems, inadvertently inhaled, to fresh air
and ventilated contaminated area. If necessary, oxygen or artificial respiration.
32) Special Protection Tools: Use breathing apparatus to avoid inhalation of irritating gases. Wear
protective clothing or other devices to prevent body contact with the electrolyte.
5.2 Battery maintenance

5.2.1 Lead-acid battery maintenance
1) The battery should be recharged immediately after each discharge. Check the electrolyte end
of the liquid level height and timely adjustments.
2) Regularly use a damp cloth to clean the surface of the battery. A dry cloth may cause static
electricity and cause accidents. It is recommended to thoroughly clean the battery surface
every two weeks.
3) Regularly check the battery connection terminals are loose or damaged, and timely
adjustment or replacement.
4) Regularly check and promptly adjust the electrolyte level, so that it is located between the
lowest level and the highest level. If the liquid level is low, you need to add deionized water or
distilled water. Prohibition of adding acid in normal use!
30
5) Regularly check the battery box with no water, found that water must be immediately dry. If
the electrolyte flows into the battery box, the use of alkaline water, diluted with water and use
plastic slender tube sucked out, while wiping the battery surface liquid to prevent short circuit.
6) The use of constant current charging the battery every two months, the use of smart
rechargeable batteries must be balanced battery charge once a month.
7) If the battery is not used for a long time, it must be recharged once a month.
5.2.2 Lithium battery maintenance

1) The battery should be recharged immediately after each discharge. According to the actual
state of the battery or battery pack to estimate the battery charging time and discharge time,
pay attention to observe the battery or battery pack abnormalities at the end of charging and
the end of discharge, such as the voltage difference of the battery.
2) When charging, it is necessary to have a professional staff to take care of it. Make sure the
plug and socket are in good contact during charging to ensure that the charging equipment is
working properly to ensure that the battery pack contacts well. If abnormal, need to be
repaired before charging.
3) Check the status of battery voltage, temperature and pressure difference displayed on the
BMS display before charging and discharging to ensure that all values are within the
normal range.
4) If there is a lot of dust, metal scraps or other debris on the battery cover and pole, timely use
compressed air to clean, avoid using water or water soaked objects for cleaning.
5) When charging and discharging, try to avoid splashing water or other conductive materials on
the battery cover and pole, such as exposure to heavy rain.
6) To achieve better results, please contact the manufacturer every six months, and by a factory
technician to conduct a battery performance check and balanced charging. Without this test,
the working hours of lithium batteries may be reduced.
31
5.3 Dimension/Service Weight
CBD20-AC1S-SU CBD30-AC1S-SU CBD20/30-ABC1S-SU CBD20/30-AC1S-ISU
Item CBD20-AZ3S-SU CBD30-AZ3S-SU CBD20/30-ABZ3S-SU CBD20/30-ABC1S-ISU
Length（L） mm 650 650 650 650
Width（W） mm 249 249 249 201
Height（H） mm 625 625 625 430
Allowable
lightest
kg 230 260 200 80
Allowable
heaviest
kg 295 295 295 /
L W
Warning
 Battery weight and dimensions have considerable influence on operational safety of
the truck.
 When installing or replacing battery, be sure that battery in the fixed position of the
towing tractor’s battery box.
32
5.4 Battery operating temperature
Lithium battery charging temperature range: 0℃～40℃, 0℃ below the low-temperature
environment under the conditions of large-scale charging will cause damage to the battery;
Discharge temperature range: -20℃～55℃, low temperature (-20℃～0℃) discharge capacity
than at room temperature may be reduced compared to normal, it is normal; battery can be 40℃～
55℃ Ambient temperature, but the battery ambient temperature is too high, especially in the
long-term high temperature battery environment, will accelerate the aging of the battery material,
shorten the battery life, it is not recommended for long-term use at this temperature.
Ambient temperature exceeding the above range of charge and discharge temperature may
adversely affect the battery performance or damage, may greatly shorten the battery life, it should
be avoided at the above temperature.
WARNING
 Do not charge the lithium battery under low temperature environment below 0℃.
33
5.5 Battery charging
5.5.1 Lead-acid battery charging
Procedures:
– Drive the truck to appointed charging place, park the truck and render if safe.
– Open the battery cover (17).
– Remove the battery plug (38) from the truck socket (39).
– Open the fill cap of each battery cell (40).
– Connect the charging plug (38) to charger socket (41).
– Start the charging procedure according to the charger operation instructions.
– End charging according to the charger operation instructions after the battery is fully charged.
– Remove the battery plug (38) from the charger socket (41).
– Connect the battery plug (38) with truck socket (39) and close the battery cover (17).
– Closed the fill cap of each battery cell (40).
After charging, the truck can be used.
40 38
17
39
38
41
WARNING
 Please charge in the well-ventilated and appointed site.
 Place “No smoking” in the charging site and prepare extinguisher.
 Before charging, please examine wire and electrical outlet for damage, otherwise do
not charge.
 Open the battery cover to release the explosive gas when charging.
 Never place metal object on the battery.
 In the progress of charging, do not take out power switch or battery plug, otherwise
it may damage plug and electrical units. Generally press down the stopping button
firstly, and then take out the plug.
34
5.5.2 Lithium battery charging
Model-type: SPC-24100
Input: AC186～260V/50-60Hz/20A
Output: DC29.2/100A
Safety precautions before charging:

 Please choose to charge in a relatively safe environment (such as to avoid liquid, fire and
other environment).
 The necessary extinguisher (yellow sand and powder fire extinguisher) should be equipped
around the charger so that emergency extinguishing can be carried out under extreme
conditions.
 Before charging, confirm that there is no dust, water and other foreign objects in the charging
gun and charging socket. If there is any foreign matter, it should be cleaned before it can be
charged. Otherwise, the charging gun and charging stand may not be well-connected to
cause heat or even fire.
 Do not modify or disassemble the charging port and charging equipment, which may result in
charging failure and fire.
 After the charging is finished, do not disconnect the charging device when it is wet or standing
in the water, as this may cause electric shock and cause personal injury.
 Provide adequate ventilation during charging. To avoid damage to charger cord plug and
receptacle, do not pull on charger cord plug. Do not twist, rock or bend plug sideways. Do not
use if plug or receptacle is damaged. Loose or feels hot otherwise fire, property damage or
personal injury may result.
 Connect only properly grounded AC outlet. Do not touch uninsulated protion of output
connector or uninsulated battery terminal. Never try to change a frozen battery. There’s the
danger of explosion! Maintenance and repair must only be carried out by a qualified specialist
who is familiar with the dangers involved and aware of relevance regulations.
CAUTION
 When using for the first time, it is recommended that engineers and technicians with
lithium battery forklift electrician's and electrician's knowledge are advised to
participate or carry out the operation under the correct guidance of our company's
technicians. It is forbidden to disassemble the lithium battery forklift battery pack
without authorization. If there are any questions or uncertain questions, please
contact the company's technical department or after-sales service department.
35
Charging steps
– Park the vehicle safely in the
designated charging area as required,
close the switch and unplug the key.
– Insert the charger power plug into a
suitable power outlet.
– Start the charging process.
– Turn on the charger power switch.
– Connect the charger plug to the lithium

battery charging socket.
– Unplug the charging plug after charging

is complete, turn off the charger
power switch, and unplug the
charger plug.
36
37
5.6 Replacing battery
Procedures： 38
– Park the truck and render it safe. 43 39

42
– Open the battery cover (11).
– Remove the battery plug (41) from truck
socket (42), and place the battery plug
and cable into the battery box (41),
ensure that it does not scratch cable
when removing the battery.
– Dismantle fixed handle (45) and battery
fixing clip (46).
44
– Lift upward and remove the right
door(19).
– Park the utility cart(48) at the battery(47).
– Carefully draw the battery (47) to the
utility cart(48) from the truck.
Battery disassembly is finished.
Installation is in the reverse order of
operations and pay attention to the battery
placing position. After installing the new 50
battery, check the cable and plug joint part for
damage.
19
Warning 51
 Battery box is very heavy, be careful
to avoid damage.
 Do not put hands between battery
and truck frame when dismounting
or installing the battery.
 Be careful when closing the battery
cover.
 Disposal to the waste battery should
accord with local environment
regulation. 50
 When replacing the battery, ensure 51
that a battery of the same

specification, dimension and weight
is fitted.
38
6 During running-in
New trucks should initially be run under low-load conditions. In particular the following
requirements should be met within the first 100 hours of operation:
– Battery over discharge must be prevented during initial use.
– Required preventive maintenance must be carried out thoroughly.
– Avoid sudden braking, acceleration or cornering.
– Limit the load weight to 70–80% of the rated load.
– Often check and fasten the fasteners of each joint part.
– Replace hydraulic oil after running-in ends.
39
7 Operation
7.1 Check before operation
In order to safely operate and keep the truck in
good condition, carefully check the truck at the
start of working day or shift.
1) Oil leak and liquid leak check
Check the truck for hydraulic oil, gear oil or
max
electrolyte leak.
min
2) Fork check
Check the fork and see whether bending or
6) Battery check
crazed.
Check the battery cover board. See
3) Front/rear wheel and balance wheel
whether the battery fixed reliable.
check
Check proportion of electrolyte. Refer to
Check the wheel and see whether there is any
“battery” section.
crazed, damaged, or abnormal wearing.
Check the terminal for loose or damage.
Check the wheel fasteners for looseness.
Otherwise it will be adjust or replace.
Inspect whether there is rope on the wheel.
Plug in and turn on the key switch.

7) Instrument display check
4) Check front fork and linkage
Refer to instrument part.
mechanism 8) Lifting and lowering button
Check the fork and linkage mechanism, see Press the lifting button and check the fork
whether bending or crazed.
lifting condition. Press the lowering button,
Whether appear interfere when move, check the fork lowering condition. Check if the
movement point wear whether severe. lifting system has abnormal sound.
5) Hydraulic oil check 9) Forward and reverse running condition
Open the cover, check if the oil level is Tilt the handle to some degree, gradually
within the scales. Add oil when press the accelerator button to the outside of
insufficient. the body with thumb, and inspect the forward
running condition; gradually press the
accelerator button to the inside of the body
40
with thumb, and inspect the reverse running
condition.
10) Brake system
When the truck run forward or backward, push
the handle to vertical position or press to level
position to check the brake condition.
11) Steering system
Left or right turn the handle to make the truck
run around 3 turns, and then check if the
steering system is normal.
12) Horn
Press the horn button to check sound.
13) Appearance
Check the truck appearance for clean, rust or
paint spalling.
14) Others
Check whether there is any abnormal noise,
whether wiring is regular or fastener loosens
etc.
41
7.2 Starting up
Procedures:
– Driver steps on the pedal（9）.
– Pull the emergency disconnect switch(2) upward.
– Insert the key in the switch lock (1), and then right turn to “ON” until reaching the stop.
After instrument self-check finished, it displays the current battery capacity, and the truck is
started.
OFF O
N
Caution
 Checks and operations to be performed before starting daily work.
42
7.3 Travelling
Procedures：
– Step on the pedal（9）.
– Place the travel switch(25) to the desired travelling direction, such as forward(F) or
backward(R), the truck brake system is released and travel to the selected direction.
– Control the truck speed by controlling the turning angle of travel switch(25). Release travel
switch(25), the travel switch return to position “0” automatically.
F
0
R
3
25 F
Waning
 Turns, cutting obliquely over slopes or parking on slopes is not permitted.
 Inclines must only be negotiated at slow speed, with the driver ready to brake at any
moment.
 Travel along required route. The road must be clean and non-slipping and meet the
technical specification of the truck.
7.4 Steering
Procedures：
– Turn the control handle(3)to left or right.
– The truck will move in the selected direction.
Note： Truck speed reduces automatically when steering.
43
7.5 Braking
The truck can be braked in the following three ways：
– Using brake release(regenerative brake)
– Using reverse brake
– Using emergency stop button(when emergency)
Using brake release
Procedures：
– Release travel switch(25) during driving, when the travel switch is at “0 “, the pallet truck will
proceed regenerative brake by rolling down until it stands still. After that, parking brake starts.
Caution
 The energy recovery of battery is realized by applying regenerative brake, which
achieves more working hours.
Using reverse brake

– Switch the travel switch(25) to the opposite direction during driving.
The pallet truck will brake by inverse current until it drives to the opposite direction.
Using emergency stop switch to brake
Procedures：
– Press emergency stop button（2）.
Then all the power function is disconnected, pallet truck brakes forcibly (electromagnetic brake)
until it stands still.
Pull up the emergency stop switch (2) when starting for the next time.
Warning
 Only apply service brake to brake when there is danger.
 Do not use emergency stop button as service brake in daily work.
44
7.6 Picking up goods
Procedures：
– Drive the forklift slowly beside the tray.
– Insert the forks under the tray slowly, until the fork back touches the tray.
– Depress operating key “Lifting” (27) until the required lifting height has been reached.
27 27
28 28
Loads have been raised.
Caution
 The driver must stand on the pedal(17), and then use the lifting function.
45
7.7 Transporting goods
Procedures：
– Control speed according to driving routine and the goods.
– Stably accelerate and brake vehicle, and keep driving in constant speed.
– Pay attention to other persons and vehicles at the intersection and the passage.
– Drive the truck by leading of other staff when vision is restricted.
Caution
 When going uphill with loads, keep the forks moving forward; when going downhill,
drive backward.
 It’s strictly prohibited traverse the slope or turn round on the slop.
46
7.8 Setting down goods
Procedures：
– Drive the forklift slowly at the goods shelf.
– Depress operating key “Lowering” (28), until the fork separates from the tray.
27 27
28 28
– Get forks out from the tray carefully.
Loads are finished setting down.
Caution
 Be careful when lowering loads, and insure the loads or truck are against damage.
47
7.9 Parking the truck as required
Park the truck according to the following steps after daily work.
Procedures：
– Park the truck to rendered place.
– Lower the fork to the lowest position.
– Turn the key left to “OFF”, and remove the key from the switch lock(1).
– Depress the emergency stop switch(2), and cut all electric function
Truck is parked.
48
8 Stop use and store the forklift
8.1 Store for a long period
If the truck parks for more than one month, you should park the truck according to the following
ways.
– Park the truck in well-ventilated, dry and no direct sunlight indoor. Meanwhile, avoid large
temperature variation, and prevent from obvious moisture, dust and corrosive gas.
– Remove the battery plug.
– Fully check the truck, especially check the wheel damage.
– Check gear oil, hydraulic oil and electrolyte for leakage.
– Apply lubrication grease.
– Check specific gravity of electrolyte and liquid level once a month.
– Do equalizing charge to the battery once a month.
– In order to avoid rust of bearing or other parts, operate the truck every six months, and check
if truck works smoothly or there is abnormal sound.
– Apply a thin layer of anti-rust oil to the mechanical part without coating every six months.
– Cover the whole truck..
8.2 Recommissioning after storing for a long time

– Remove rust preventive oil on exposed parts.
– Clean impurity and water on the hydraulic oil tank.
– Recharge battery, fit on truck and connect.
– Carefully check before start. Inspect starting, travelling, slowing down, steering, braking and
parking etc. function.
49
9 Maintenance
9.1 Maintenance summary
– The forklift must be regularly checked and maintained to keep it in good working order.
– Inspection and maintenance are often easily overlooked. Early detection enables problems to
be settled in a timely manner.
– Use original Hangcha Group spare parts.
– Do not use different types of oil when changing or topping up oil. Waste oil and battery fluid
must not be poured away indiscriminately, but recycled or disposed of in accordance with
local environmental laws and regulations.
– Establish and follow a comprehensive maintenance and service schedule.
– Maintain current and complete records of all maintenance and servicing activities.
– Untrained personnel must not attempt to carry out truck repairs.
Ca uti on
 No open flames.
 Turn off the key switch, depress the emergency stop switch and disconnect the
battery plug before carrying out any servicing or maintenance. （ except some
troubleshooting）.
 Clean electrical parts with compressed air. Do not clean with water.
 Do not put your hands, feet or any part of your body between the mast and
dashboard.
 When the working environment is severe, maintain in advance.
50
9.2 Periodic maintenance schedule
D= work every 8 hours(or per day)
W= work every 40 hours(or per week)
M= work every166 hours(or per month)
T= work every 500 hours(or 3 months)
S= work every 1000hours(or 6 months)

〇 — Check, revise, adjust
× — Replace
Battery
Service
Service required Tools D W M T S
item
Eyeballi
Electrolyte level 〇〇〇〇
ng
Densim
Electrolyte proportion 〇〇〇〇
eter
Battery quantity 〇〇〇〇〇
Storage battery
Terminal looseness 〇〇〇〇〇
Looseness of connecting wire 〇〇〇〇〇
Cleanness of the battery surface 〇〇〇〇
If there are tools on the battery 〇〇〇〇〇
The tightness and smoothness of

〇〇〇〇
air cap
Far away from firing 〇〇〇〇〇
Controller
Service
item
Check wear condition of connector 〇〇
Check the running condition of

Controller
〇〇
contactor
Check interlock inching switch for
〇〇〇〇
running
Check the connection among motor,
〇〇
battery and power unit
51
Motor
Service
item
Clean the foreign body on the motor 〇〇〇〇
Clean or replace the bearing 〇

DC motor
Check the carbon brush and

commutator for worn, whether spring 〇〇or× 〇or×
is normal
Whether the connection is correct and
〇〇〇
firm.
Brush carbon powder on shift plate
〇〇
and shift device.
Clean the foreign body on the motor 〇〇〇〇
Clean or replace the bearing 〇

AC motor
Check if there is abnormal vibration,

〇〇or× 〇or×
noise, if pedestal is firm.
Whether the connection is correct and
〇〇〇
firm.
Check if the temperature or current is
〇〇
normal.
Driving system
Service
item
Reduction box
Check for noise 〇〇〇〇〇
Check for leakage 〇〇〇〇〇
Add lubricating grease ×

Steering mechanism
Bearing lubrication 〇〇〇〇
Check if the steering flexible 〇〇〇〇〇
Check for noise 〇〇〇〇〇
Control handle swivel angle 〇〇〇〇〇
Wheel（Drive wheel, auxiliary wheel, load wheel）
Service
item
Eyeballi
Check for abrasion or cracks 〇〇〇〇〇
ng
Check for bolt fastening and
Wheel 〇〇〇〇
re-tighten.
Check if there is foreign body like rope
〇〇〇〇〇
on the wheel
52
Brake system
Service
item
Brake inching Electromagnetic brake
Check for brake condition when the

control handle on horizontal position 〇〇〇〇〇
switch
and vertical position.

Check the inching switch for
〇〇〇
looseness or damage.
Check the installation for fastening. 〇〇〇
Check the surface abrasion for

〇〇
equality.
Check if the clearance is proper and
〇〇
adjust, if necessary.
Check the brake for flexibility and
〇〇〇〇〇
effective.
Hydraulic system
Service
item
166hrs
Hydraulic reservoir
for the
Check for oil level, change oil 〇〇〇 ×
first
time
Clean suction strainer 〇
Clean foreign matter 〇
Check for block, return spring stuck or

solenoid
〇〇〇
valve
damage
Check for wiring looseness. 〇〇〇
Check for oil leakage 〇〇〇〇〇

Safety valve
Check for safety valve operation

〇〇〇
condition.
Oil
pressur
Measure safety valve pressure 〇
e
gauge
Check for oil leak, looseness,
Piping, joint
〇〇〇
collapse, deformation and damage
×
Replace hoses. 1-2year
s
Check hydraulic pump for oil leakage
Hydrauli
〇〇〇〇〇
c pump
or noise
Check pump drive gear for wear 〇
Check for inching switch work

switch
inching
Lifting
〇〇〇
condition.
Check inching switch for looseness or
〇〇〇
damage.
53
Lifting assembly
Service
item
Check link mechanism for tension,
〇〇〇〇〇
damage or rust
Check if there is abrasion between
shaft and bearing of front and rear 〇〇〇
fork.
Link mechanism
Check if there is deformation or

fracture on the upper and down 〇〇〇
connecting rod.
Check if there is crack or fracture on
〇〇〇〇〇
front fork or rear fork.
Check each joint for looseness 〇〇〇
Pin shaft lubrication 〇〇〇
Check piston rod, rod screw and Test

connection for looseness, deformation hamme 〇〇〇〇〇
Lifting cylinder
or damage r
Check for operation 〇〇〇〇〇
Check for oil leak 〇〇〇〇〇
Check lifting cylinder fixed bolt for

〇〇
looseness.
Check forks for damage,
〇〇〇
deformation or wear
Fork
Check fork base and hook welding for

〇〇〇
defective cracks or wear
Others
Service item Service required Tools D W M T S
Wire damage or looseness 〇〇〇〇

Wire
Looseness of circuit joint 〇〇〇
Emergency
disconnect Check for work condition 〇〇〇〇〇
switch
Direction and
speed control Check for work condition 〇〇〇〇〇
button
Lifting, lowering
Check for work condition 〇〇〇〇〇
switch
Check for work and
Horn 〇〇〇〇〇
installation condition
Check meters for proper
Meters 〇〇〇〇〇
operation
Pedal(only for Check the pedal if folded up
〇〇〇〇〇
stand-on type) and down normally.
Arm guard (only
for stand-on If the arm guard can fold up. 〇〇〇〇〇
type)
54
9.3 Truck lubrication
C
A C
C
B
Filler plug for hydraulic oil

Filler plug for gear oil
Drain plug for gear oil
Gliding surfaces
Grease nipples
Code Designation Mark, code Remark
Normally：L- HM32
A Hydraulic oil High and cold environment：L- Hydraulic oil tank
HV32
B Gear oil GL-5 85W/90 Reduction box
3# Automobile general lithium Nipples and glinding

C Grease
base lubricant surfaces
55
Replace gear oil
– Park the truck on level ground.
– Clean filler plug and drain plug.
– Screw off filler plug（46）.
– Place a proper container under drain
plug(47), screw off the drain plug(47), and 46
discharge the oil to the container.

– After fully discharging the oil in the reduction
box, retighten the drain plug(47).
– Add appointed gear oil (GL-5 85W/90) from
oil port. Add oil with the help of funnel and
tube for convenience. When the oil
overflows, it means the adding amount is
enough.
– Retighten filler plug(46) and clean the
reduction surface.
47
Warning
 The discharged waste oil must be
disposed according to relevant
stipulations of the state and never
dump at will.
OIL
46
56
9.4 Replace the key safe parts periodically
Users should replace the parts periodically according to the following table. If the part is abnormal
before the replacing time, it should be replaced immediately.
Key safe part’s description Term of using (year)
Hydraulic hose for lifting system 1-2
High-pressure hose, hose for hydraulic

2
system
Inner sealing element, rubber matter of the
2
hydrulic system
9.5 Tighten wheel nut

Retighten the wheel nut after breaking-in finished. Periodically check and tighten wheel nut.
– Tighten the wheel nut(45) with torque spanner according to specified order.
– First tighten with 10N.m torque.
– Then tighten with 80N.m torque.
2
45
4
5
1
3
57
9.6 Take down rear closure plate and hood
Procedures： ,
16 54
– Park truck on level ground.
– Remove four hexagon flange bolts(53) that
fix the rear closure plate(7) with socket
spanner, and then lift the rear closure
plate(7) up, then it is dismantled.
15
– Remove one hexagon flange bolt(53) and
four hexagon flange bolts(54) that fix the
hood, and then lift the hood(15) up, then it is
dismantled.
– Remove one hexagon flange bolt(54) that fix 7
the small hood(16), and then lift the small
hood(16) up, then it is dismantled. 53
Rear closure plate and hood are dismantled.
To install, reverse the order of dismantle.
Warning
 Do not operate the truck after dismantling rear enclosure plate and hood.
 After dismantling rear enclosure plate and hood, discharge controller and other
energy storage part before maintenance.
58
59
PartⅡ Structure, principle and
maintenance
1 Drive system
Drive system for stand-on truck adopts flexible coupling of truck frame and four-bar linkage, and is
divided into two types as manual steering and electric steering according to steering mode:
Drive system is mainly consisted of linkage, drive seat, reduction box, drive wheel, drive motor and
electromagnetic brake etc..
9 8
2
6
3
5
1. Linkage 6. Steering pinion （ only for

2. Drive seat electric steering）
3. Steering big gear（only 7. Steering motor （ only for
for electric steering） electric steering）
4. Drive wheel 8. Drive motor
5. Reduction box 9. Electromagnetic brake
Fig.2-1 Drive unit structure
60
1.1 Reduction gearbox
Reduction gearbox of this truck is a small and light controllable wheel driving device, which adopts
double reduction, the first stage adopts cylindric spiral gear reduction and the second stage
adopts planetary reduction. This reduction gear box owns traits like small size, light weight, large
transmission ratio, small radius of gyration, high efficient and simple structure, which enables turn
on site and equip with motor vertically thus cause the radius of gyration on the carriage small.
Moreover, this reduction gear box does not need to shift, but realize direction shift (forward or
reverse) directly by motor positive inversion, and is easy to use and maintain.
1. Housing 12.Gasket 23.O-ring

2. Adjusting pad 13.Hexagon bolt 24.Hexagon socket cap screws
3. Tapered roller bearing 14. Adjusting pad 25.Breather plug assembly
4. Gasket 15. Spiral bevel driving gear 26.Cover plate
5. Oil seal 16. Tapered roller bearing 27.O-ring
6. Connecting flange 17.Driven gear 28.Sealing gasket
7. Stud 18. Adjusting pad 29. Magnetic plug
8. Hexagon nut with flange 19.Gasket 30.Hexagonal socket head plug
9. Tapered roller bearing 20.Nut 31.O-ring
10. Spiral bevel driven gear 21.Driving gear
11. Adjusting pad 22. Terminal pad
Fig. 2-1 Reduction gearbox structure
61
1.1.1 Working principle
Simple picture of reduction gearbox refers to Fig.2-2, motor driving gear(1) drives driven gear (2),
driven gear (2) drives drive spiral bevel gear (3) to transfer to driven spiral bevel gear (4), then the
driven spiral bevel gear (4) drives the output of output flange (5). Drive unit transmission circuit:
drive unit directly drives the driving gear through motor. Power transmission order is that from 1
（drive motor） to 2 (driving gear) to 3 (driven gear) to 4(gear shaft) to 5(annular gear) to drive the
wheel output. Drive system does not need gear shift, reversing, but realize direction shift (forward
or reverse) directly by motor positive inversion
1. Drive gear(pinion gear)

2. Driven gear
3. Driving spiral bevel gear
4.Driven gear
5. Output flange
Fig.2-2 Drive diagram of
reduction gear box
62
1.1.2 Disassembly and assembly order
Disassemble the reduction gearbox according to the following sequence.
– Dismantle driving wheel(wheel).
– Open the drain plug and discharge the oil.
– Dismantle pivotal bearing and up housing assembly.
– Dismantle driven cylindrical gear.
– Open the cap, dismantle spiral bevel driven gear and output flange etc.
1.1.3 Notice to installment and use
– Before installing, wipe off the oil on the shell surface
– In case that the oil leaks during use, do not dismount and disassemble the product.
– Prevent the assembling surface and exposed flange from being knocked or damaged,
otherwise it may influence the installment and use precision.
– Working oil should keep clean, the new machine should change new oil in 50 hours for the
first use and every 1000 hours later.
– Work oil should meet the grade requirement（GL-5 85W/90）.
1.1.4 Fault diagnosis and corrections
Condition Possible reason Corrections
Lack oil Add oil
Low transmission efficient and

Quantity of the oil is ineligible. Replace
overheat oil temperature
Gear or bearing is damaged Replace
Unstable running Gear or bearing damage Replace
Wear or damage of oil seal Replace

Oil leakage
Leakage from the gasket Tighten bolt or replace
63
1.2 Motor
Traction motor
Traction motor is three phase AC motor, maintenance free, but need check and clean periodically.
When fastening the upper nut, lock the lower nut to avoid looseness, recommended tightening
torque is T=10.2～12.4N.m.
Rated Rated Rated Max. Rated Insulation Frequency Duty Temperature Remark
power voltage current current speed grade Hz
kW V A A r/min min ℃
Pedestrian-
1.5 16 90 170 2295 H 79.6 S2-60 40
type
2.2 16 125 235 2985 H 103 S2-60 40 Stand-on
W V U
Lifting bolt
Speed sensor
Thermistor
64
Steering motor
DC steering motor is a permanent magnet brush DC motor equipped with planetary reduction
gearbox.
○
1 Output shaft
○
2 Output shaft bearing
○
3 Internal gear
○
4 Second stage planet gear
○
5 Split-type planetary carrier
○
6 First stage planet gear
○
7 Motor shaft
○
8 Motor shaft bearing
○
9 Motor enclosure
○
10 Motor stator
○
11 Motor rotor
○
12 Motor rear cover
Technical parameter
Rated Rated Rated Rated Servicelife Rated Duty Insulation Protection Temperature
power voltage current speed ofbrush torque min grade grade
kW V A r/min h N.m ℃
0.2 24 13 3300 2000 0.562 S2-10 B IP20 -10～40
Motor wiring and rotation direction
Observe motor direction from motor output shaft：
When red outgoing line connects the positive power and black
outgoing line connects the negative power, output shaft end rotates
clockwise.
When red outgoing line connects the negative power and black
outgoing line connects the positive power, output shaft end rotates
counterclockwise.
Replace the brush

Service life of the brush is 2000hours. 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,
65
motor should work under limited speed to ensure safety until the
brush working surface polishes.
66
Notices for motor use
– The motor is only used under the work condition that specified on the nameplate and
in the manual. Otherwise there is danger of electric shock, injury or device damage.
– Stator parts have adjusted at test station, so users should not dismantle or adjust at will.
– Keep clear and dry around the motor. Do not put other goods on or in the motor.
– Often clean sand and other adhesion on the motor in order not to affect its heat dissipation.
– Never overloaded.
– Never leave the motor near the strong magnetic objects.
– Make sure the correct of input voltage grade.
– If there is any abnormal smell, stop and inspect immediately.
– The cabling between motor and controller should be as short as possible.
– If there is any malfunction during the operating time, power off , stop and inspect immediately,
such as electric leakage, speed dropping suddenly, vibration sharply, big noise, overheat and
smoking or smoking motor terminal bolt.
– Check for overheat of motor regularly during the working time.
– Check regularly for securely installation of the motor, and check for looseness, smoke and
insulation aging of the motor terminal bolt.
– Do not maintain in the charged state, make sure operate without power. Otherwise there
maybe unknown danger.
– Do not use in the flammable and combustible environment, otherwise there may be explosion,
fire, electric shock, injury or machine damage.
– Transportation, installation, wiring, travelling, operation, maintenance or repair must be
carried out by professional personnel. Otherwise there may be explosion, fire, electric shock,
injury or machine damage.
– Do not put hands or goods at the motor opening, otherwise there is danger of electric shock,
injury or device damage
– Do not use damaged motor. Otherwise there is danger of injury and fire.
– Do not make any change to the motor arbitrarily.
67
AC motor fault diagnosis
Fault Probable cause

①Power is not on(at least two phase off)
After power is on, the motor does not
②Fuse fusing(at least two phase fusing)
rotate, but without noise, odor or
③Overcurrent relay adjusts too small
smoke.
④Wiring error of control equipment
①Lack one phase power, or reverse connection of
stator coil one phase
After power is on, the motor does not ②Short circuit of stator winding
rotate and fuse burnout. ③Grounding of stator winding
④Wiring error of stator winding
⑤Fuse section too small.
① Open circuit of stator, rotor winding(one phase
disconnection) or one phase power is off.
②Start and end of the winding outgoing line wrongly
connect or internal winding oppositely connect.
③Power return contact loosens and contact resistance
After power is on, the motor does not
is large.
rotate with buzzing noise.
④Motor load too large or rotator gets stuck.
⑤Power voltage too low.
⑥Small motor assembles too tight or bearing grease
too hard.
⑦Bearing gets stuck.
①Power voltage too low.
②△Motor wrongly connected to Y
③Cage rotor open weld or crack
Motor starts hard, and the motor
④Local coil of stator and rotor wrongly or oppositely
speed is much lower than rated
connected.
speed with rated load.
⑤Add too much number of windings when repair motor
winding.
⑥Motor overload.
①When rewind, numbers of stator three-phase winding
is not equal.
Current is unbalance when motor
②Two ends of winding wrongly connected
without load and three phases differ a
③Unbalance power voltage.
lot.
④There is interturn short circuit or coil oppositely
connected in the winding.
Motor without load, while loaded, ①Guide bar of cage rotor open weld or crack
ammeter indicator is unstable and ②Wound rotor fault(one phase open circuit) or bad
swings. brush and collecting ring short circuiting device contact.
68
①Reduce too much number of stator windings when
repair motor winding.
②Power voltage too high.
③Y connected motor wrongly connect to Δ
Motor without load, current is
④During motor assemble, rotor oppositely connects,
balance, but the value is large.
make stator core unaligned, effective length shortens.
⑤Air gap over large or uneven.
⑥When remove old winding for overhaul, use improper
way that burn the iron core.
①Insulation paper of rotor and stator or slot wedge

rubs.
②There is foreign body as sand in oil or bearing wear.
③Stator and rotor core loosen.
Abnormal noise when motor runs ④Bearing lack oil.
⑤Air duct stuffing or fan rub the fan housing.
⑥Stator and rotor core rub.
⑦Power voltage too high or imbalance.
⑧Wrongly stator winding or short circuit.
①Too big wear bearing clearance
②Uneven air gap
③Rotor imbalance
④Revolving shaft bend.
Big motor vibration during running ⑤Iron core deforms or loosens.
⑥Housing or basic capacity is insufficient.
⑦Motor foot screw loosen
⑧Open circuit of cage rotor open welding, open circuit
of wound rotor, or winding fault with stator.
①Over much or few grease
②Bad oil quantity and contains impurity.
③Mismatch between bearing and journal or end
Bearing overheat. cap(too loose or too tight)
④Eccentricity of bearing bore, rub with the axle.
⑤Motor end cap or bearing cap not even assembled
⑥Coupling between motor and load not adjust
69
⑦Too large or too small bearing clearance
⑧Motor axle bend.
①Too high power voltage, greatly increase the core
heating.
②Too low power voltage, the motor drives rated load,
over large current heats the winding.
③When remove winding for overhaul, use improper
way that burn the iron core.
④Rotor and stator core rub.
Motor overheating or smoking
⑤Motor overloads or start up frequently.
⑥Cage rotor break.
⑦Motor lacks phase, two phases run.
⑧After rewinding, dipping paint of stator winding is
improper.
⑨In high temperature, much dirt on the motor surface
or ventilation duct block.
70
DC motor fault diagnosis

All copper sheet blacken ①Pressure of the brush is not right
①Short circuit of commutator segments
Commutator segments blacken in ②Short circuit of armature coils
group according to certain sequence
③ The welding of commutator segments and armature
coils is not good or short circuit.
Commutator segments blacken, but ①Center line shift of the commutator
without sequence ②Rough, un-round of the commutator surface
①Motor vibrate
②Gap between brush and brush box is too large
③ The distance between brush box and commutator
Wear, color change and fracture of working surface is too long
brush
④The mica between commutator segments extrudes
⑤Brush material is not good.
⑥Trade mark of brush is not right
①Overloaded of motor
②Commutator is not clear, smooth or round
③Mica plate or part commutator segment extrude
④Brush does not grind well
Large spark ⑤Brush pressure is not large enough
⑥Incorrect brush trade mark
⑦Brush locked in the brush box
⑧Brush carrier loosen or vibrate
⑨Incorrect pole polarity and sequence
①Large brush spark
② Electrical brush and flexible conductor have bad
Brush and brush wire overheat
contact
③Small flexible conductor area
Noise in the brush 1 Uneven commutator surface
71
1.3 Electromagnetic brake
The adopted brake of this truck is spring weighted electromagnetic brake. This brake is one-chip
brake, owns two friction surfaces. It can generate strong braking torque in the power-off position
by pressure spring, electromagnetic effect realizes the release of brake.
1.Mounting screw
2.Stator component
6
5
3.Braking friction plate
4 4.Axle sleeve
3
5.Friction disk
2
6. Dust cover
1
Fig.2-1 Parts drawing of
electromagnetic brake
1.3.1 Working principle

Shaft(9) connects spline housing(4)through flat key; spline housing(4) connects friction disk
assembly(3) through spline. When the stator (11) is off power, spring (10) generated force works
on the armature(8), friction disk assembly(3) that drives the shaft(9) to rotate, grips between
armature(8) and friction disk(5), thus generates braking torque. For this moment, there will be a
gap “Z” between armature(8) and brake friction plate(3). When need to release the brake,
stator(11) connects the DC, then the generated magnetic field draws the armature(8) move to the
stator(11), spring(10) is compressed when armature(8) moves, at this time, friction disk
assembly(3) is loosened, brake is released.
72
1. Mounting screw
6
3. Braking friction plate
4. Axle sleeve
1 5. Friction disk
7
6. Dust cover
5
7. Hollow screw
3
8 8. Armature
9 9. Motor shaft
4
10.Pressure spring
10
11 11.Stator
Z. Air gap
Z
Fig. 2-5 Structure of
electromagnetic brake
73
1.3.2 Install the brake
– Put the flat key(12) in the key groove of motor shaft(9), press 13
4 12
the shaft sleeve on the shaft(9), and fix with inner snap
9
spring(13).
– Put friction disk(5) on the motor end face.
– Cover the braking friction plate above the shaft sleeve.
– Assemble stator component(2) and three mounting
screws(1). Note: remove three rubber pads from the stator
component. 14
Z 15
6
– Screw down there mounting screws(1) with torque wrench,
and check braking air gap “Z” with feeler gauge(15).
74
– Put dust cover（6）.
– Connect brake wire.
Warning
 No wire surface damage to avoid circuit damage.
 Do not process product locating surface or hole voluntarily so as not to affect
magnet loop.
 Do not force too much when press fitting on the motor shaft, do not damage the
friction surface, remove burrs on the mounting hole and surface, install shaft sleeve
on the shaft, and fix it with axial snap spring.
 Measure the brake connected DC voltage, and compare the voltage with the one
stipulated on the nameplate. 10% deviation is allowable.

 During installation and use of the brake, keep away from oil dirt.
U=x V DC±10%
OIL
75
1.3.3 Adjust brake air gap
Rated air gap ”Z” will be large for wear. Make sure the brake get enough brake torque, readjust air
gap before the air gap reaches the largest air gap value. Air gap can be adjusted repeatedly, when
the thickness of friction braking plate reaches the allowable minimum thickness (refer to
specification table), replace the friction disk plate.
When the air gap exceeds maximum air gas value, the brake may be unable to release, friction
braking plate burn out, braking force or retentivity decreases, noises increase, or even cause
severe accident. So check and re-adjust the air gap periodically, and cut off the truck general
power.
Specifications
Rated Rated Rated air Max. air Min. rotor Tightening torque of
torque power gap gap thickness mounting screw
16 N.m 30 W 0.2 mm 0.5 mm 8.1mm 9.5 N.m
When the brake is off power, adjust three hollow screws(7), adjust the air gap between armature
and friction brake plate to rated value “Z” with the help of feeler gauge, and ensure that air gap of
each direction is the same. Procedures are as follows”
– Screw off three mounting screws(1).
– Rotate three hollow screws(7) clockwise a little with spanner.
– Screw down mounting screws(1).
– Use feeler gauge to check if air gap ”Z” meets requirement. Readjust until ”Z” reaches the
rated range.
7
Z
-
+
In general working condition, the first air gap adjustment should proceed after brake working for
1500 ～ 2000hours, frequency of air gap adjustment is 6 months a time. In severe working
condition, like frequently brake, repeatedly sudden brake, the first adjustment can be shortened
and adjust the interval.
76
1.3.4 Maintenance
– If work in high temperature environment for long time, please prevent rust, it may influence
use if there is rust on the suction surface.
– Do not touch the friction surface with hand, no oil stain, otherwise it cannot reach the
maximum torque.
– General use environment temperature is -10℃～+40℃.
– Please check periodically, and the check item : if the switch motion is normal; if there is noise;
if there is abnormal heating; if any impurity, oil stain mixed into friction part or rotating part; if
clearance of friction part is proper, exciting voltage normal.
77
1.3.5 Common fault and troubleshooting
Fault Probable cause Corrective action

Power is obstructed Connect
Too low exciting voltage Check voltage and adjust.
Brake does not work Improper air gap Adjust air gap
Stator coil breaks Replace stator
Oil dirt mixed in Clean oil dirt

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

Unstable operation in previous Breaking-in for a while
use
Slipping Reduce load or replace large

Large load
specification
Adjust load peak or large the
Large load change
specification
Too high exciting voltage Check voltage and adjust.

Clutch or motor interfere to the Check control circuit, eliminate
brake interference
High temperature
High environment temperature Set ventilation
High operating frequency Adjust to proper frequency
Over large load Reduce load

Product service environment
Silence design
needs silence
Impurity mixed in. Clear away the impurity
Large noise
Bad mounting Replace mounting surface or shaft
Large rotational inertia or Reduce rotational inertia or
dynamic unbalance value dynamic unbalance value
78
1.4 Dismantle the driving system from the truck
1）Open rear hood assembly.
2 ） Remove four fixed bolts on the steering rocker

arm(neglect this step for electric steering truck)
Changes: change to electric steering drawing and
disassembly ways.
3 ） Remove wires that connect the driving
system(like motor, brake wiring)
4）Remove the connecting pin between linkage and
truck frame.
5）Hoist out the driving system.
To install, reverse the order of disassembly.
79
2 Hydraulic system
Hydraulic system is mainly composed of hydraulic unit, left/right lifting cylinder, pressure cylinder
and rubber tube etc.
5
6 7
3
1
1. Hydraulic unit
2. Left lifting cylinder
3. Right lifting cylinder
4. Pressure cylinder
5. Oil pipe assembly
6. Rubber tube assembly
7. Rubber tube assembly
Fig.2-6 Hydraulic system
80
2.1 Hydraulic system working principle
Brief introduction to the working principle of hydraulic system：
When depressing the lifting button of the control handle, lifting motor works, drive the hydraulic
pump through coupling device, hydraulic oil enters lifting cylinder through one-way valve, and
forks lift.
When depressing the lowering button of the control handle, lifting motor does not rotate, the
solenoid valve open by this time, hydraulic oil in the lifting cylinder returns to the oil tank through
solenoid valve and governor valve, and the forks drop.
Hydraulic schematic diagram
81
2.2 Hydraulic unit
The truck adopts combined hydraulic unit, and is composed of DC motor, relay, shaft coupling,
valve seat and valves(solenoid valve, safety valve, one-way valve, governor valve and oil
blockage), gear pump, oil pipe, oil filter and oil tank etc.
Parameter
Pump motor Rated voltage/power 24V / 2.2kW
Relay Rated voltage/current 24V/150A
Gear pump Rated displacement 1.66mL/r
Solenoid valve 24V DC coil Normally-closed valve element
Speed limit valve 6L/min
Overflow valve（Safety valve）set pressure 2t:15.0MPa / 3t:16.5MPa
Filter precision of suction filter 250um
Fluid port thread G1/4”
Oil temperature -10℃～+70℃
82
Adjust the pressure of hydraulic unit
The pressure has been adjusted before sold, and users do not need adjust under in general
conditions. If user needs to adjust, according to the actual situation, adjust the overflow valve
pressure by pressure regulating valve knob, but can not exceed the nominal pressure of the
system. Adjustment method is as follows:
– Take apart the cover.
– Connect oil pressure gauge to the pressure mouth
– Loosen main safety valve locking nut, screw the adjusting screw in clockwise, and
increase the main safety valve pressure. Screw the adjusting screw in counterclockwise,
and reduce the main safety valve pressure.
– Adjust to meet the requirement.
– Re-lock the locknut, and install into the cover.
Warning
Overflow valve not only works as pressure adjusting, but also is an element for safe
pressure limiting in the system. So the user is better not to adjust the overflow valve
during use.
2
1
4
-
+
83
Maintenance
– After the first 100 hours of operation with hydraulic oil being added, replace new oil. Replace
new oil every half year(about1000 working hours) later. Hydraulic oil must be filtered when
adding, and the filter fineness is not less than 200um.
– Hydraulic unit cannot eliminate impurity in the hydraulic cylinder, so keep the clean of
executive component and pipeline to prevent dirty get into the hydraulic system and cause
the failure of control valve.
– Keep oil quantity in the hydraulic oil tank, add oil after certain working cycles. If the pump
inhales air, it will cause the damage of pump and sealing.
– Apply hydraulic oil with high viscosity in high working temperature, and low viscosity in low
working temperature. Refer to “Truck used oil and lubrication”.
– Note that power characteristic (DC, AC) and voltage are in accordance with mark when motor
and magnetic valve wiring. Motor reverse rotation and no oil idling are absolutely forbidden.
84
2.3 Dismantle the hydraulic unit from the truck
1) Dismantle the hood.
2) Dismantle the connector of the hydraulic unit
and the cylinder.
3) Remove the wiring from the motor, contactor
and control valve.
4) Remove the tightening bolt that fix hydraulic
unit.
5) Take out the hydraulic unit.

Assembling order is opposite to the disassembling order.
85
2.4 Dismantle the lifting cylinder from the truck or replace
1) Take apart the rear hood assembly.
2) Remove pipe joint on the cylinder.
3) Remove fixed screws at the end of the cylinder.
4) Remove pin on the upper support point of the
cylinder.
5) Take out the lifting cylinder, replace a new one
or repair.
Assembling order is opposite to the disassembling order.
86
2.5 Hydraulic system fault diagnosis and correction
Failure
Fault Check and troubleshooting
component
Check if motor works normally, power supply is normal, or
Motor
motor meets steering requirement.
Disconnect the connector of hydraulic unit and cylinder, jog
Forks can’t the motor, check if there is hydraulic oil ejects from the oil
Gear pump
lift port. If oil ejects, it means the pump is no problem; if no oil
ejects, it means the gear pump is bad, replace it.
Check if the system pressure is normal, and adjust if it is off
Overflow valve
the system regulated safe pressure.
Check if the solenoid directional valve leaks, if needed,
Solenoid
replace the solenoid directional valve leaks, or dismantle the
directional valve
valve, clean it with gasoline, and then install.
First dismantle one-way valve, unscrew it, after clean the
Forks drop One-way valve impurity near the steel ball, clean each part with gasoline,
slowly and then install.
Check if there is oil leakage on oil pipe and the joint, replace
Oil pipe
or eliminate if needed.
Remove the cylinder, check if the oil seal of the piston is in
Cylinder
good condition, or replace it.
Remove the one-way valve, disassemble it and clean with
One-way valve
gasoline, and then install.
Forks drop Solenoid Remove the solenoid directional valve, disassemble it and
fast directional valve clean with gasoline, and then install.
Check if there is oil leakage on oil pipe and the joint,
Oil pipe
eliminate if needed.
Touch the motor with screwdriver, listen at the other end of
Motor the screwdriver and if motor generates noises or not,
Abnormal
replace motor if needed.
noises in the
After unloading, check if the hydraulic oil level in the oil tank
hydraulic Hydraulic oil
meets the requirement. If not, add oil to specified level.
unit
Filter Check if suction filter blocks, clean strainer with gasoline.
87
3 Electric system
3.1 Principles of electrical system
CBD20/30-AC1S-SU、CBD20/30-ABC1S-SU
88
CBD20/30-AZ3S-SU、CBD20/30-ABZ3S-SU
89
CBD20/30-AC1S-ISU、CBD20/30-ABC1S-ISU
90
CBD20/30-AC2S-SU、CBD20/30-ABC2S-SU
91
CBD20/30-AC2S-ISU、CBD20/30-ABC2S-ISU
92
3.2 Controller
3.2.1 Maintenance
Controller, contactor and fuse protector are installed on the mounting panel of controller. Apply a
layer of thermal silicone grease at the bottom of controller when installing controller.
Maintenance
Controller has no spare parts for user to repair, do not try to open, repair or change the controller,
this will damage the controller and void the warranty; often keep the controller clean and dry.
It’s suggested to keep the controller clean and dry, periodically check and get rid of diagnose
historical files.
Clean
Regular cleaning the controller outer surface can be conducive to prevent corrosion and other
electrical fault caused by dirt, dust and chemicals, which are part of the environment and always
exist in battery power supply system.
Be careful when operating the truck power supplied by battery. Including but not limit to the
following: correct training, wear goggles, do not wear loose clothing and jewelry.
Carry out maintenance according to the following cleaning procedure. Never clean the controller
with high pressure washer.
– Remove battery to disconnect power.
– Connect load between controller B+ and B-(such as the contactor coil or horn) to
discharge the capacitor in the controller.
– Remove dirt and corrosion at the power and signal terminal with a damp cloth. Controller
can’t suffer the water impact with pressure.
– Make sure the wiring is correct and fastened.
Warning
 Strictly prohibit water in the product. Strictly prohibit operating with electricity.
Strictly prohibit reverse polarity. Strictly prohibit motor short circuit.
93
3.2.2 Diagnosis and troubleshooting
Diagnosis procedure
Truck cannot travel
Check if the controller

LED light flashes
Flash
Light is off
If normally flashes
Switch in encoder
Normal flashing way Fault flashing way
Display No display If battery has electricity If motor is normal
Check if Check if If If other Use Refer to

input the output contactor external encoder instructi
Check if the input signal signal absorbs facility to check ons to
end signal of the normal(us from normally is fault check
key switch is able controller normal reason the
normal. encoder) to motor is correspo
normal (if nding
two fault
terminals code of
output LED
after flash.
accelerato
Normal Abnormal r input)
Input Relevant
Eliminate
normal, part fault
key switch Eliminate
external
fault fault
facility
normal,
output
abnormal
Controller Controller
fault fault
Controller
fault
94
Get the fault information from three ways：
– Get fault information from the instrument: When the truck has fault, the LED3(RED) indicator
light is on, LCD displays fault type and code.
– Get fault information by switching in handheld programmer. Refer to Handheld Programmer.
– Get fault information by observe controller built-in LED indicator lights. Refer to LED Status
Indicator.
95
3.2.3 Controller fault diagnosis and correction
Controller can detect the fault or error message under each condition.
Diagnosis
Obtain fault information through three ways: ①Obtain fault information from two fault codes that
displayed on the instrument(the first two codes is for the travelling controller, while the second two
codes for steering controller); ②Obtain fault information from observing the state of LED indicator
light on the controller; ③Obtain fault information from reading the information that displayed on
the handheld programmer.
1232 controller contains one LED indicator light(display red or yellow),which can display in four
different modes though different colors of lights combination. see as below：
Display Information
Controller power is not on; or vehicle has dead battery; or other
LED light is off
severe damage.
LED light flashes yellow Controller is in normal working status.
Controller failed to supervise or did not load software. Restart KSI
LED light is often red
cycle, load software if necessary.
LED flashes yellow or red
Controller has detected a fault.
alternately
Red and yellow lights flash alternately in a repeated interval when the controller has detected one
failure. Each code consists of two digits. Red flashes once or twice stands for the following yellow
flashes stands for the first or second of the fault code; the yellow LED then flashes the appropriate
number of times for the first digit. The red LED flashes twice to indicate that the second digit of the
code will follow; the yellow LED flashes the appropriate number of times for the second digit.
96
For example：fault name “Battery Undervoltage” (corresponding code 23).
In the fault menu of handheld programmer, display “Undervoltage Cutback”, real-time battery
voltage displays in the monitor menu (“Keyswitch Voltage”).
LED light of the controller will display this mode repeatedly：

Red Yellow
Red Yellow
✱✱ ✲✲
✱ ✲✲
✲
（The first digit）（2）
（The second digit）（3）
Number code used yellow LED is listed in the troubleshooting table(table 6), it also lists probable
failure cause, settlement of condition and correction to each failure.
Troubleshooting
Fault code table can afford following information：
– Fault code
– Code name showed on Curtis programmer
– Performance caused by fault
– Probable cause of fault
– Deep reason for fault
– Resolution state
When faults happen, try to restart by resetting the key switch after confirmed that faults are not
caused by faulty wiring connection or mechanical failure. If the faults are still on, shut down the
key, check for incorrect connection or corruption of the pin 35 connecter, reconnect after repaired
and cleared, and then restart again.
97
Controller fault code
Fault Programmer display Deep fault
Probable fault reason
code Fault display reason/troubleshooting
12 Controller Overcurrent 1. External short of phase U,V,W Reason： Phase current exceeds
Motor stops working motor connections. limited current
Main connector disconnects 2. Motor parameters do not match. Troubleshooting ： restart the key
EM brake shutdown 3. Controller malfunction. switch
Throttle invalid
Brake
Pump stops working
13 Current Sensor Fault 1. Leakage to vehicle frame from Reason ： Deviation reads out to
Motor stops working phase U,V, or W controller current sensor.
Main connector disconnects 2. Controller malfunction Troubleshooting ： restart the key
Electromagnetic brake disconnects switch
Throttle invalid
Brake, Pump stops working
14 Precharge Failed 1. External load on positive Reason：Key switch input voltage
Motor stops working terminal of the capacitor that failed to charge the capacitor.
Main connector disconnects prevents the capacitor from Troubleshooting ： Reset or
Electromagnetic brake disconnects charging. re-input interlock switch through
Throttle invalid VCL function precharge().
Brake
Pump stops working
15 Controller Severe Undertemp 1. Severe controller working Radiator temperature is lower
Motor stops working environment. than -40℃.
Main contactor disconnects Troubleshooting：Raise the temp
Electromagnetic brake disconnects above -40 ℃ , restart the key
Throttle failure switch or interlock switch.
Brake
Pump stops working
16 Controller Severe Overtemp 1. Severe controller working Reason：Radiator temperature is
Motor stops working environment. higher than 95℃.
Main contactor disconnects 2. Truck overloads. Troubleshooting ： Drop the temp
Electromagnetic brake disconnects 3. Incorrect controller mounting below 95 ℃ . Restart the key
Throttle failure switch or interlock switch.
Brake, pump stops working
17 Severe Undervoltage 1. Setup error of battery parameter. Reason： When MOSFEET axle
Too low voltage 2. Power consumption of non working, capacitor voltage is
Driving torque reduce controller system. lower than the minimum voltage
3. Too large battery impedance. limit.
4. Battery disconnects. Troubleshooting ： Raise the
5. Fuse protector disconnect, or the capacitor voltage.
main contactor disconnect.
98
18 Severe Overvoltage 1. Setup error of battery parameter. Reason ： When MOSFEET axle
Overhigh voltage 2. High battery impedance. working, capacitor voltage
Motor stops working 3. Battery disconnects when exceeds the minimum voltage
Main contactor disconnects regenerative breaking. limit.
Electromagnetic brake disconnects Troubleshooting ： Reduce the
Throttle invalid voltage and then restart the key
Brake switch.
Pump stops working
21 Controller Undertemp Cutback 1. Controller works in limited Reason：Radiator temperature is
No fault(unless VCL set the condition. lower than-25℃.
incurred fault) 2. Severe controller working Troubleshooting ： Make the
environment. radiator temperature higher than
-25℃.
22 Controller Overtemp Cutback 1. Severe controller working Reason ： Radiator temperature
Drive or regenerative braking environment. exceeds 85℃.
torque reduces. 2. Truck overloads. Troubleshooting ： Reduce the
3. Incorrect controller mounting temperature.
23 Undervoltage Cutback 1. Insufficient battery power. Reason ： Too low capacitor
Driving torque reduces 2. Setup error of battery parameter. voltage.
3. Power consumption of non Troubleshooting：Raise capacitor
controller system. voltage.
4. Too large battery impedance.
5. Battery disconnects.
6. Fuse protector disconnects or
main contactor disconnects.
24 Overvoltage Cutback 1. During regenerative braking, Reason ： When MOSFEET axle
Regenerative braking torque regenerative braking current cause working, capacitor voltage
reduces the raising of battery voltage. exceeds the maximum voltage
2. Setup error of battery parameter. limit.
3. Too large battery impedance. Troubleshooting ： Reduce
4. When regenerating braking, capacitor voltage.
battery disconnects.
25 +5V Supply Failure 1. External load impedance is too Reason： 5V supply outside the
No fault(unless VCL set the low. 5V±10% range
incurred fault) Troubleshooting ： Adjust voltage
within range.
26 Digital Out 6 Failure 1. External load impedance is too Reason： Digital Output 6 current
Digital Out 6 driver is not active. low. exceeds15mA.
Troubleshooting：Adjust load, set
“set_digout()” by VCL, and restart.
27 Digital Out 7 Overcurrent 1. External load impedance is too Reason：Digital Output 7 current
The Digital Out 7 driver is not low. exceeds15mA.
99
active Troubleshooting：Adjust load, set
“set_digout()” by VCL, and restart.
28 Motor Temp Hot Cutback 1. Motor temperature reaches or Reason ： Input voltage value of
Driving torque reduced. exceeds parameter limit, thus motor temperature sensor is 0 or
cause current output reduce. larger than 10V.
2. Motor temperature parameters Troubleshooting ： Return the
incorrect. motor temperature to be within
3. If motor does not apply the permitted limits.
temperature sensor, programming
parameter “Temp compensation”
and “Temp cutback” must set
“OFF”.
29 Motor Temp Sensor Fault 1. Motor temperature sensor is Reason ： Input voltage value of
Max. speed drops to LOS status connected wrongly. motor temperature sensor is 0 or
and motor temperature cutback 2. If motor does not apply larger than 10V.
invalid. temperature sensor, programming Troubleshooting: Adjust input
parameter “Temp compensation” voltage value of motor
and “Temp cutback” must set temperature sensor to the normal
“OFF”. scope.
31 Coil 1 Driver Open/Short 1. Connected load open or short. Reason： Driver 1 (pin 6) is either
Driver 1 output shut 2. Connecting pin stained. open or shorted. This fault can be
3. Wrong wiring. set only when “Main Enable” set
to “OFF”.
Troubleshooting：Correct open or
short circuit, restart output.
31 Main Open/Short 1. Connected load open or short. Reason ： Main contactor driver
Motor stops working 2. Connecting pin stained. (pin 6) is either open or shorted.
Main contactor disconnects 3. Wrong wiring. This fault can be set only when
Electromagnetic brake disconnects “Main Enable” set to “ON”.
Throttle invalid Troubleshooting：Correct open
Brake circuit/short circuit, restart output.
Pump stops working
32 Coil2 Driver Open/Short 1. Connected load open or short. Reason： Driver 2 output(pin 5) is
Driver 2 output shut 2. Connecting pin stained. either open or shorted. This fault
3. Wrong wiring. can be set only when “EM brake
Type” set to 0.
32 EMBrake Open/Short 1. Connected load open or short. Reason： EM Brake output(pin 5)
Electromagnetic brake disconnects 2. Connecting pin stained. is either open or shorted. This
Throttle invalid 3. Wrong wiring. fault only occurs when “EM brake
Brake Type” set to 0.
100
33 Coil3 Driver Open/Short 1. Connected load open or short. Reason：Driver 3 output (pin 4) is
Driver 3 output shut 2. Connecting pin stained. either open or shorted
3. Wrong wiring. Troubleshooting：Correct open or
34 Coil4 Driver Open/Short 1. Connected load open or short. Reason：Driver 3 output (pin 3) is
Driver 4 output shut 2. Connecting pin stained. either open or shorted
35 PD Open/Short 1. Connected load open or short. Reason：PD(pin 2) is either open
PD shut 2. Connecting pin stained. or shorted
36 Encoder Fault 1. Motor encoder error. Reason：Encoder fault
Electromagnetic brake disconnects 2. Wrong wiring. Troubleshooting：Restart key
switch.
37 Motor Open 1. Motor phases is open. Reason：Motor phase, U,V,W
Motor stops working 2. Wrong wiring. detected open
Main contactor disconnects Troubleshooting：Check phase
Electromagnetic brake disconnects and restart the key switch.
Throttle invalid
Brake
Pump stops working
38 Main Contactor Welded 1. Main contactor tips are welded. Reason：Main contactor keep too
Motor stops working 2. Motor phases U and V is much connecting, capacitor
Main contactor disconnects disconnected or open. voltage can’t discharge.
Electromagnetic brake disconnects 3. An alternate voltage path is Troubleshooting：Restart the key
Throttle invalid providing a current to capacitor( B+ switch
Brake connection terminal)
Pump stops working
39 Main Contactor Did Not Close 1. Main contactor does not close Reason：When the main contactor
Motor stops working 2. Contactor contacts have is closed, capacitor voltage does
Main contactor disconnects oxidized, melted, or connection not charge B+ voltage.
Electromagnetic brake disconnects status is unstable. Troubleshooting：Check the
Throttle invalid 3. External load on the capacitor. contactor, restart the key switch.
Brake 4. Fuse protector disconnects.
Pump stops working
41 Throttle Wiper High 1. Throttle pot wiper voltage too Reason： Throttle pot wiper(pin
Throttle invalid high 16) voltage is higher than the high
fault threshold(can be changed
with the VCL function
101
setup_pot_faults()）
Troubleshooting： Reduce the
throttle pot wiper voltage
42 Throttle Wiper Low 1. Throttle pot wiper voltage too low Reason： Throttle pot wiper(pin
Throttle invalid 16) voltage is lower than the low
Troubleshooting： Raise the
throttle pot wiper voltage
43 Pot2 Wiper High 1. Pot 2 wiper voltage too high Reason：Pot 2 wiper(pin 17)
Full brake voltage is higher than the high
Troubleshooting： Reduce the pot
wiper voltage
44 Pot2 Wiper Low 1. Pot 2 wiper voltage too low. Reason： Pot 2 wiper(pin 17)
Full brake voltage is lower than the low fault
threshold(can be changed with
the VCL function
Troubleshooting：Increase the pot
wiper voltage
45 Pot Low Overcurrent 1. Potentiometer impedance is too Reason： Pot low end (pin 18)
Throttle invalid low. exceeds 10mA.
Full brake Troubleshooting: Reduce low end
current, restart the key switch
46 EEPROM Failure 1. Error writing to the EEPROM. It Reason：Controller system tries to
Motor stops may be caused by VCL writing to write into EEPROM but failed.
Main contractor stops. EEPROM, or CANBUS, or Troubleshooting：Download
EM brake stops incorrect parameter editing. correct software(OS), set correct
Throttle stops parameter, and then restart the
Interlock stops key switch.
Driver1-4 stop
PD stops
Brake
Pump stops
47 HPD/Sequencing Fault 1. Wrong sequence setting of key Reason：The wrong input of key
Throttle invalid start, interlock, direction and start, interlock, direction and
throttle input sequence setting. throttle cause HPD and
2. Wiring, switch key, interlock, sequencing fault.
102
direction or throttle input fault. Troubleshooting：Re-input
according to correct sequence.
47 Emer Rev HPD 1. Emer Rev already finished, but Reason：After Emer Rev finishes,
Throttle invalid the throttle, forward or reverse each input does not return to
input and interlock do not return to neutral, that cause the fault.
neutral. Troubleshooting：Re-input
according to correct sequence.
49 Parameter Change Fault 1. In order to protect truck safety, Reason：Parameter change
Motor stops working change of certain special needs restart of the key switch.
Main contractor stops working parameter is only valid after restart Troubleshooting：Restart the key
EM brake stops working the key switch. switch
Throttle invalid
Brake
Pump stops working
51-67 OEM Faults 1. Users can define fault by Define according to users
themselves, show the fault through themselves.
VCL code.
68 VCL RunTime Error 1. VCL runtime. Reason：VCL runtime error.
Motor stops Troubleshooting：Edit VCL
Main contactor stops software and correct, check new
EM brake stops software to make correct
Accelerator stops parameter matching; restart the
Interlock stops key switch.
Driver 1-4 stop
PD stops
Brake
Pump stops
69 External Supply Out of Range 1. External load on 5V and 12V Reason：Upper limit of external
supplies too high or too low. power supply(total current: 5V(pin
2. Parameter error in the Checking 26) and 12V(pin 25) is defined by
Menu, like “ExtSupply Max”, “Ext External Supply Max and lower
Supply Min” limit is defined by External Supply
Min
Troubleshooting：Adjust external
current.
71 OS General 1. Inner controller invalid. Reason：Inner controller invalid.
Motor stops Troubleshooting：Restart the key
Main contactor stops switch.
EM brake stops
Accelerator stops
Interlock stops
Driver 1-4 stop
103
PD stops
Brake
Pump stops
72 PDO Timeout 1. Time between CAN PDO Reason：Time between CAN PDO
Interlock stops messages received exceeds PDO messages received exceeds PDO
CAN NMT State set to Timeout Period Timeout Period
Preoperational Troubleshooting：Restart the key
switch, or accept CAN NMT
message
73 Stall Detected 1. Motor is stalled. Reason：No motor encoder is
EM brake stops 2. Motor encoder fault. detected.
Switch the control mode to 3. Wiring damaged. Troubleshooting：Throttle
LOS(Limited operation status) 4. Problem with power supply for Command=0,Motor RPM=0
motor encoder. Restart the key switch, or detect
the effective signal of motor
encoder in LOS mode, and set
the parameter to Throttle
Command=0,Motor RPM=0.
87 Motor Characterization Fault 1. Refer to the following code Reason： Motor matching
Motor stops during motor matching： process failure.
Main contactor stops 0=Normal Troubleshooting：Correct the fault
EM brake stops 1= Controller receives encoder and restart the key switch.
Accelerator stops signal, but pulse value not defined.
Brake Set pulse value manually
Pump stops 2= Motor temperature sensor
failure
3= Motor high temperature cutback
failure
4= Motor overtemp cutback failure
5= Motor low temperature cutback
failure
6= Low voltage cutback failure
7= High pressure cutback failure
8= Controller can’t detect encoder
signal and passage signal
disappears.
9= Motor parameter setting
exceeds the scope.
89 Motor Type Fault 1. Motor type parameter values Reason：Motor Type parameter
exceed the range setting value is an illegal value.
Troubleshooting：Reset and
restart the key switch.
104
91 VCl/OS Mismatch 1. The controller VCL does not Reason：The controller VCL does
Motor stops match OS. not match OS.
Main contactor stops Troubleshooting：Update new
EM brake stops VCL and OS.
Accelerator stops
Interlock stops
1-4 output stops
PD stops
Brake
Pump stops
92 EM Brake Failed to Set 1. Truck continues to move after Reason：After EM brake locks, the
EM Brake failure the EM brake has been truck still moves.
Throttle invalid commanded to set Troubleshooting：Check if the
2. Small EM braking force. throttle works normal.
93 Encoder LOS (Limited Operating 1. LOS activated due to motor Reason：LOS activated due to
Strategy) installing or encoder fault. motor installing or encoder fault.
2. Wrong wiring. Troubleshooting：Restart the key
3. Truck is stalled. switch, if it is caused by motor
installing, make sure encoder
work under normal condition,
Throttle Command=0,Motor
RPM=0.
94 Emer Rev Timeout 1. Emer Rev timeout activated due Reason：Emer Rev function
EM Brake failure to EMR Timer overdue activated to operate until Emer
Throttle invalid 2. Emer Rev switch is always at Rev timing end.
ON position. Troubleshooting：Check Emer
Rev switch.
98 Illegal Model Number 1. Controller model can’t be Reason：Controller model can’t be
Motor stops identified. identified
Main contactor stops 2. Software and hardware do not Troubleshooting：Choose correct
EM brake stops match. controller, and download correct
Throttle stops 3. Controller damage. controller software.
Brake
Pump stops
99 Dualmotor Parameter Mismatch Enable parameter of dualmotor is Reason：When the dual drive
Close main contactor set as ON, and control mode software enabled, control mode
Close EM brake selecting parameter not set as 0 should set as 0（Speed Mode
Close accelerator （Speed Mode Express) or 1 Express) or 1（Speed Mode）,
Brake and close the pump （Speed Mode） otherwise there will be fault.
Troubleshooting：Adjust to proper
value and switch KSI.
105
106
1222 Controller fault diagnosis and correction
LED
状态指示灯
1222 controller can detect the fault under each condition. Shown as troubleshooting table,
steering controller fault usually influences the traction controller.
Diagnosis
Obtain fault information through three ways: ①Obtain fault information from two fault codes that
displayed on the instrument; ②Obtain fault information from observing the state of LED indicator
light on the controller; ③Obtain fault information from reading the information that displayed on
the handheld programmer.
1222 controller contains two LED lights which can display four different messages though different
colors of lights combination. See as below;
Display Message
Controller is disconnected, dead battery, or other several
Both LED light off
malfunction.
Yellow and red LEDs
Controller is in flash program mode.
both are on
Yellow LED flashing Controller works properly
Faults can be detected by controller. Fault codes are composed of
Red LED and yellow LED two figures. The red lights flashing times represents the code of the
flashing alternately first and second figure while the flashing times of the yellow lights
represents the exact number of the corresponding figure.
Red and yellow lights flash alternately in a repeated interval when the controller has detected one
failure. Each code consists of two digits. Red flashes once or twice stands for the following yellow
flashes stands for the first or second of the fault code; the yellow LED then flashes the appropriate
number of times for the first digit. The red LED flashes twice to indicate that the second digit of the
code will follow; the yellow LED flashes the appropriate number of times for the second digit.
107
For example：Fault code ”Command Analog3 Out of Range”（corresponding code 42）.
In the fault menu of handheld programmer, display “Command Analog3 Out of Range”, real-time
battery voltage displays in the monitor menu (Command Input » Analog Input » Analog 3).
LED light of the controller will display this mode repeatedly：

Red Yellow
Red Yellow
✱ ✲✲✲
✱✱ ✲✲
✲
（The second digit）（2）
（The first digit）（4）
Number code used yellow LED is listed in the troubleshooting table(table 6), it also lists probable
failure cause, settlement of condition and correction to each failure.
Troubleshooting
Fault code table(table 6) can afford following information.:
– Fault code and subcode
– Display fault name on the Curtis programmer
– Display caused by the fault
– Fault setting condition and probable fault reason
– Steering fault motion（fault cause by steering）
– Traction fault motion（fault caused by traction）
As to each fault, table display one of the following four fault motion：
– Only warn—1222 controller can still work normally.
– Turn off—Turn off the 1222 controller immediately, and disconnect fault output(pin 23).
– Warn and turn off—1222 controller can still work, until traction motor stops or steering
timeout. Turn off the controller after the above happens.
– Keep and then turn off—Whatever the operator inputs, 1222 controller try to keep the
current wheel condition, until traction motor stops or steering timeout. Turn off the controller
after the above happens.
When faults occurred, if it is confirmed not wiring error or vehicle mechanical fault, try to restart
through vehicle switch lock. If fault still exists, turn off the switch lock, check if the connector of pin
35 connects right or has stain, reconnect and restart.
108
Curtis 1220 controller fault diagnosis and correction
1220 controller can detect the fault under each condition. Shown as troubleshooting table,
steering controller fault usually influence the traction controller.
Obtain fault information through two ways：
① Obtain fault information from two fault codes that displayed on the instrument(the first two
codes is for the travelling controller, while the second two codes for steering controller);
② Obtain fault information from reading the information that displayed on the handheld
Programmer:
Handheld Programmer will display all historical fault information since the last clearance.
Programmer display error name.
For example: Command Analog1 Out of Range(code 41).
In the fault menu of handheld programmer, it displays “Command Analog1 Out of Range”;
real-time battery voltage displays in the monitor menu（Command Input » Analog Input » Analog
1）.
1220 fault code

Code Fault reason and display Fault reason
23 motor polarity fault 1. Steering motor positive and negative polarity
steering stop reversal
traction stop 2. Encoder phase sequence reversal
36 motor stalled 1. Big steering system resistance
steering stop 2. Steering meet mechanical limit
traction stop 3. Home position detector switch invalid
37 motor open 1. Bad contact of steering motor cable connector
steering stop 2. Bad contact of steering motor brush
traction stop
41 command analog1 out of range 1. Direction angle sensor open
steering stop 2. Direction angle sensor damage
traction stop
42 command analog2out of range 1. Direction angle sensor open
steering stop 2. Direction angle sensor damage
traction stop
47 encoder fault 1. Encode open
steering stop 2. Steering encode is disturbed
traction stop 3. Steering encode damage
53 home position not found 1. Home position is far from test strip
steering stop 2.Home position damage
traction stop
73 following error 1. Big steering resistance
steering stop 2. Steering motor malfunction
traction stop
109
1311 Handheld Programmer
1311Handheld Programmer is a handheld tool that allows user programming, testing and
diagnosing the traction motor controller, refer to the following picture. Program setting handheld
terminal owns one menu navigation key, one data Inc/Dec key and three bookmark keys to control
all programmable functions.
Display window includes a seven-line 128 × 64 pixel LCD screen, this screen can show the test
and pictures at the same time, visible in the lightest condition, and adjust program to set menu.
Program is driven by the menu, and enters the next menu by pressing menu navigation button.
When the program is connected to motor controller, all motor controller information uploads to the
handheld programmer.
显示屏幕
Screen
Menu菜单导航键
navigation
key
数据更改键
Data Inc/Dec key
1 3
2
Bookmark key
书签键
Display screen：It can show seven-line test and pictures at the same time.
Menu navigation key： Move the cursor on the screen up or down to pass the menu list(up or
down arrow),open or close submenu(right or left arrow)
Data Inc/Sec key： Alter data values by display cursor.
Bookmark key：Three bookmark keys allow you to return fast or reach your favor or often use
menu interface without through the menu navigation. Press on the relevant bookmark button for 4
seconds, it can store relevant menu interface to this button. Press the relevant bookmark key, it
can skip to the corresponding menu interface of your chosen bookmark. After close the
programmer, the bookmark button will not be kept.
110
ZAPI fault code
Machine status
Restart Alarm/
Alarms Error Code Description Effect when the test is
procedure Warning
done
One of two (or both)

Valve, pump, traction
Watchdog circuit outputs Valve or pump or
02A08 Watchdog stopped, Lc opened, start-up,stby, traction Alarm
becomes high due to an traction request
Eb applied
HW or SW problem
The software is corrupted Valve, pump, traction
02A08 Flash Checksum or the flash on the inverter stopped, Lc opened, continuous Alarm
is damaged. Eb applied
Valve or pump or
02A09 Flash Checksum or the flash on theinverter is stopped, Lc opened, start-up,stby, traction Alarm
traction request
damaged. Eb applied
Valve or pump or
02A10 WRONG RAM or the flash on theinverter is stopped, Lc opened, start-up,stby, traction Alarm
traction request
damaged. Eb applied
The traction rotor is stuck Valve, pump, traction
02A11 Stall rotor or the encoder is not stopped, Lc opened, Alarm
working Eb applied
The software is not Valve, pump, traction
02A12 Controller Mism compatible with the stopped, Lc opened, start-up key-recycle Alarm
controller. Eb applied
A parameters set restore Traction, pump
02A13 Param. Restore was made since the last No effect start-up or Warning
keyoff EVP request
The program checks the
contents of main EEPROM Valve or pump or
02A13 Eeprom Ko stopped, Lc opened, start-up,stby, traction Alarm
registers and find corrupted traction request
Eb applied
values
Failure in the high current Valve or pump or
02A17 Logic failure #3 stopped, Lc opened, start-up, stby Alarm
HW protection circuit traction request
Eb applied
Pump motor output is too Valve, pump, traction start-up, stby,during
Valve or pump or
02A28 Pump Vmn Low low, with respect to pwm stopped, Lc opened, pump Alarm
traction request
applied Eb applied function
Pump motor output is too Valve, pump, traction
Valve or pump or
02A29 Pump Vmn High high, with respect to pwm stopped, Lc opened, during pump function Alarm
traction request
applied Eb applied
Motor output voltage higher Valve or pump or
02A31 Vmn high stopped, Lc opened, start-up, traction
than expected traction request
Eb applied
When the mos of EB is Valve or pump or
02A40 Aux driv. Shrt. stopped, Lc opened, start-up,stby,marcia Alarm
shorted traction request
Eb applied
start-up,
The battery voltage is too Valve, pump, traction
stand-by(only Valve or pump or
02A41 Wrong Battery low or too high (< 0,8 Vbatt stopped, Lc opened, Alarm
immediatelyafter Lc traction request
OR > 1,2 Vbatt) Eb applied
closing)
Driver of EB coil is Valve, pump, traction
Valve or pump or
02A42 Aux driver open damaged (not able to stopped, Lc opened, stby, traction Alarm
traction request
close) Eb applied
The EVP driver isdamaged
02A48 EVP driver open or the EVP coil impedance EVP stopped Continuous Key-on recycle Warning
is too low
Press the lift and drop
02A49 LIFT + LOWER Pump stopped Continuous Key-on recycle Warning
buttons simultaneously
There are too many pump
02A49 Many pump reqs Pump stopped Continuous Pump request Warning
requests at the same time
Evp driver is failed shorted Valve, pump, traction
Valve or pump or
02A50 Evp driv. short (always ON) mismatch stopped, Lc opened, start-up, stby Alarm
traction request
between the valve set-point Eb applied
111
Machine status
Restart Alarm/
procedure Warning
done
and its feedback

The Evp1 coil is not
connected between PAUX
and EVP output, and the
02A50 Evp coil open EVP stopped Continuous Key-on recycle Warning
parameter EVP TYPE in
the set-option menu is set
Analog or Digital
The truck is in stby with Valve or pump or
02A51 Tiller open tiller switch LC opens standby traction Warning
opened for more than 30s request
Pump current feedback is
02A52 Pump I=0 ever always 0A even when Pump motor stopped pump function pump request Warning
pump motor is running
In stby condition (no
current applied to the Valve, pump, traction
Valve or pump or
02A53 Stby i high traction motor) the current stopped, Lc opened, start-up, stby Alarm
traction request
feedbacks are aout of Eb applied
permitted stby range
The outputs of the
amplifiers (used to
measure the motor voltage) Valve, pump, traction
Valve or pump or
02A53 Wrong Zero are cheked this alarm stopped, Lc opened, init Alarm
traction request
occurs when voltage Eb applied
signals >3V or <2V at the
init
Overvoltage/Undervoltage Valve, pump, traction
Valve or pump or
02A54 Logic Failure #1 condition has been stopped, Lc opened, start-up Alarm
traction request
detected Eb applied
Motor voltage feedback stby, immediately Valve or pump or
02A55 Logic Failure #2 stopped, Lc opened, Alarm
circuits are damaged after Lc closing traction request
Eb applied
Pump chopper current
02A56 Pump I NO zero sensor feedback is out of Pump motor stopped start-up, stby pump request Warning
permitted stby range
Power capacitors voltage Valve or pump or
02A60 Capacitor charge stopped, Lc opened, start-up Alarm
does not increase traction request
Eb applied
The maximum
The output of the controller
currentis reduced to
02A61 Thermic sens ko thermal sensor is out of continuous Warning
half and speed is
range.
reduced
Traction controller
The controller has reached
reduces the maximum
the thermal cutback
02A62 Th. Protection current linearly from continuous Warning
temperature of 85°C when
Imax (85°C) down to
the current is IMAX
0A (105°C)
Input mismatch between Valve, pump, traction
Valve or pump or
02A64 Tiller error hard&soft switch input and stopped, Lc opened, start-up,stby, traction Alarm
traction request
tiller input Eb applied
Traction motor temperature
The maximum
sensor is opened (if digital)
currentis reduced to
02A65 Motor temperat or has overtaken the continuous Warning
half and speed is
threshold of 150°C (if
reduced
analog)
Battery is <= 20% when theValve, pump, traction
Valve or pump or
02A66 Battery Low parameter BATTERY stopped, Lc opened, start-up,stby, traction Alarm
traction request
CHECK is set>0 Eb applied
The controller can not Valve, pump, traction
Valve or pump or
02A67 NO CAN MSG. receive the signal from the
stopped, Lc opened, start-up,stby, traction Alarm
traction request
handle Eb applied
Smart driver is open, not
02A68 Smart driver KO stopped, Lc opened, start-up Key re-cycle Alarm
able to provide EB positive
Eb applied
02A68 Waiting for node A Canbus network node is continuous Warning
112
Machine status
Restart Alarm/
procedure Warning
done
in alarm condition. uC is
waiting for it to resolve its
error condition.
Sens. Mot. The motor temperature Valve or pump or
02A69 stopped, Lc opened, start-up,stby, traction Alarm
Temp.KO sensor is damaged traction request
Eb applied
Error is detected in eeprom Controller works using
02A71 Eeprom ko continuous Warning
or in eeprom management Deafult parameters
Motor output voltage lower Valve or pump or
02A72 Vmn low stopped, Lc opened, start-up, traction Alarm
than expected traction request
Eb applied
When the positive of the
AUX OUTPUT isdriven by
02A74 Aux Batt. Short stopped, Lc opened, start-up, stby Alarm
the tiller, the positive is high
Eb applied
and the tiller is released.
EV1 on/off valve drivers
Drv. Shor. EV1 valve on/off
02A74 shorted On/off valves stopped start-up, stby Warning
dri request
(always ON)
dri request
(always ON)
dri request
(always ON)
Driver of LC coil is shorted,
so it is not able to open the Valve or pump or
02A74 Driver shorted stopped, Lc opened, start-up Alarm
LC, or LC coil is traction request
Eb applied
disconnected
Driver of Ev1 is open, not valve Ev1
02A75 Cont. Drv. Ev1 Ev1 stopped during Ev1 function Warning
able to close request
Driver of LC coil is Valve, pump, traction
Valve or pump or
02A75 Contactor Driver damaged (not able to stopped, Lc opened, start-up Alarm
traction request
close) Eb applied
Valve or pump or
02A75 Contactor closed LC contact is stuck stopped, Lc opened, start-up Alarm
traction request
Eb applied
Key-off signal is Shortcircuit on LC or EB
02A76 stopped, Lc opened, start-up Key re-cycle Alarm
low at Key-on coil
Eb applied
Coil short. Shortcircuit on LC or EB Valve or pump or
02A76 stopped, Lc opened, stby, traction Alarm
MC-EB coil traction request
Eb applied
start-up, stby,during
Shortcircuit on On/off valve on/off
02A76 Coil shor. Ev. On/off valves stopped valve Warning
valves coil reques
function
The LC coil has been Valve, pump, traction
Valve or pump or
02A77 Contactor Open driven but LC does not stopped, Lc opened, stby, traction Alarm
traction request
close Eb applied
The acceleretor value is
higher than the minimum
start-up,
02A78 Vacc not ok value recorded, and the Traction is stopped Traction request Warning
stand-by,traction
direction/enable switches
are opened.
Incorrect pump starting start-up, standby,
02A79 Pump inc start Pump stopped Pump request Warning
sequence traction
start-up,
02A79 Incorrect start Incorrect starting sequence Traction is stopped Traction request Warning
stand-by,traction
The travel demands are
start-up,
02A80 Forw+backward active in bothdirections at Traction is stopped Traction request Warning
stand-by,traction
the same time
113
Machine status
Restart Alarm/
procedure Warning
done

Valve or pump or
02A82 Encoder Error Problem on the encoder stopped, Lc opened, traction Alarm
traction request
Eb applied
The voltage on CNC#4 is
out of the parameters
range，The accelerator
input is out of the range
02A85 Vacc out range Pump stopped Continuous Pump request Warning
Vacc_min ÷ Vacc_max,
which has been acquired
with “PROGRAMM VACC”
function
Output of built in Smart
Driver, which supplies Eb Valve, pump, traction
Valve or pump or
02A86 Pos. EB shorted coil positive, is high (= stopped, Lc opened, start-up Alarm
traction request
+batt) when the tiller switch Eb applied
is opened.
Accelerator poti negative
(Npot) voltage is out of start-up,
02A86 Pedal wire ko Traction is stopped Traction request Warning
range (less than 0,3V stand-by,traction
or >2V)
The pump accelerator
value is
Pump Vacc not
02A89 higher than the minimum Pump stopped Continuous Pump request Warning
OK
value recorded, and the
lift/lower switches are open
short circuit on the power Valve or pump or
02A89 Power mos short stopped, Lc opened, start-up Alarm
mosfets traction request
Eb applied
The voltage on CNC#9 is
Pump Vacc Pump stopped, EVP
02A90 out of the parameters Continuous Pump request Warning
range stopped
range
The Maximum current gain
parameters are the default
Controller works,
values,which means the
02A92 Current gain butwith low maximum start-up, stanby Warning
maximum current
current
adjustment procedure has
not been carried out yet
Problem on the A/D Valve or pump or
02A96 Analog input stopped, Lc opened, traction Alarm
conversion of uC traction request
Eb applied
valve
stopped,(eventually)
The PEV connector (B2) is
pumpstopped,
not connected to the
02A98 Pev not OK (eventually)traction continuous Alarm
battery or the voltage is
stopped,(eventually)
different.
Lc opened and MC
applied
Error on the parameters of
the slip profile setting，The start-up,
02A99 Slip profile Traction is stopped Traction request Warning
slip profile inside the stand-by,traction
controller is not correct
Switch OFF the
interlock switch again
after emergency Valve or pump or
06A00 EMERGENCY Emergency reverse start-up,stby, traction Alarm
reverse finished, and traction request
then this fault
disappears.
1) Check if zero
proximity switch is
correctly installed;
EPS NOT 2) Check if zero Valve or pump or
06A00 Zero is not found start-up,stby, traction Alarm
ALIGNED proximity switch traction request
selection is correct;
3) Check if zero
proximity switch
114
Machine status
Restart Alarm/
procedure Warning
done
output data is correct;

This warning is
signaled when low
logic level signal is
detected by the
control during
initialization phase.
Fault analysis：It may
be caused by too low
voltage, and is
suggested to check
the following items:
-Key switch is based
on external loading
(like DC-DC converter
activates, relay or
contactor switch input
signal is lower than
starting voltage);
- Check the
Valve or pump or
06A00 KEYOFF Key switch short connection of power start-up,stby, traction Alarm
traction request
cable with battery
positive and negative
electrode as well as
main contactor and
controller –BATT and
+BATT. Connect with
screw and the torque
range is
13NM÷15NM.
- If the pressure drop
is not detected on the
power supply line, this
warning is signaled
once the key switch is
ON. The fault may
occur on the controller
hardware, so it's
necessary to replace
the controller.
Exceed current exceeds Check if the motor
limit hardware circuit suits for eps-dc0 (not Valve or pump or
06A01 HIGH CURRENT start-up,stby, traction Alarm
current hardware to large), if so, replace traction request
limitations the controller.
When the motor
receives the travelling
command, the motor
V phase current is 0.
1) Check if the
controller fuse is
POWER normal;2) Check if the Valve or pump or
06A02 POWER FAILURE#1 start-up,stby, traction Alarm
FAILURE #1 power line and traction request
controller is firmly
connected;3) Check if
controller V phase is
well connected;4)
Replace the
controller.
When the motor
command, the motor
POWER Valve or pump or
06A03 POWER FAILURE#2 W phase current is 0. start-up,stby, traction Alarm
FAILURE #2 traction request
1)Check if the
controller fuse is
normal; 2)Check if the
115
Machine status
Restart Alarm/
procedure Warning
done
power line and

connected; 3)Check if
controller W phase is
well connected;
4)Replace the
controller.
When the motor
command, the motor
W phase current is 0.
1) Check if the
controller fuse is
POWER normal; 2)Check if the Valve or pump or
06A04 POWER FAILURE#3 start-up,stby, traction Alarm
FAILURE #3 power line and traction request
connected; 3)Check if
controller W phase is
well connected;
4)Replace the
controller.
Possible causes:
1) After switching on,
the current amplifier is
detected not within
2.2-2.8V during
Valve or pump or
06A05 STBY I HIGH Standby current is high initialization; start-up,stby, traction Alarm
traction request
2) Current amplifier
output exceeds 0.15V
drifting after
initialization. Solution:
replace the controller.
1) Check if stepper
motor connecting line
D LINE SENSOR Stepper motor Q LINE is well; 2) Resistance Valve or pump or
06A06 start-up,stby, traction Alarm
KO voltage is invalid between Q line and B- traction request
is too small(approach
30Ω).
1. Check if stepper
motor connecting line
is well;
Q LINE SENSOR Stepper motor D LINE Valve or pump or
06A07 2. Resistance start-up,stby, traction Alarm
KO voltage is invalid traction request
between D line and B-
is too small(approach
30Ω)
Possible causes:1.
EEPROM address
read-write error;2.
Hourmeter gets over
three hour records;3.
Valve or pump or
06A08 EEPROM KO EEPROM damage It occurs also when start-up,stby, traction Alarm
traction request
the busy bit of the
EEPROM does not
rise within 12 msec.
Solution: replace the
controller.
This warning is
signaled if the
detected motor
voltage amplifier Valve or pump or
06A09 VMN NOT OK VMN fault start-up,stby, traction Alarm
output is not between traction request
2.2V and 2.8V when
startup. Please
06A10 HIGH This warning is signaled Improve controller start-up,stby, traction Valve or pump or Alarm
116
Machine status
Restart Alarm/
procedure Warning
done
TEMPERATURE once the controller cooling; or replace traction request

temperature exceeds 75℃. controller.
Once this fault is
DATA signaled, please wait Valve or pump or
06A11 Data acquisition start-up,stby, traction Alarm
ACQUISITION until the data is traction request
acquired.
Voltage of W and U is
LOGIC FAILURE inconsistent with Valve or pump or
06A12 LOGIC FAILURE #1 start-up,stby, traction Alarm
#1 demand voltage, traction request
Voltage of W and V is
LOGIC FAILURE inconsistent with Valve or pump or
#2 demand voltage, traction request
W and U voltage
LOGIC FAILURE amplifier output Valve or pump or
#3 exceed 0.25V drifting, traction request
W and V voltage
LOGIC FAILURE amplifier output Valve or pump or
#4 exceed 0.25V drifting, traction request
The safety contactor
of the slave contactor
The safety contactor of the is detected closed
Valve or pump or
06A16 KS CLOSED slave contactor is closed ahead of time by the start-up,stby, traction Alarm
traction request
ahead of time. main contactor,
please replace the
controller.
of the main contactor
The safety contactor of the is detected closed
Valve or pump or
06A17 KM CLOSED main contactor is closed ahead of time by the start-up,stby, traction Alarm
traction request
ahead of time. slave contactor,
please replace the
controller.
of the slave contactor
The safety contactor of the
is detected not closed Valve or pump or
06A18 KS OPEN slave contactor is not start-up,stby, traction Alarm
in time by the main traction request
closed in time.
contactor, please
of the main contactor
The safety contactor of the
is detected not closed Valve or pump or
06A19 KM OPEN main contactor is not start-up,stby, traction Alarm
in time by the slave traction request
closed in time.
contactor, please
This warning is signaled
when CAN BUS is set to
PRESENT. eps-dc0 wait
for the message that
Find reasons from
MAIN CONT. traction controller had Valve or pump or
06A20 traction controller and start-up,stby, traction Alarm
OPEN closed main contactor traction request
keep controller open.
through CAN. This warning
is signaled when no closing
message within 1.5
second.
Bus messages between Replace the
main and slave controller. Valve or pump or
06A21 MICRO SLAVE start-up,stby, traction Alarm
microprocessors have traction request
frozen to OXFF value.
Disconnect angle Check steering
S.P OUT OF Valve or pump or
06A22 sensor,angle input voltage encoder hardware or start-up,stby, traction Alarm
RANGE traction request
is out of range. line.
117
Machine status
Restart Alarm/
procedure Warning
done
Check steering
F.B OUT OF Disconnect steering Valve or pump or
06A23 encoder hardware or start-up,stby, traction Alarm
RANGE encoder. traction request
line.
1) The detected
stepper motor
directions from main
microprocessor and
slave microprocessor
are different when
using the stepper
motor;2) In the
closed-loop control
MICRO SLAVE Main and slave system, main Valve or pump or
KO microprocessors mismatch. contactor detected traction request
stepper motor
direction is wrong,
and also is different
from the one detected
from the main
contactor;3) Steering
limit is not detected by
main contactor, but by
the slave contactor.
Controller detects that
two continuous speed
readings on the
encoder differs a lot:
as the system
encoder cannot
change speed a lot in
a short time, so it
maybe the encoder
error(one or two
encoder lines damage
or break), check the
encoder mechanical
and circuit function; or
the electromagnetic
ENCODER interference on the Valve or pump or
06A25 Encoder error start-up,stby, traction Alarm
ERROR sensor bearing traction request
causes the Alarm; if
not the above
reasons, please
Please notice that
human operation can
also cause this failure,
such as the following
condition:1)The truck
bumped into barrier
accidentally and
cannot travel;2)
Depress the brake
suddenly when the
truck in high speed.
BAD ENCODER Encoder phase sequence Interchange encoder Valve or pump or
SIGN is wrong. A and B phases. traction request
GAIN EEPROM EEPROM memory current Replace the Valve or pump or
KO value is different. controller. traction request
1) Check if CAN BUS
communication lines
CAN BUS communication are well connected; Valve or pump or
06A28 CAN BUS KO start-up,stby, traction Alarm
fault. 2) Check if the traction request
communication
baudrate is
118
Machine status
Restart Alarm/
procedure Warning
done
consistent.
3) Check if the CAN
communication is
open.
4) Check if the CAN
communication loop
resistance is 60Ω.
Disconnect angle sensor,
when the senor is using
with feedback
potentiometer, feedback
encoder measures that
POSITION steering wheel angle Check coupling, angle Valve or pump or
ERROR equals the FEEDBACK sensor hardware link. traction request
ENC and FEEDBACK POT
in the test menu as
expected. This warning is
signaled when the
difference is above 20°.
Controller slave chip
SERIAL ERROR did not receive master Valve or pump or
#1 chip message, traction request
Serial error. replace the controller.
Steering motor current is
MICRO SLAVE Valve or pump or
06A40 opposite to the command start-up,stby, traction Alarm
#4 traction request
direction. Replace controller
Main contactor does not
SLAVE COM. Valve or pump or
06A41 receive messages from start-up,stby, traction Alarm
ERROR traction request
slave contactor. Replace controller
Valve or pump or
06A42 NO SYNC Replace controller start-up,stby, traction Alarm
Out of sync fault. traction request
Maximum current gain
parameter is factory
default. It indicates
that the maximum
current adjustment
Valve or pump or
06A43 CURRENT GAIN Current gain fault. parameter program start-up,stby, traction Alarm
traction request
has not yet operated.
Solution: ZAPI
technician will set the
current gain
parameter correctly.
CLOCK PAL Valve or pump or
06A44 Replace controller start-up,stby, traction Alarm
NOT OK Clock fault traction request
STEER Two voltage signals of Check lines or replace Valve or pump or
SENSOR KO angle sensor mismatch. angle sensor. traction request
This signal is alarmed
when the feedback
Replace steering Valve or pump or
06A46 JERKING FB potentiometer(CPOT open) start-up,stby, traction Alarm
encoder. traction request
changes larger than 0.3V
within 16 millisecond.
If steering encoder
FB POT mechanical link is normal Valve or pump or
LOCKED or something block the traction request
wheel.
MOTOR Valve or pump or
06A48 motor temperature hot start-up,stby, traction Alarm
TEMPERAT. traction request
This signal is alarmed
MOTOR when the steering motor Check the controller Valve or pump or
LOCKED current and max. current mechanical part. traction request
keep close over 1 second.
Stepper motor Q and D line
STEPPER MOT Valve or pump or
06A50 frequency do not match Replace controller start-up,stby, traction Alarm
MISM traction request
with the voltage value.
06A51 MICRO SLAVE start-up,stby, traction Valve or pump or Alarm
119
Machine status
Restart Alarm/
procedure Warning
done
#3 traction request
Main microprocessor
MICRO SLAVE encoder is different from Valve or pump or
#8 slave microprocessor traction request
encoder.
INPUT ERROR Valve or pump or
06A53 Harness connection error. start-up,stby, traction Alarm
#1 traction request
CAN BUS KO Slave CAN BUS Valve or pump or
SL. communication fault. traction request
SL EPS NOT Valve or pump or
06A55 Controller malfunction. Replace controller start-up,stby, traction Alarm
ALL. traction request
Valve or pump or
06A56 SL CENTERING Controller malfunction. Replace controller start-up,stby, traction Alarm
traction request
MICRO SLAVE Valve or pump or
Replace controller start-up,stby, traction Alarm
#8 traction request
120
C2 Controller fault code
fault Fault name Possible cause Trigger and clear the Action implemented
code conditions by the controller
during a failure
do
1-2 Controller overflow 1. External connections of Trigger: phase current Turn off the motor,
(Controller Overcurrent) Fault motor U, V and W overcurrent detection main contactor,
type: 1 = U phase overcurrent 2. Motor encoder signal is upper limit clearance: electromagnetic
2 = W phase overcurrent disturbed reset controller brake, accelerator,
3 = V phase overcurrent 3. Misadjustment of motor full power brake
4 = Controller current> 135% parameters
limit 4. Controller fails
flow value
1-3 Current sensor fault (Current 1, U, V or W phase to car body Trigger: The current Turn off the motor,
Sensor) leakage (short circuit in stator) sensor has an invalid main contactor,
Fault type: 1 2. Controller fails offset reading electromagnetic
Clear: Reset control brake, accelerator,
implement all
Power brake
1-4 Pre-charging fault 1. Loload connected to the Trigger: The controller Turn off the motor,
（Precharge Failed ） controller B + terminal capacitance charge main contactor,
fault type: suppresses capacitor charging has failed electromagnetic
1. Disruption inside the controller Clear: open / off brake, accelerator,
2. Energy limit 2. Check the voltage displayed interlock or reset full power brake
3. Time limit by Programmer \ System controller
Monitor Menu \ Controller \
Capacitor Voltage
1-5 Controller with severe low 1, The controller works in an Trigger: Radiator Turn off the motor,
temperature (Controller Severe extreme environment 2, check temperature is main contactor,
Undertemp) Fault type: 1 the Programmer \ System below-40°C electromagnetic
Monitor Clear: Radiator brake, accelerator,
Menu\Controller\Controller temperature all
Temperature above-40°C, Power brake
The temperature displayed Then you can reset
the controller
1-6 Controller severe high 1, The controller works in Trigger: The radiator Turn off the motor,
temperature (Controller Severe extreme environments temperature is below main contactor,
Overtemp) fault type: 1 2. Heavy load + 95°C electromagnetic
3. The controller is not installed Clear: have a radiator brake, accelerator,
properly temperature below + full power electric
4, Check for Programmer \ 95°C and then reset brake
System Monitor Menu \ the controller
Controller \ Controller
Temperature
The temperature displayed
1-7 Controller B + end has a 1. Non-controller system Trigger: Main The drive-free torque
severely low pressure consumes photobattery contactor output
（SevereB+Undervoltage） 2. High internal resistance in After suction closing,
Fault type: 1 the battery FET bridge road work:
3. The battery is not connected or causeThe low
when driving the motor voltage off current
4. The fuse connecting B + is output exceeds 64ms
broken or the main contactor is or reaches the low
not engaged voltage off voltage
5, Controller battery parameter value of the controller
set error 6, check Programmer \ Clear: controller
System Monitor current output> 0%
Voltage displayed by Menu \ over 100ms, or
Controller \ Capacitor Voltage capacitance voltage>
low voltage off voltage
value
121
1-7 Controller KSI end 1. Non-controller system consumes Trigger: the KSI voltage Turn off the motor,
is severely low photobattery is below the low voltage main contactor,
pressure 2. The KSI input line has a high off voltage for 2 seconds electromagnetic brake,
（Severe KSI resistance Clear: KSI voltage> low accelerator, full power
Undervoltage 3. The KSI line is disconnected when voltage off voltage value brake
） driving the motor
Fault type: 1 4. The fuse is broken
5, Check for the Programmer \ System
Monitor Menu \ Controller \ Keyswitch
Voltage display
The voltage of
1-8 Severe high 1. The controller battery parameters are Trigger: the capacitor Turn off the motor,
pressure of the set incorrectly voltage of FET bridge main contactor,
controller B + end 2. Regenerative braking, when there is exceeds the severe high electromagnetic brake,
(Severe B + a current recharge battery, the battery voltage setting accelerator, full power
Overvoltage) internal resistance is too high Clear: the capacitance brake
Failure type: 1 3. The battery is not connected during voltage is below the
the regenerative braking severe high voltage
4. Check the voltage displayed by setting value, and the
Programmer \ System Monitor Menu \ reset to control
Controller \ Capacitor Voltage implement
1-8 High controller KSI 1. The battery voltage to the controller Trigger: The KSI voltage Turn off the motor,
terminal KSI (pin1) exceeds the severe high exceeds the severe high main contactor,
(Severe KSI voltage setting voltage setting value electromagnetic brake,
Overvoltage) 2. Check the voltage displayed by Clear: the capacitance accelerator, full power
Failure type: 1 Programmer \ System Monitor Menu \ voltage is below the brake
Controller \ Keyswitch Voltage severe high voltage
setting value, and the
reset to control
implement
1-9 Monitor to the 1. The motor speed exceeds the Max Trigger: The motor speed Close the interlock,
speed limit fault Speed Supervision setting exceeds the set value, electromagnetic brake,
Fault type: 1 2, The Max Speed Supervision setting and the duration also
value is incorrect exceeds the set value
3, Check the Programmer \ Application Clear: Reset control
Setup \ Max Speed Supervision
settings
implement
1-10 Monitor to 1. When the vehicle is stopped, the Trigger: In the shutdown Turn off the motor,
operational control controller output frequency and phase state, the motor main contactor,
failure current exceed the parameter setting frequency and phase electromagnetic brake,
Fault type: 1 value under Travel Control Supervision current exceed the accelerator, full power
2. Wrong parameter set under Travel parameter setting value brake
Control Supervision at Travel Control
3, Check for the Programmer \ Supervision
Application Clear: Reset control
The Setup \ Travel Control Supervision
settings value
implement
2-2 Controller high 1, The controller works in extreme Trigger: The radiator Down-drive and
temperature environments temperature is below + braking torque
reduction 2. Heavy load 85°C
(Controller 3. The controller is not installed Clear: have a radiator
Overtemp properly temperature below +
Cutback) 4. Controller performance is limited at 85°C and then reset the
Fault type: 1 this temperature 5, check Programmer \ controller
System Monitor
Menu\Controller\Controller
Temperature
The temperature displayed
122
2-3 Low voltage 1. The battery needs to be charged, and Trigger: the capacitor Decline drive torque
reduction the controller performance is limited at voltage is below the
(Undervoltag e this voltage UndervoltageCut back limit
Cutback) Failure 2. Controller battery parameters are not after the FET bridge works
type: 1 set correctly Clear: Capacitor voltage is
3. The non-controller system consumes above the UndervoltageCut
the photobattery back limit
4. High internal resistance in the battery
5. The battery is not connected when
driving the motor
6. The fuse connecting B + is broken or
the main contactor is not engaged
7, Check for Programmer \ System
Monitor Menu \ Controller \ Currents \
UndervoltageC utback
Monitor Menu \ Controller \ Capacitor
Voltage display
The voltage of
2-4 High pressure 1. During normal operation, the current Trigger: After the FET Downke torque
reduction generated by the regenerative brake is bridge works, the capacitor note: This fault is
（Overvoltage recharged to the battery. Too high battery voltage exceeds the only detected during
Cutback ） voltage, the controller performance is OvervoltageCutb ack limit regenerative
Fault type: 1 limited 2, and the controller battery Clear: Capacitor voltage is braking
parameters are set correctly above the OvervoltageCutb
3. Regenerative braking, when there is a ack limit
current recharge battery, the battery
internal resistance is too high
4. The battery is not connected during
the regenerative braking
5, Check for Programmer \ System
Monitor Menu \ Controller \ Currents \
OvervoltageCu tback
Monitor Menu \ Controller \ Capacitor
Voltage display
The voltage of
2-5 A 5V output failure 1. External 5V load is small (pin16) 2. Trigger: 1,5V output over Turn off the 5V
(Ext 5V Supply Check the voltage and current of 5V 5V ± 10%; 2,5V current is output
Failure) Failure output displayed by Programmer \ limited by parameter
type: System Monitor Menu \ Outputs setting; clear: reset
1. The output of 5V controller, or VCL reset
voltage exceeds
the range of 2,5V
voltage
Current exceeds
the range
2-6 A 12V output fault 1. External 12V load is small (pin23) 2, Trigger: 1,12V output over Turn off the 12V
(Ext 12V Supply check the voltage and current of 12V 12V ± 15%; 2, output
Failure) Fault type: output from Programmer \ System The 12V current is limited
1, of the output Monitor Menu \ Outputs by the parameter setting;
The 12V voltage Clear: Reset Controller, or
exceeds the range VCL reset
2,12 Voltage of the
Current exceeds
the range
2-8 Motor high 1. The motor temperature is greater than Trigger: Motor temperature 1. Lower the drive
temperature or equal to the Temperature Hot setting is greater than or equal to torque
reduction fault type: value, resulting in the controller output the Temperature Hot set 2, If MotorBraking
1 flow limit 2, the motor temperature and value Thermal
sensor parameters are set in error 3, Clear: Reduce the CutBack_Ena ble =
check Programmer \ AC Motor Setup \ temperature to the normal On, drop
Temperature Sensor value brake torque
123
2-9 Motor temperature 1. Motor temperature Trigger: Motor temperature Enter the LOS mode to
sensor (Motor Temp sensor is not well sensor input reduce the motor speed,
Sensor) connected; (pin9) Conversion voltage over and the motor high-level
Fault type: 1 2. Incorrect sensor polar range clearance: motor reduction function is
connection (pin9 and temperature sensor input voltage turned off
pin12） Return to normal range
3. Motor temperature and
sensor parameters are set
in error 4, check
Programmer \ System
Monitor Menu and AC
Motor \ Temperature
3-1 Main Contactor Drive 1. Drive load is open or Trigger: Main Enable = On Turn off the motor, main
fault (Main Driver) short circuit When the main contactor drives contactor,
fault type: 2, The connector pin foot an open or short circuit electromagnetic brake,
1. Drive short circuit or contactor coil is dirty clearance: repair the post-reset accelerator, full power
2. Drive the current 3. Wrong connector controller brake
3. Open circuit / short mispressing or wrong
circuit wiring
(High detected, should
be low)
4. Open circuit / short

circuit
(Low detected, should
be high) 5, broken line
3-2 Electromagnetic brake 1. Drive load is open or Trigger: At EM Brake Type> 0, Close the
drive fault (EM Brake short circuit the electromagnetic brake (pin 4) electromagnetic brake,
Driver) fault type: 1, 2, The connector pin foot drives the open or short circuit accelerator, full power
short circuit to drive or contactor coil is dirty clearance: repair the rear reset brake
2. Drive the current 3. Wrong connector controller
3. Open circuit / short mispressing or wrong
circuit wiring
(High detection,
Should be low)
4. Open circuit / short
circuit
(Low detection,
Should be high)
5. Break the line
3-5 Down drive failure Equivalent to the Driver 1
（Lower Fault ） Fault
3-6 Encoder failure 1. Motor encoder fails Trigger: Motor encoder signal Close the
（Encoder Fault ） 2. Wrong pressing or detection clearance: reset electromagnetic brake,
fault type: wiring controller, or if parameter LOS accelerator, full power
1. Check the loss 3, Check for Programmer Upon Encoder Fault = On, reset brake
2. Overcurrent leads to \ System Monitor Menu \ interlocking switch, enter LOS
pulse loss 3, speed AC Motor \ Motor RPM fault mode (9-3 fault)
pulse signal loss 4, and 4, Check for Programmer
motor matching \ AC Motor Setup \
5. Encoder for Quadrature Encoder \
Electrical part failure Encoder Fault Setup
3-7 Motor open 1. Motor phase is open Trigger: open circuit of motor U, Turn off the motor, main
（Motor Open ） circuit V, and W are detected contactor,
Fault type: 1 2. Wrong pressing or Clear: Switch KSI electromagnetic brake,
wiring accelerator, all
Power brake
124
3-8 Main contactor 1. Main contactor Trigger: the main contactor is Turn off the motor, main
adhesion contacts are frequently released after absorption, and the contactor,
（Main Contactor bonded capacitor voltage is not reduced electromagnetic brake,
Welded ） 2. Motor V phase or U Clear: Reset control accelerator, all
Fault type: 1 phase open circuit implement Power brake
3. An external voltage is
directly connected to the
controller B + terminal
column
3-9 Main contactor does not Type 1: Trigger: After the main contactor Turn off the motor, main
engage (Main 1. The main contactor is controlled, the capacitor contactor,
Contactor Did Not does not engage voltage does not charged to the electromagnetic brake,
Close) fault type: 1, 2. The main contactor battery voltage clearance: reset accelerator, full power
main contactor does not contact is defective controller brake
engage 2 after the 3. The controller B +
control command, terminal is connected
working main contactor with a large load,
is disconnected resulting in the capacitor
cannot be effectively
charged
4. Break off the
high-current fuse
5. Main contactor
parameter setting error
Type 2:
1. The main contactor is
disconnected at
operation
2. The contactor coil
connection is
disconnected
3. Contactor fault
4-2 Accelerator input fault 1, The accelerator input Trigger: The accelerator input Close the accelerator
(Throttle Input) voltage is beyond the voltage is beyond the range of the
Fault type: 1, External is range of the Analog Low Analog Low and Analog High
too low or too high and Analog High settings
settings, and the Clear: Accelerator input voltage
corresponding analog returns to normal range, reset
quantity input is defined control
as the accelerator input implement
2, Check Programmer \
Controller Setup \
Analog Inputs \ Analog 1
Type 3, check
Programmer \ Controller
Setup \ Analog Inputs \
Configure
4-6 Memory data read and 1. Memory data read Trigger: The controller read and Close the motor, main
write fault (NV Memory and write failure write EEPROM number contactor,
Failure) 2. Internal failure of the According to the failure electromagnetic brake,
fault type: controller Clear: download the correct accelerator, interlock,
1. Invalid verification software and the corresponding drive 1, drive 2, drive 3,
2, Data write error 3, parameter settings, and reset the drive 4, drive 5,
data read out error 4, controller proportional drive, full
data write power brake
Did not complete due to
the power failure
4-7 High pedal sequence 1. The key switch, Trigger: An incorrect key switch, Close the accelerator
protection (HPD interlocking, direction interlocking, directional switch,
Sequencing) fault type: switch and accelerator and accelerator input operation
1 input operation sequence triggers an HPD or
sequence are incorrect SRO fault
2. Wiring or pressing Clear: Count back in the correct
errors in the keyswitch, order
interlocking, direction
switch and accelerator
input break 3, the key
switch, interlocking,
direction switch and
125
accelerator input are
damp
4, Check for
Programmer \ System
Monitor Menu \ Inputs \
Switch Status
5, Check for
Programmer \ System
Monitor Menu \ Inputs \
Throttle Command
4-7 Emergency Reverse 1. Emergency reverse Trigger: The emergency reverse Turn off the accelerator
high pedal protection operation has ended, but operation has ended, but the and the electromagnetic
(EMR Rev HPD) there is no return of accelerator input, direction switch, brake
Fault type: 1 accelerator input, and Interlock are not cleared. If
direction switch and EMR Interlock is set to ON, the
interlock accelerator, direction switch, and
Interlock input need to be
cleared. If EMR Interlock is set
to OFF, the accelerator and
direction switch inputs need to be
cleared
4-9 Parameter change 1. After the interlock is Trigger: Adjust the parameter Turn off the motor, main
failure closed, modify the clearance requiring the switch contactor,
(Parameter Change) safety-related KSI: reset controller electromagnetic brake,
Failure type: recorded parameters, namely the accelerator, full power
parameters parameters marked with brake
CAN ID the PCF
4-10 Emergency reverse 1, One or two of the two Trigger: the emergency reverse Close the interlock and
switch redundancy fault emergency reverse switch is often open and often the electromagnetic
(EMR Switch switches do not work, closed is not synchronized brake
Redundancy) Failure resulting in an invalid Clear: correct the switch status,
type: 1 state 2, where the switch and reset the control
is damp or into dirt implement
5-1 Custom fault 1~32 User-custom, User-custom, implemented via User-custom,
~ (User 1~32 Fault) implemented via VCL VCL implemented via VCL
7-13 Failure type:
User Custom
6-8 VCL Runtime Error 1. Runtime fault is Trigger: A VCL runtime error was Close the motor, main
(VCL Run Time Error) defined by VCL, refer to detected contactor,
system information Clear: Modify the VCL, and reset electromagnetic brake,
2. The drive command the controller accelerator, interlock,
and the drive letter do drive 1, drive 2, drive 3,
not match when drive 4, drive 5,
controlling the drive with proportional drive, full
the VCL power brake
7-2 CAN PDO Timeout 1. Two adjacent PDO's Trigger: Two adjacent PDO's Close the accelerator
（PDO receive information over receive information over the set
Timeout) Fault type: 1 the set PDO timeout PDO timeout time
time Clear: received
2. Adjust the PDO The CAN NMT Letter
settings to view the Interest, or reset the controller
Programmer /
Application Setup / CAN
Interface / PDO Setups
7-3 motor stalling 1. Motor plugging Trigger: No signal change of Turn off motor,
(Stall Detected) Failure 2. Motor encoder fails motor encoder detected Clear: electromagnetic brake,
type: 1 3. Wrong correct reset controller, or if parameter accelerator and control
pressing or wiring LOS UponEncoder Fault = On, mode to
4. The power supply part reset interlock switch after Fault For the LOS, the motor
of the motor encoder is cleared, enter LOS Fault mode output is limited
abnormal (9-3 Fault), allow limit motor
5, Check for output
Programmer \ System
Monitor Menu \ AC
Motor \ Motor RPM
126
7-7 Monitoring fault 1. Controller internal Trigger: Internal failure Turn off the motor, main contactor,
（Supervision failure of the controller electromagnetic brake, accelerator,
） Clear: reset controller interlock, drive 1, drive 2, drive 3,
Fault type: the Curtis drive 4, drive 5, and ratio
monitoring code Drive, full-power braking
7-9 Enter the 1. Controller internal Trigger: The controller Turn off the motor, main contactor,
check-monitoring fault failure is damaged electromagnetic brake, accelerator,
(Supervision Input Clear: reset controller interlock, drive 1, drive 2, drive 3,
Check) Failure type: 1 drive 4, drive 5, proportional drive,
full power
Rate brake
8-2 PDO mapping error 1, PDO mapping has Trigger: Incorrect PDO close PDO
（PDO assigned excessive data mapping was detected
Mapping Error ） bits, or incompatible Clear: the reset
Fault type: 1 targets controller
2. Adjust the PDO settings
to view the Programmer /
Application Setup / CAN
Interface / PDO Setups
8-3 Internal hardware 1. An internal fault of the Trigger: detected Turn off the motor, main contactor,
failure controller is detected controller internal fault electromagnetic brake, accelerator,
(Internal Hardware) clearance: reset full power brake
Failure type: Curtis controller
hardware code
8-7 Motor match error 1. Motor matching failed Trigger: The motor Turn off the motor, main contactor,
(Motor Characterizati during the motor matching matching has failed electromagnetic brake, accelerator,
on Error) process during the motor full power brake
matching process
Clear: reset controller
8-8 Encoder pulse signal 1. The encoder step Trigger: Encoder step Turn off the motor, main contactor,
error setting is not consistent settings detected electromagnetic brake, accelerator,
(Encoder Pulse Error) with the actual situation Clear: confirm that the full power brake
Failure type: 1 2, the calibration encoder step number
parameter setting to check setting is consistent
the Programmer \ AC with the actual, reset
Motor Setup \ Quadrature control
Encoder \ Encoder Steps Manufacturer
3. The motor loses its IFO
control, and the motor
rotates rapidly without the
accelerator signal input
8-9 The parameter 1. Parameter values were Trigger: detected Shut down motor, main contactor,
exceeds the range detected beyond the range parameter values electromagnetic brake,Accelerator,
（Parameter Out of 2, Check and rewrite the beyond the range full power braking
Range ） parameters with the CIT Clear: Override the
fault type: tool parameter
Record the target To the normal range
CAN ID s
127
9-1 Firmware bad (Bad Incorrect controller Trigger: The downloaded The controller cannot
Firmware) fault type: 1 firmware software matches the not fully start
1, The CRC or OS are controller hardware
mismatched Clear: Download can match
2, Incompatible OS was Equipped with software
used
9-2 Electromagnetic brake 1. Vehicle operation is Trigger: The operation of the Close the
setting for brake failure detected, after the vehicle is detected after the electromagnetic brake
(EM Brake Failed to Set) electromagnetic brake is electromagnetic brake is set and accelerator
Failure type: 1 set and delayed
2. The electromagnetic Clear: 1 Activate Accelerator The standing slope
brake can not stop the (EM Brake Type = 2); 2 function is triggered
motor rotation after braking Activate Interlock (EM after the interlocking
Brake Type = 1） activation
9-3 Encoder LOS Mode 1, Encoder 3-6 fault or 7-3 Trigger: Encoder 3-6 fault or LOS pattern
(Encoder LOS) fault, enter 7-3 fault, if the parameter
Fault type: 1 LOS pattern LOS Upon Encoder Fault =
2. Motor encoder fails On, reset the interlocking
3. Wrong pressing or wiring switch, enter the LOS fault
4. Vehicle blockage mode（9-3 fault ），
Allow the limiting of the motor
output
Clear: Switch KSI, or if LOS
is triggered, if the encoder is
OK, Motor RPM = 0,
Throttle
Command = 0
9-4 Emergency reverse 1. Emergency reverse Trigger: Trigger emergency Turn off the accelerator
timeout triggers and ends because reverse, run to expiration and the
(Emer Rev Timeout) the emergency reverse Clear: Close the emergency electromagnetic brake
Failure type: 1 time expires inverted input
2. The Emergency reverse
input is stuck
9-9 Parameter mismatch 1. Incorrect motor feedback Trigger: 1, opens the Turn off the motor, main
(Parameter Mismatch) selection is used for dual-drive function 2 in contactor,
Fault type: 1, the dual different motor technology torque mode, and the electromagnetic brake,
drive is turned on in torque applications SPMSM motor feedback accelerator, full power
mode function 2. Dual dual drive is turned selects the coding brake
on in torque mode implement
3. Dual-drive functionality is
turned on when using a
single controller
2, SPMSM electricity 3. AC induction power
The machine feedback Machine feedback chose the
was selected encoder positive Yu Xuan
3, AC induction positive Clear: Adjust the

residual is selected for parameterTo the appropriate
motor feedback value, reset
controller
9-10 Monitor the interlock brake 1. During the interlock Trigger: During interlock Turn off the motor, the
fault (Interlock Braking braking process, the motor braking, the motor speed electromagnetic brake,
Supervision) Fault type: speed exceeds the exceeds the parameters set and the main contactor
1. The motor speed parameters set under under Interlock Braking
exceeds the interlock Interlock Braking Supervision
brake monitoring speed Supervision Clear: reset controller
limit range 2, View the Programmer /
2, the interlock is Application Setup
disconnected, and the / Interlock Braking /
electromagnetic brake is Supervision Enable.3, View
not set within the set time Programmer / Application
3. Interlock is broken, the Setup
electromagnetic brake is / Interlock Braking /
not set, and the rotor Interlock Braking
position exceeds the RPM Supervision
position limit
128
9-11 Monitor the emergency 1. During the emergency Trigger: During the emergency Turn off the motor, the
reverse fault (EMR reverse process, the motor reverse process, the motor electromagnetic brake,
Supervision) fault type: speed exceeds the speed exceeds the and the main contactor
1 parameters set under parameters set under
Emergency Reverse Emergency Reverse
Supervision Supervision
2, View the Programmer / Clear: Resets the controller
Application Setup
/ Emergency Reverse /
Emergency Reverse
Supervision.
10-1 Drive 1 fault 1. Drive load is open or short Trigger: Drive 1 open or short Turn off drive 1
（Driver 1 Fault ） circuit circuit or drive over-current,
fault type: 2, The connector pin foot or beyond the Driver 1
1. Drive short circuit contactor coil is dirty Overcurrent setting parameter
2. Drive the current 3. The connector is pressing value
3. Open circuit / short error or wiring error 4, Clear: repair the short circuit
circuit exceeding the Driver 1 or the open circuit after the
(High detected, should Overcurrent setting reset control
be low) parameter value Manufacturer
5, Check out Programmer /
Controller Setup / Outputs /
Driver 1 / Driver 1
Overcurrent.
4, open/short circuit
(low detected, should
be high)
5. Break the line
fault type: 2, The connector pin foot or exceeding the Driver 2
3. Open circuit / short error or wiring error 4, Clear: Resets the controller
circuit exceeding the Driver 2 after repairing short circuit or
(High detection,Should Overcurrent setting open circuit
be low) parameter value
4. Open circuit / short 5, Check out Programmer /
circuit Controller Setup / Outputs /
Driver 2 / Driver 2
Overcurrent.
10-3 Drive 3 fault 1. Drive load is open or short Trigger: drive open or short Turn off drive 3
（Driver 3 Fault ） circuit circuit or drive overcurrent,
3. Open circuit / short error or wiring error 4, Clear: Repair short or open
circuit exceeding the Driver 3 after reset controller
(High detected, should Overcurrent setting
be low) 4, open / short parameter value
circuit 5, Check out Programmer /
(Low detected, should Controller Setup / Outputs /
be high) Driver 3 / Driver 3
5. Break the line Overcurrent.
fault type: 2, The connector pin foot or beyond the Driver 4
3. Open circuit / short error or wiring error 4, Clear: Repair short or open
circuit exceeding the Driver 4 after reset controller
(High detected, should Overcurrent setting
be low) 4, open / short parameter value
circuit 5, Check out Programmer /
(Low detected, should Controller Setup / Outputs /
be high) Driver 4 / Driver 4
5. Break the line Overcurrent.
129
（Driver 5 Fault ） circuit circuit or drive over current,
2. Drive the current 3. The connector is pressing error value
3. Open circuit / short or wiring error 4, exceeding the Clear: Repair short or open
circuit Driver 5 Overcurrent setting after reset controller
(High detected, should parameter value
be low) 4, open / short 5, Check out Programmer /
circuit Controller Setup / Outputs / Driver
(Low detected, should be 5 / Driver 5 Overcurrent.
high) 5, broken line
10-8 Drive assignment fault 1, One drive serves as 2 or more Trigger: Drive assignment Turn off the
(Driver Assignment) functions 2, view Programmer / conflict drive
Failure type: 5 drive Controller Setup / IO Assignments Clear: The reset controller after
serial number guide / Coil Drivers: resolving drive allocation
Cause the fault Main contactor drive conflicts
Electromagnetic brake drive,
pump contactor drive
11-1 Simog input 1 1. The analog volume 1 input Trigger: 1 the input voltage is None, unless
Over the range voltage is higher than the Analog above the parameter set the VCL adds a
（Analog 1 Out of 1 High set value threshold; 2 the input voltage is special
Range ） 2, The input voltage of analog lower than the parameter treatment
fault type: volume 1 is lower than Analog 1 setting
1. More than the upper Low Threshold of placement;
limit Set the value Clear: the input voltage back to
2. Low is limited to 3, View the Programmer / the parameter setting range,
Controller Setup /Analog Inputs / reset control
Analog 1 implement
4, View Programmer / Controller
Setup / Analog Inputs / Configure
/ Analog 1 Low / Analog 1 High
11-2 Simog input 2 1. Analog quantity 2 The input Trigger: 1 input voltage is None, unless
Over the range voltage is higher than the Analog above the threshold set by the VCL adds a
(Analog 2 Out of Range) 2 High set value parameter; 2 input voltage is special
Failure type: 2, The analog volume 2 input below the threshold set by treatment
1. More than the upper voltage is lower than Analog 2 parameter;
limit Low Clear: the input voltage back to
2. Low is limited to Set the value the parameter setting range,
3, View Programmer / Controller reset control
Setup / Analog Inputs / Analog 2 implement
11-3 Simulation quantity input 1. Analog quantity 3 The input Trigger: 1 input voltage is None, unless
3 voltage is higher than the Analog above the threshold set by the VCL adds a
Over the range 3 High set value parameter; 2 input voltage is special
(Analog 3 Out of Range) 2, Analog 3 The input voltage is below the threshold set by treatment
Failure type: below Analog 3 Low parameter;
1. More than the upper Set the value Clear: the input voltage back to
limit 3, View Programmer / Controller the parameter setting range,
2. Low is limited to Setup / Analog Inputs / Analog 3 reset the controller
11-4 Simog input 4 1, analog quantity 4 input voltage Trigger: 1 input voltage is None, unless
Over the range is higher than Analog 4 High set above the threshold set by the VCL adds a
(Analog 4 Out of Range) value parameter; 2 input voltage is special
Failure type: 2, Analog 4 The input voltage is below the threshold set by treatment
1. More than the upper below Analog 4 Low parameter;
limit Set the value Clear: the input voltage back to
2. Low is limited to 3, View Programmer / Controller the parameter setting range,
Setup / Analog Inputs / Analog 4 reset the controller
130
B-5 Simulation quantity 1. Analog quantity 5 The input Trigger: 1 input voltage None, unless the VCL
input 5 voltage is higher than the Analog 5 is above the threshold adds a special
Over the range High set value set by parameter; 2 treatment
(Analog 5 Out of 2, The input voltage of analog input voltage is below
Range) Failure type: quantity 5 is lower than Analog 5 Low the threshold set by
1. More than the Set the value parameter;
upper limit 3, View Programmer / Controller Clear: the input voltage
2. Low is limited to Setup / Analog Inputs / Analog 5 back to the parameter
4, View Programmer / Controller setting range, reset
Setup / Analog Inputs / Configure / control
Analog 5 Low / Analog 5 High implement
11-6 Simulation quantity 1, Analanalog 6 input voltage is Trigger: 1 input voltage None, unless the VCL
input 6 higher than the Analog 6 High set is above the threshold adds a special
Over the range value set by parameter; 2 treatment
(Analog 6 Out of 2, Analanalog 6 input voltage is input voltage is below
Range) Failure type: lower than Analog 6 Low the threshold set by
1. More than the Set the value parameter;
11-7 Simulation quantity 1. The analog volume 1 input voltage Trigger: 1 Input voltage None, unless the VCL
input 7 is higher than the Analog 7 High set is above the threshold adds a special
Over the range value set by the parameter; 2 treatment
（Analog 7 Out of 2, Analog 7 The input voltage is The input voltage is
range) below Analog 7 Low set the value lower than the
Failure type: 3, View Programmer / Controller threshold.
1. More than the Setup / Analog Inputs / Analog 7 Clear: the input voltage
upper limit 4, View Programmer / Controller back to the parameter
2. Low is limited to Setup / Analog Inputs / Configure / setting range, reset the
Analog 7 Low / Analog 7 High controller
11-8 Simog input 1 1, Analogue volume 8 The input Trigger: 1 input voltage None, unless the VCL
Over the range voltage is higher than the Analog 8 is above the threshold adds a special
(Analog 8 Out of High set value set by parameter; 2 treatment
Range) Failure type: 2, The analog volume 8 input voltage input voltage is below
1. More than the is lower than Analog 8 Low the threshold set by
upper limit Set the value parameter;
2. Low is limited to 3, View Programmer / Controller Clear: the input voltage
Setup / Analog Inputs / Analog 8 back to the parameter
11-11 Simog input 1 1. The analog amount is 14 and the Trigger: 1 input voltage None, unless the VCL
Over the range input voltage is higher than the is above the threshold adds a special
（Analog 14 Out of Analog 14 High set value set by parameter; 2 treatment
Range ） 2. The analog volume 14 input input voltage is below
fault type: voltage is below the Analog 14 Low the threshold set by
1. More than the set value parameter;
11-12Analog allocation fault 1, An analog quantity is used as 2 or Trigger: An analog None, unless the VCL
(Analog Assignment) more functions quantity is used as 2 or adds a special
Failure type: 9 Analog 2, An analog quantity is input beyond more functions or input treatment
serial number causes the range beyond the range
this failure 3, View Programmer / Controller Clear: Resolve the
Setup / IO Assignments / Controls driver Reset controller
after device allocation
conflict
12-1 Branding error 1. Software and hardware brands do Trigger: Software and Turn off the motor,
（Branding Error ） not match software are main contactor,
Fault type: 1 2. Contact the local Curtis technical incompatible electromagnetic brake,
support to handle the fault Clear: As available, accelerator, full power
load the branded brake
software, or use a
branded controller and
131
configure the correct file
and CIT worker
With
12-3 Hardware The OS and the controller are not Trigger: Incorrect OS Turn off the motor,
compatibility failure compatible Clear: Download the main contactor,
(Hardware 1. The downloaded software and the matched OS electromagnetic brake,
Compatibility controller hardware are not accelerator, all
） compatible Power brake
Fault type: 1
12-5 Input fault of lifting A troubleshooting fault associated Trigger: Failure Close up and rise
（Lift Input Fault ） with the boost input source triggers diagnosis associated
Fault type: 1 the fault.For example, the boost with the boost input
input source is an analog input, and source will trigger the
all faults related to the analog input fault
are collected and reported Clear: resolve any
assignment conflicts or
enter beyond scope
Rear reset controller
12-6 Drop input failure The fault diagnosis associated with Trigger: The fault Close down
（Lower Input Fault ） the drop input source triggers the diagnosis associated
Fault type: 1 fault. For example, if the drop input with the drop input
source is an analog input, all failures source triggers this fault
associated with that analog input are Clear: Resolve any
aggregated to that fault and reported allocation conflicts, or
input out of range, and
then reset the controller
132
Attachment：Table for bolt’s tightening torque
Unit：N·m
Grade
Bolt’s diameter
4.6 5.6 6.6 8.8
6 4～5 5～7 6～8 9～12
8 10～12 12～15 14～18 22～29
10 20～25 25～31 29～39 44～58
12 35～44 44～54 49～64 76～107
14 54～69 69～88 83～98 121～162
16 88～108 108～137 127～157 189～252
18 118～147 147～186 176～216 260～347
20 167～206 206～265 245～314 369～492
22 225～284 284～343 343～431 502～669
24 294～370 370～441 441～539 638～850
27 441～519 539～686 637～784 933～1244

Note：·Use entirely 8.8 grade bolt in the important joint position.
·Bolt’s grade can be found in the head of the bolt, if it can’t be found, the grade is 8.8.
133
Related safety standards (for trucks exporting to Europe)
The TRUCKS covered are conform to the following European Directives and standards:
2006/42/EC Machinery Directive
2014/30/EU EMC Directive
EN ISO 12100:2010 Safety of machinery — General principles for design — Risk
assessment and risk reduction
EN ISO 3691-1:2015+A1:2020 Industrial trucks — Safety requirements and verification — Part 1:
Self-propelled industrial trucks, other than driverless trucks, variable
reach trucks and burden-carrier trucks
EN 1175:2020 Safety of industrial trucks – Electrical/electronic requirements
EN 16307-1:2020 Industrial trucks — Safety requirements and verification — Part 1:
Supplementary requirements for self-propelled industrial trucks, other
than driverless trucks, variable-reach trucks and burden-carrier trucks
EN 12053:2001+A1:2008 Safety of industrial trucks — Test methods for measuring noise
emissions
EN 13059:2002+A1:2008 Safety of industrial trucks — Test methods for measuring vibration
EN 12895:2015+A1:2019 Industrial trucks — Electromagnetic compatibility
The noise tests are according to EN 12053:2001+A1:2008

● The vibration tests are according to EN 13059:2002+A1:2008.
● The static test coefficient used for lifting accessory is 1.33.
● Test measurements of noise and whole-bode vibration:
Whole-body Sound pressure
Sound power level
Vibration level at the
Model
operator’s position
dB(A)
m/s2 dB(A)
CBD20-AC2S-SU 0.7 66 84
CBD30-AC2S-SU 0.7 66 84
EC DECLARATION OF CONFORMITY
Original Declaration
MANUFACTURER:
Name HANGCHA GROUP CO., LTD.
Address 666 Xiangfu Road, Lin'an District, Hangzhou City, Zhejiang Province 311305, P.R. China
TECHNICAL DOCUMENT WAS COMPILED BY:

Name Andy Yang
Address Die das technische Datenblatt erstellt hat Mariechen-Graulich-Straße 12a,
65439 Flörsheim am main Germany Tel: 0049-61453769188
HEREBY DECLARES THAT THE PRODUCT DESCRIBED BELLOW:

Name Electric Pallet Truck
Model CBD20-AC2S-SU
Serial No.
COMPLIES WITH THE PROVISIONS OF THE FOLLOWING EUROPEAN DIRECTIVES

2006/42/EC Machinery Directive
2014/30/EU EMC Directive
COMPLIES WITH THE PROVISIONS OF THE FOLLOWING STANDARDS

EN ISO 12100:2010 EN ISO 3691-1:2015+A1:2020
EN 1175:2020 EN 16307-1:2020
EN 12053:2001+A1:2008 EN 13059:2002+A1:2008
EN 12895:2015+A1:2019
Place: Hangzhou, Zhejiang, P.R. China

Date:
Signature and stamp:
Name:
Position: Legal Representative
According to Annex II 1.A of the Directive 2006/42/EC
Maintenance Record
Date Repair, maintenance content Serviceman

HANGCHA GROUP CO., LTD.
■ Address: 666 Xiangfu Road, Hangzhou, Zhejiang, China

■ Fax: 0086-571-88926789 0086-571-88132890 ■ ZIP:311305
■ Web: http://www.hcforklift.com ■ E-mail: sales@hcforklift.com

OMM-A-2.0-X3.0-Rider Pallet Truck-202301-EN-CE

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A Series

OPERATION AND MAINTENANCE

HANGCHA GROUP CO., LTD.

© 5/ 2022 HANGCHA GROUP CO., LTD

1.2 Use as required

Cold-storage truck should meet the followings when working:

1.5 Cautions for the use of lithium battery truck

1.7 Attachment installation or modification to the truck

CBD Electric pallet truck

A Product serial number

C1（Z3\C2） Controller type

I Lithium battery（Lead acid battery without I）

1 Switch lock 12 Rear frame

2 Emergency stop switch 13 Front frame

3 Control handle 14 Load wheel

4 Right protection pad 15 Hood

5 Left protection pad 16 Small hood

6 Left panel 17 Battery cover

7 Rear closure plate 18 Fork

8 Right panel 19 Side door

10 Auxiliary wheel 21 Cup holder

Start the truck by connecting the control voltage. Take away

25 Travel switch Control travelling direction and speed.

When pressing the horn button, it will give out sound

28 “Lowering” button Lower lifting device.

LCD 55% 55%

The LCD type is an 8-alphameric character,

when there is more than on fault. Relevant  Built-in anti-reverse circuit;

4 controllers of the vehicle, the red

Rated capacity Q (kg) 2000 3000

Rated load center distance c (mm) 600 600

Wheel base y (mm) 1505 1505

Front tyre, size/ quantity mm Φ230×75 / 1 Φ230×75 / 1

Rear tyre, size/ quantity mm Φ85×80 / 4 Φ85×80 / 4

Additional wheels size/ quantity mm Φ125×50 / 2 Φ125×50 / 2

Thread, front b10 (mm) 575 575

Thread, rear b11 (mm) 370 370

Free lift h3 (mm) 125 125

Fork lowest height h13 (mm) 85 85

Overall length L1⑯(mm) 2372 2372

Platform height mm 175 175

Overall width b1 (mm) 800 800

Fork dimension ISO2331 s/e/l (mm) 64/170/1150 64/170/1150

Distance between fork-arms b5 (mm) 540/680 540/680

Ground clearance, laden, below mast m1 (mm) 21 21

Turning radius Wa (mm) 21343) 21343)

Lift speed, laden/unladen m/s 0.047/0.064 0.036/0.053

Lowering speed, laden/ unladen m/s 0.075/0.071 0.060/0.058

Lift motor rating at S3 15% kW DC 2.2 DC 2.2

Steering motor kW DC 0.2 DC 0.2

Controller manufacturer/ type Curtis AC Curtis AC

Note：1）VDI 2198: +430mm.

Rated capacity Q (kg) 2000 3000

Rated load center distance c (mm) 600 600

Wheel base y (mm) 1505 1505

Front tyre, size/ quantity mm Φ230×75 / 1 Φ230×75 / 1

Rear tyre, size/ quantity mm Φ85×80 / 4 Φ85×80 / 4

Additional wheels size/ quantity mm Φ125×50 / 2 Φ125×50 / 2

Thread, front b10 (mm) 575 575

Thread, rear b11 (mm) 370 370

Free lift h3 (mm) 125 125

Fork lowest height h13 (mm) 85 85

Overall length L1⑯(mm) 2372 2372

Platform height mm 175 175