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Hyundai 20BRJ-9B Operator's And Service Manual
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Hyundai 20BRJ-9B Operator's And Service Manual

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16/20BRJ-9B, 20BRJ-9BH
Operator's Manual / Service Manual
Do not use the reach truck before reading and
understanding these operating instructions.
NOTE:
-
Please check the designation of your present type at
the last page of this document as well as on the ID-
plate.
- Keep it for future reference.
- This car can only be used in the factory area, tourist
attractions and amusement areas.
WARNING
0

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Summary of Contents for Hyundai 20BRJ-9B

  • Page 1 16/20BRJ-9B, 20BRJ-9BH Operator’s Manual / Service Manual WARNING Do not use the reach truck before reading and understanding these operating instructions. NOTE: Please check the designation of your present type at the last page of this document as well as on the ID- plate.
  • Page 2 FOREWORD Before operating the truck, read this ORIGINAL INSTRUCTION HANDBOOK carefully and understand the usage of the truck completely. Improper operation could create danger. This handbook describes the usage of different electric pallet trucks. When operating and servicing the truck, make sure, that it applies to your type.
  • Page 3 CONTENTS 1. CORRECT APPLICATION ..........................4 2. DESCRIPTION OF THE REACH TRUCK ......................5 a. Overview of the main components ......................5 b. Main technical data ........................... 6 c. Description of the safety devices and warning labels ................10 d. Location of nameplate ..........................13 e.
  • Page 4 b. Lubricating points ............................ 38 c. Check and refill hydraulic oil ........................39 d. Checking electrical fuses ......................... 39 9. TROUBLE SHOOTING ........................... 41 10. Hydraulic circuit ............................42 11. Brake System Schematic ..........................43 12. DIAGNOSTICS AND TROUBLESHOOTING, DISPLAY, AND WIRING DIAGRAM ..........45 a.
  • Page 5 1. CORRECT APPLICATION To ensure the safety of personal and equipment, drivers shall observe the following precautions: Only drivers who have been trained and hold a forklift driving license can drive; The forklift is suitable for hard and flat indoors floor; Check the control and alarm devices before driving the forklift.
  • Page 6 2. DESCRIPTION OF THE REACH TRUCK Overview of the main components Fig. 1: Overview main components Seat assembly 14. Mast tilting control stick Accelerator pedal 15. Signal lamp switch Brake pedal 16. Horn button Safety pedal switch 17. Brake switch 18.
  • Page 7 Main technical data Fig 2: Structure schematic drawing...
  • Page 8 Table 1: Main technical data for standard version Manufacturer`s type designation 16BRJ-9B 20BRJ-9B 20BRJ-9BH Battery Battery Battery Power(battery,diesel, petrol gas,manual) Sit-on Sit-on Sit-on Operator type Load Capacity / rated load Q (t) Load centre distance c (mm) Load distance, centre of drive axle to fork...
  • Page 9 4.34 Aisle width for fork carriage 800X1200 Ast (mm) 2780 2900 2980* lengthways 4.35 Turning radius Wa (mm) 1650 1750 1840* Distance to the rotor arm front end 2000* 4.37 1780 1900 (mm) Travel speed, laden/ unladen km/h 10.5/10.5 10.5/10.5 10.5/10.5 Lift speed, laden/ unladen 0.35/0.50...
  • Page 10 2563 3234 8410 8000 2730 3400 8910 8500 2897 3567 9410 9000 3063 3734 9910 9500 3230 3900 10410 Mast Table 20BRJ-9B 4500 1563 2235 5410 5000 1730 2400 5910 5500 1897 2568 6410 6000 2063 2735 6910 6500 2230...
  • Page 11 Description of the safety devices and warning labels Warning labels: Fig 3: Warning label Crane hook label: The place for allowed crane. Warning label: Do not stand under or on the fork, otherwise it may cause injury. Warning label: Do not stand inside mast or reach your hand inside, otherwise it may cause injury. Model sticker: Indicate the type of the truck.
  • Page 12 Safety device Fig 4: Safety devices...
  • Page 13 Emergency button: Please press this button immediately to cut of the power supply when the truck is out of control, all lifting-, lowering-functions will be stopped. Drive key switch: To prevent against unauthorized access, turn the key counterclockwise and pull it out. Brake: To stop the truck when it is driving.
  • Page 14 Location of nameplate Location of nameplate Fig. 5: Location of nameplate The frame number is located on the body, mast and fork frame of the vehicle, and the vehicle equipped with hook type fork also has the corresponding frame number on the fork.
  • Page 15 Identification plate (ID-plate) Fig. 6: Nameplate position Nameplate Fig. 7: Name plate...
  • Page 16 3. WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS Do not use truck in environments with explosive gas, explosive dust or acid and alkali corrosion;  Do not use truck in the environment with poor outdoor or ground conditions;  Do not put feet or hands under or inside the lifting mechanism; ...
  • Page 17 4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING Commissioning After receiving our new reach truck or for re-commissioning you have to do following before (firstly) operating the truck: Check if all parts are included and not damaged • • Mast installation (please follow the instructions to install mast); Do the work according to the daily inspections as well as functional checks.
  • Page 18 Table 2: Truck carriage weight and mast weight Type 16BRJ-9B 20BRJ-9B 20BRJ-9BH Truck carriage pack 2350 2550 3300 weight [kg] Truck carriage pack 1900x1400X2300 2100x1400X2300 2100x1600X2300 size [mm] Lift height H3 [mm] 5500 7500 9500 5500 7500 9500 10500 11500...
  • Page 19 Loading and unloading USE DEDICATED CRANE AND LIFTING EQUIPMENT.  DO NOT STAND UNDER THE SWAYING LOAD.  DO NOT WALK INTO THE HAZARDOUS AREA DURING LIFTING.  PLACE THE TRUCK ON A LEVEL GROUND. Transporting DURING TRANSPORTATION ON A LORRY OR TRUCK, ALWAYS FASTEN THE TRUCK SECURELY. ...
  • Page 20 Decommissioning Lower the fork to the lowest position, put the wood blocks under the driving cab to prevent damage to the driving wheel as it shown in Fig.10 for long time storage. Grease all greasing po ints mentioned in this handbook (regular inspection), and eventually protect the truck against corrosion and dust.
  • Page 21 5. REGULAR INSPECTION This chapter describes pre-shift checks before putting the truck into operation. Regular inspection is effective to find the malfunction or fault on this truck. Check the truck on the following points before operation. Remove load from truck and lower the forks. DO NOT USE THE TRUCK IF ANY MALFUNCTION IS FOUND.
  • Page 22 6. OPERATIONAL INSTRUCTIONS a. Operational control devices position Fig.11 Operation control diagram b. Power-on operation Before operating the truck, make sure that the load is stable and will not cause poor visibility. Pull the emergency button (1), insert the key switch (2), and turn it clockwise to the "ON" position, then step on the safety switch (6).
  • Page 23 sharp slowdown, please stamp the brake pedal(5). Drive carefully the truck to the destination. Watch the route conditions and adjust the travelling speed with the accelerator button. This truck is equipped with enough safety equipment to avoid accidents. When the height of the fork is higher than the free lifting height, the speed of the truck will be reduced to achieve smooth walking and safe work.
  • Page 24 • Press the emergency switch (1), the truck can stop. Attention: when the fork is loaded with goods, the brake should be operated slowly. Do not use emergency button please in case of the goods falling. f. Load curve diagram The Load curve diagram indicates the maximum capacity Q [kg] for a given load centre c [mm] and the corresponding lift height H [mm] for the truck with horizontal load.
  • Page 25 i. Mast front shift and back shift Push the control stick (8) forwards, the mast shifts to the front. Push the control stick (8) backwards, the mast shifts to the back. j. Fork left shift and right shift Push the control stick (14) forwards, the forks shifts to the left. Push the control stick (14) backwards, the forks shifts to the right.
  • Page 26 Emergency Descent...
  • Page 27 1.28g/ml. The truck is equipped with following acid traction battery-type: 20BRJ-9B 1 pc 48V 4PzS 560AH (standard) [1216x355x754 mm (LxWxH)] 20BRJ-9BH 1 pc 48V 5PzS 700AH (standard) [1216x428x754 mm (LxWxH)] (For lifting height above 10m)
  • Page 28 16BRJ-9B 1 pc 48V 3PzS 420L (standard) [1216x283x754 mm (LxWxH)] 1 pc 48V300Ah1HR [1216x355x754 mm (LxWxH)] 1 pc 48V400Ah1HR [1216x355x754 mm (LxWxH)] 1 pc 48V554Ah1HR [1216x355x754 mm (LxWxH)] THE WEIGHT OF THE BATTERIES HAS AN INFLUENCE TO THE TRUCKS OPERATING BEHAVIOR. PLEASE CONSIDER THE MAXIMUM OPERATING TEMPERATURE OF THE BATTERIES.
  • Page 29 Description of Lithium-Ion batteries A lithium-ion battery is a type of battery with a rechargeable high-performance energy cell.  The battery is designed for industrial vehicles and can withstand severe shocks and knocks.  Batteries have special interfaces for charging and discharging to prevent the use of incorrect batteries and ...
  • Page 30 Fig. 16: Identification plate Table 4: Identification plate Item Description Item Description Manufacturer trademark Hardware revision Model designation Rated voltage Serial No. Rated Capacity Production date Energy Battery manufacturer Battery weight Manufacturer's address...
  • Page 31 Safety Instructions, Warning Indications and other Notes Safety regulations for handling lithium-ion batteries Do not try to make any repairs or servicing of lithium batteries Risk of electric shock and burning The battery’s charging and discharging connectors have open terminals, avoid any body contacts, contamination or direct contacts with objects which can cause short circuit connection of terminals.
  • Page 32 recharging of fully charged battery. The charger will not work while battery is fully charged. Potential hazards If equipment is used according to its design purpose, following the correct operations procedures, there are no hazards anticipated. The following hazards can arise in the event of improper use: •...
  • Page 33 Symbols - Safety and Warnings Table 5: Symbols - Safety and Warnings Used lithium-ion batteries must be treated as hazardous waste. Lithium-ion batteries marked with the recycling symbol and the sign showing a crossed-out waste bin must not be disposed of with ordinary household waste. Avoid fire and short circuits causing overheating.
  • Page 34 Additional firefighting instructions To prevent secondary fires, the lithium-ion battery must be cooled from the outside. Fluids or solids must never be directed into the lithium battery. Suitable extinguishing agents • Carbon dioxide extinguisher (CO2) • Water (not on mechanically opened or damaged batteries) Unsuitable extinguishing agents •...
  • Page 35 Battery lifetime and maintenance The Lithium-ion batteries are maintenance-free. Full discharge can damage the battery Self-discharge can cause the battery to fully discharged state. Full discharge shortens the service life of the battery and can cause deep discharge and activation of related safety protocols when battery will not be able to be charged anymore.
  • Page 36 Instructions for safe handling New lithium-ion batteries are transported and stored with a charge status of at least <70 %. • Do not modify the battery. Do not open, damage, drop, penetrate or deform the battery. • • Do not throw the battery into a fire. •...
  • Page 37 8. REGULAR MAINTENANCE • Only qualified and trained personnel are allowed to do maintenance on this truck. • Before maintaining, remove the load from the forks and lower the forks to the lowest position. If you need to lift the truck, follow chapter 4b by using designated lashing or jacking equipment. •...
  • Page 38 14 Check the function of brake • Electrical system 15 Inspect the electric wiring for damage • 16 Check the electric connections and terminals • 17 Test the Emergency switch function • 18 Check the electric drive motor for noise and damages •...
  • Page 39 General 41 Check if all decals are legible and complete • 42 Check if the protective screen and or guarding is not damaged • 43 Inspect the castors, adjust the height or replace these if worn out. • 44 Carry out a test run •...
  • Page 40 c. Check and refill hydraulic oil It is recommended to use hydraulic oil: • Type: H-LP 32, DIN 51524 • Viscosity: 41.4 – 47 Waste material like oil, used batteries or other must be probably disposed and recycled according to the national regulations and if necessary brought to a recycling company.
  • Page 41 Table 7: Size of the fuses RateDKT 1232SE Rate configuration configuration FU 1 FU 1 FU 2 FU 2 FU 3 FU 3 FU 4 FU 4 FU 5 500A FU 01 500A...
  • Page 42 9. TROUBLE SHOOTING If the truck has malfunctions follow the instructions, mentioned in chapter 6 Table 8: Trouble shooting TROUBLE CAUSE MAINTENANCE Lift only the max. capacity, mentioned Load weight too high on the ID-plate Battery discharged Charge the battery Check and eventually replace the Load lifting failure Lifting fuse failure...
  • Page 43 10. Hydraulic circuit Fig. 19: Hydraulic circuit...
  • Page 44 11. Brake System Schematic Fig 20: Brake schematic (travel brake)
  • Page 45 Fig. 21: Braking schematic CURTIS (parking brake)
  • Page 46 12. DIAGNOSTICS AND TROUBLESHOOTING, DISPLAY, AND WIRING DIAGRAM a.1232SE Configuration These controllers detect a wide variety of faults or error conditions. Faults can be detected by the operating system or by the VCL code. This section describes the faults detected by the operating system. Diagnostics information can be obtained in either of two ways: (1) By reading the display on the handheld programmer, which displays all faults currently set as a history of faults set since the last time the history was cleared, and the handheld programmer displays the faults by...
  • Page 47 DISPLAY STATUS Neither LED illuminated Controller is not powered on/ vehicle has dead battery/ or severe damage. Yellow LED flashing Controller is operating normally. Yellow and red LEDs both on solid Controller is in Flash program mode. Red LED light on solid No software loaded, or an internal hardware fault detected by the Supervisor or Primary microprocessor.
  • Page 48 CURTIS-3501 Display Unit(1232SE)： State of charge (SOC) of the battery is displayed on the right side of the indicator, if the battery is fully charged, the indicator displays 100% (10 segments), when SOC of battery is 20%, the battery symbol will light on (the sixth one from left in the picture above ), indicating the battery needs charging.
  • Page 49 Fig. 22:1232SE Electrical diagram...
  • Page 50 1232SE Description of electrical components Symbol Designation Symbol Designation Battery 48V/480AH Battery sliding monitor switch Mast moving limit Emergency button switch Mast speed limit Towering motor switch Forward shifting limit Pump motor switch Backward shifting Steering motor limit switch Forward and Towering controller backward shifting speed limit switch...
  • Page 51 AC transfer Backing-up lamp Platform switch Buzzer Fuse10A Brake relay FU1~FU4 K1-K2 Parking switch Horn button Lamp button CAN communication S Brake switch Valve controller Direction 180°/ 360°Transfer switch switch Travel speed limit switch 1232SE drive controller and oil pump motor controller fault code table: PROGRAMMER LCD DISPLAY CODE...
  • Page 52 Shutdown Pump Precharge failed Shutdown Motor; Shutdown Main Set: Precharge failed to charge Contactor; Shutdown 1) External load on capacitor bank the capacitor bank to KSI EMBrake; that prevents the capacitor bank voltage from charging Clear: Cycle Interlock input or Shutdown Throttle;...
  • Page 53 Shutdown Throttle; Brake; Shutdown Pump. 1) Battery Menu parameters are misadjusted Set: Capacitor bank voltage 2) Non-controller system drain on dropped below the Severe battery Undervoltage limit with Severe Undervoltage 3) Battery resistance MOSFET bridge enabled Reduced drive torque. 4) Battery disconnected while Clear: Bring capacitor voltage driving above Severe Undervoltage...
  • Page 54 1) The batteries need recharging. 2) Battery parameters are misadjusted Set: Capacitor bank voltage 3) Non-controller system drain on dropped below the Undervoltage Cutback battery Undervoltage limit ， 3 Reduced drive torque 4) Battery resistance too high Clear: Bring capacitor voltage 5) Battery disconnected while below the undervoltage limit driving...
  • Page 55 Set: Digital Output 7 current Digital Out 7 exceeded 15 mA Overcurrent Clear: Remedy the overcurrent External load impedance is too low Digital Output 7 will not cause and use the VCL function turn on Set_DigOut() to turn the driver on again 1) Motor temperature is at or above the programmed...
  • Page 56 Main Open/Short Shutdown Motor; Set: Main contactor driver (pin 1) Open or short on Shutdown Main 6) is either open or shorted. driver load Contactor; Shutdown This fault can be set only when 2) Dirty connector pins EMBrake; Main Enable = ON 3) Bad crimps or faulty Shutdown Throttle;...
  • Page 57 Set: Motor encoder phase Encoder Fault 1) Motor encoder failure failure detected. Shutdown EMBrake; 2) Bad crimps or faulty wiring Clear: Cycle KSI Motor Open Shutdown Motor; Shutdown Main Set: Motor phase U, V or W Contactor; Shutdown 1) Motor phase is open detected open EMBrake;...
  • Page 58 Clear: Bring throttle pot wiper charge below the fault threshold Set: Throttle pot wiper (pin 16) voltage is lower than the low fault threshold (can be changed Throttle Wiper Low with the VCL function Throttle pot wiper voltage too low Shutdown Throttle;...
  • Page 59 EEPROM Failure Shutdown Motor; Shutdown Main Contactor; Shutdown Failure to write to EEPROM Set: Controller operating EMBrake; memory. This can be caused by system tried to write to Shutdown Throttle; EEPROM memory writes initiated EEPROM memory and failed. Shutdown Interlock by VCL, by the CAN bus, by Clear: Download the correct Shutdown Driver 1...
  • Page 60 Brake; Shutdown Pump. These faults can be defined by the OEM and OEM Faults 51-67 See OEM documentation are implemented in the application-specific VCL code. VCL RunTime Error Shutdown Motor; Shutdown Main Contactor; Shutdown Set: Runtime VCL code error EMBrake; condition Shutdown Throttle;...
  • Page 61 Supply Max and External Supply Min parameter settings. Clear: Bring the external supply current within range OS General Shutdown Motor; Shutdown Main Contactor; Shutdown EMBrake; Shutdown Throttle; Shutdown Interlock Set: Internal controller fault Internal controller fault Shutdown Driver 1 detected Shutdown Driver 2 Clear: Cycle KSI Shutdown Driver 3...
  • Page 62 Set: No motor encoder Stall Detected 1) Stalled Motor movement detected Shutdown EMBrake; 2) Motor encoder failure Clear: Either cycle KSI or detect Motor disabled; 3) Bad crimps or faulty wiring valid motor encoder signals Controller Mode 4) Problems with power supply for while operating in LOS mode changed to LOS (Limited the motor encoder...
  • Page 63 VCl/OS Mismatch Shutdown Motor; Shutdown Main Contactor; Set: VCL and OS software do Shutdown EMBrake; not match; when KSI cycles, a Shutdown Throttle; check is made to verify that The VCL software in the controller Shutdown Interlock they match and a fault is issued does not match the OS software in Shutdown Driver 1 then they do not.
  • Page 64 1) Emergency Reverse was Set: Emergency Reverse was activated and concluded because Emer Rev Timeout activated and ran until the EMR the EMR Timeout timer has Shutdown EMBrake; Timeout timer expired. expired Shutdown Throttle; Clear: Turn the emergency 2) The emergency reverse input is reverse input OFF stuck ON Set: Illegal Model_Number...
  • Page 65 OEM Faults FAULT DESICRIPTION NOTE POSSIBLE CAUSE Steering CAN Comm failure EPS CAN Communication Timeout Severe Steering Fault Severe Steering Failure Steering Fault Steering failure Pedal Switch Short Accelerator pedal switch=on before power-on (normally it should be Off). VCL HPD Fault The power-on acceleration signal exceeds the dead zone.
  • Page 66 2. Motor parameters are mis-tuned. 3. Controller defective. 1. Leakage to vehicle frame from Current Sensor phase U, V, or W (short in motor Cycle KSI Shutdown. 1 = Stop. Fault stator). 2. Controller defective. 1. External load on capaciter bank(B+ connection terminal) that Precharge prevents the capacitor bank from...
  • Page 67 1. Improper mounting or cooling of controller. Controller Heatsink Warning 2. Excessive load on vehicle. 1 = Stop. Overtemp temp< 85°C. Only. 3. Controlleroperatinginanextreme environment. 5V Supply External Load Impendance on the Hold then Cycle KSI 1 = Stop. Failure +5V supply is too low.
  • Page 68 1. Stalled steer motor. 2. Steer motor encoder failure. Warning Motor Stalled 3. Bad crimps or faulty wiring. Cycle KSI then 1 = Stop. 4. Problems with power supply of shutdown the steer motor encoder. 1. Motor phase is open. Warning 2.
  • Page 69 Feedback Position feedback device's Analog Hold then Analog5 Out of Cycle KSI 1 = Stop. 5 input (pin 16) is out of range. Shutdown. Range Feedback Position feedback device's Analog Hold then Analog6 Out of Cycle KSI 1 = Stop. 6 input (pin 17) is out of range.
  • Page 70 1. When the interlock switch inputs are a crossed configuration (N.O. Interlock Interlock Input and N.C.), the two inputs are Interlock Switch 1 <> Interlock 1 = Stop. checked.A fault is set if Switch 1 = Off. Supervision Input 3. (pin 9) = Switch 3 (pin 11).
  • Page 71 Software Fault1 Reserved for future use. 1. Software defective. Software Fault2 Cycle KSI Shutdown. 1 = Stop. 2. Controller defective. Software Fault3 Reserved for future use. 1. Software defective. Software Fault4 Cycle KSI Shutdown. 1 = Stop. 2. Controller defective. 1.
  • Page 72 b. F4A Configuration These controllers detect a wide variety of faults or error conditions. Faults can be detected by the operating system or by the VCL code. This section describes the faults detected by the operating system. Diagnostics information can be obtained in either of two ways: (1) by reading the display on a hand-held or PC programmer or (2) by observing the fault codes issued by the Status LEDs.
  • Page 73 The controller's two LEDs will display this repeating pattern: The numerical codes used by the yellow LED are listed in the troubleshooting table, which also lists possible fault causes and describes the conditions that set and clear each fault. Summary of LED display formats The two LEDs have four different display modes, indicating the type of information they are providing: DISPLAY STATUS...
  • Page 74 Whenever a fault is encountered and no wiring or vehicle fault can be found,shut off KSI and turn it back on to see if the fault clears. If it does not, shutoff KSI and remove the 35-pin connector. Check the connector for corrosion or damage, clean it if necessary, and re-insert it.
  • Page 75 BDI: The battery icon on the main interface of the 3401T-5002 meter will display different colors according to the battery power, and the battery power range is 0~100%. The specific meanings of the color display of the battery icon are as follows: 20%~100%: Green battery icon is on.;...
  • Page 76 /+：When all 5-digit pin codes are entered, press the /+ key, and the 3401T-5002 will automatically verify whether the passwords are entered correctly or not. If the password is correct, the meter will enter the corresponding menu, if the password is wrong, the meter will prompt that the password is wrong. Note: When the password input is less than 5 digits, pressing the /+ key is an invalid operation.
  • Page 77 Fig. 23: Electrical diagram (truck with F4A controller)
  • Page 78 F4A Symbol specification Code Item Code Item battery48V Battery monitoring switch Emergency power off switch Front shift limit switch Traction motor Backward shift limit switch Oil pump motor Front and rear shift speed limit switch Steering motor Mast descent speed limit switch SteeringController Park switch Traction Controller...
  • Page 79 Electric Controls...
  • Page 80 Qty. Item code Name Remark 920100100014 500A Fuse 910200200014 Screw GB70.1-M4x12-8.8 920100400002 Fuse holder SYY 213033020004 Copper row 910100300010 GB5783-M6x16-8.8 Bolt 910400500005 Spring washer GB93-6 910400100005 GB97.1-6-200HV Flat washer 921400100004 1222-5101 controller 213133020000 Aluminum plate 920100400001 Fuse holder 910200500024 Screw GB818-M4x16-4.8 921400100043 Controller...
  • Page 89 Shutdown Motor; Shutdown The accelerator signal comes VCL HPD Main Contactor; Shutdown EM first, operate in the correct Controller Fault Brake; Shutdown Throttle; Full Faults order Brake. Shutdown Motor; Shutdown VCL SRO Main Contactor; Shutdown EM The switch signal comes first, Controller Fault Brake;...
  • Page 90 Brake; Shutdown Throttle; Full Brake. BMS low AH no action Need charging Battery Faults Shutdown Motor; Shutdown BMS voltage Main Contactor; Shutdown EM Check battery Battery difference Brake; Shutdown Throttle; Full Faults Brake. Shutdown Motor; Shutdown BMS Severe Main Contactor; Shutdown EM Check battery Battery Overvoltage...
  • Page 91 Brake; Shutdown Throttle; Full Brake. Shutdown Motor; Shutdown Not Curtis Main Contactor; Shutdown EM Check display configuration Controller Display Brake; Shutdown Throttle; Full Faults Brake. Shutdown Motor; Shutdown Pump Solve the handshake problem Main Contactor; Shutdown EM Handshake with Controller (matching, Controller Brake;...
  • Page 95 Controller hardware is Controller cannot incorrect Contro Bad Firmware be fully started 1, CRC or OS does not match ller 2. An incompatible OS is used Shutdown EM Brake, shutdown 1. The truck is operating when throttle, the EM brake is set. Trigger the hold- Contro EM Brake Failed to Set...
  • Page 96 3. The AC induction motor feedback Throttle; turned on when the single selects sine and cosine Full Brake Controller is applied Interlock Braking Supervision 1. During the interlock braking Fault Type： process, the motor speed 1. The motor speed exceeds the limit exceeds the parameters set range of interlock brake monitoring under Interlock Braking...
  • Page 97 6. Output limited with no current 5. Check Programmer / Fault Type3-5 requires driver fault Controller Setup / Outputs / detection to be turned on Driver 1 / Driver 1 Overcurrent. Driver 2 Fault 1. The driver load is open or Fault Type: short circuited 1.
  • Page 98 4. Open/short (low detected, should 4. The driver is overcurrent, be high) exceeding the value set by 5. Disconnection Driver 4 Overcurrent 6. Output limited with no current 5. Check Programmer / Fault Type 3-5 requires driver fault Controller Setup / Outputs / detection to be turned on Driver 4 / Driver 4 Overcurrent.
  • Page 99 Driver 7 Fault 1. The driver load is open or Fault Type: short circuited 1. Driver short circuit 2. The pin of the connector or 2. driver overcurrent the coil of the contactor is dirty 3. Open/short (high detected, should 3.
  • Page 100 2. the lower limit is limited to 2. Analog 1 input voltage is lower than Analog 1 Low Settings 3. Check Programmer / Controller Setup / Analog Inputs / Analog 1 4. Check Programmer / Controller Setup / Analog Inputs / Config / Analog 1 Low/Analog 1 High 1.
  • Page 101 4. Check Programmer / Controller Setup / Analog Inputs / Config / Analog 3 Low/Analog 3 High 1. The input voltage of analog 4 is higher than the setting value of Analog 4 High 2. Analog 4 input voltage is lower than Analog 4 Low Analog 4 Out of Range None, unless VCL...
  • Page 102 2. the lower limit is limited to 2. The input voltage of analog 6 is lower than Analog 6 Low Settings 3. Check Programmer / Controller Setup / Analog Inputs / Analog 6 4. Check Programmer / Controller Setup / Analog Inputs / Config / Analog 6 Low/Analog 6 High 1.
  • Page 103 / Analog Inputs / Config / Analog 8 Low/Analog 8 High 1. The input voltage of analog 9 is higher than the setting value of Analog 9 High 2. The input voltage of analog 9 is lower than Analog 9 Low Analog 9 Out of Range Settings None, unless VCL...
  • Page 104 3. Check Programmer / Controller Setup / IO Assignments / Controls 1. The input voltage of analog 18 is higher than the setting value of Analog 18 High 2. The input voltage of analog 18 is lower than the setting Analog 18 Out of Range value of Analog 18 Low None, unless VCL...
  • Page 105 2. Contact local Curtis technical EMBrake, support to handle the fault Shutdown Throttle, Full Brake BMS Cutback 1. Battery current decreases None, unless VCL Solve battery or battery Batter 2. The battery cell voltage is reduced adds special problems 3. The battery cell voltage is too much handling to reduce None, unless VCL...
  • Page 106 PWM Input 28 Out of Range 1. Input disconnection 2. The measured input frequency is lower than (PWM_Input_28_Low_Frequency) - (PWM_FrequencyInput_28_Frequency _Fault_Tolerance) 1. The fault diagnosis execution 3. The measured input frequency is cycle is every 4 milliseconds. If higher than (PWM_Input_ 28_ High_ no PWM signal is generated Frequency) within 16 milliseconds, or the...
  • Page 107 Tolerance) 4. The measured duty cycle is lower than the set limit, (PWM_Input_29_Low_Duty_Cycle) - (PWM_Input_29_Duty_Cycle _Fault_Tolerance) 5. The measured duty cycle is higher than the set limit, (PWM_Input_29_High_Duty_Cycle)+(P WM_Input_29_Duty_Cycle_Fault_Tole rance) Primary State Error These are internal problems that occur during startup, parameter initialization, secondary micro-update, or other runtime problems 1 = PRIMARY_DEVICE_STARTUP = 0,...
  • Page 108 PRIMARY_STARTUP_TIMER_FAILURE, 11 = PRIMARY_WAIT_CAN_HANDSHAKING_ DONE, 12 = PRIMARY_RUNNING The fault diagnosis associated with the lifting input source will trigger the fault. For example, if the lifting input source is an analog input, all Shutdown Lift Contro Lift Input Fault faults related to the analog Input ller input will be collected and...
  • Page 109 Pump The fault diagnosis associated with the descent input source will trigger the fault. For example, if the descending input source is an analog input, Shutdown Lower Contro Lower Input Fault all faults related to the analog Input ller input will be collected and reported Clear: Resolve any assignment conflicts, or enter out of range,...
  • Page 110 parameter (Hazardous_Speed) these checks IMU Failure 1=SPI communication failure Check whether the 2=Curtis factory self-test failure configuration is correct or the 3=runtime check failure, error data Contro None vehicle is moving during received from IMU ller calibration 4=The calibration test of the gyroscope Cycle key switch is out of range, and the maximum calibration deviation exceeds...
  • Page 111 1222 Steering motor controller troubleshooting table: 1222 Controller Fault Code Tract Steer Name Possible Cause Clear Condition Fault Fault Action Actio Hardware Fault Hardware error detected Cycle KSI Shutdown. Stop. Controller 1. External short of phase U,V, or W Overcurrent motor connections.
  • Page 112 3. Battery disconnected while driving. 4. Blown B+ fuse or steer contactor did not close. Severe Overvoltage 1. Battery or battery cable resistance too high for a given regen current. Cycle KSI Shutdown. 2. Battery disconnected while regen Stop. braking. Controller 1.
  • Page 113 1. Open or short on driver load. Warning Contactor Open/Short 2. Dirty connector pins. Cycle KSI then Stop. 3. Faulty wiring. shutdown 1. Externalloadimpedanceonthe fault Warning Fault Output output is too low. Cycle KSI then Open/Short Stop. 2. Controller defective. shutdown 1.
  • Page 114 Command Analog1 input device's Analog 1 input (pin 8) Hold then Cycle KSI Out of Range is out of range. Shutdown. Stop. Command Analog3 Command input device's Analog 3 Hold then Cycle KSI Out of Range input (pin19) is out of range. Shutdown.
  • Page 115 1. A parameter value or the software was changed that required a power Parameter Charge cycle. Cycle KSI Shutdown. Fault 2. This fault is set automatically to Stop. force the vehicle operator to cycle power, for safety purposes. 1. When the interlock switch inputs are a crossed configuration (N.O.
  • Page 116 The external load on the 5V supply is 5V Current Out of drawing either too much or too little Cycle KSI Shutdown. Range Stop. current. 1 Software Fault1 Reserved for future use. 1. Software defective. 2 Software Fault2 Cycle KSI Shutdown.
  • Page 117 13 Standard torque Tightening torque The following charts give the standard tightening torques of bolts and nuts. METER TABLE 4T, 5T Classification 10.9 Bolt type Torque kgf · m (lbf · ft) Torque kgf · m (lbf · ft) Bolt size 0.2 ±...
  • Page 118 INCH TABLE 4T, 5T Classification Bolt type Bolt size Torque kgf · m (lbf · ft) Torque kgf · m (lbf · ft) 0.6 ± 0.06 1.7 ± 0.2 5/16 1.2 ± 0.12 3.0 ± 0.3 2.0 ± 0.20 5.6 ± 0.5 7/16 3.2 ±...
  • Page 119 Newton meter : 1 Nm = 0.1kgfm TIGHTENING TORQUE OF SPLIT FLANGE BOLTS The following torque shall be applied to the split flange bolts. Thread Torque (kgf·m) 1.1 ± 0.1 2.6 ± 0.2 4.6 ± 0.3 8.5 ± 0.4 19 ± 1.0 33 ±...
  • Page 120 Tube O.D (inch) Thread (in) Torque (kgf·m) UN 13/16 - 16 9.5 ± 0.95 UN 1 3/16 - 12 18 ± 1.8 UN 1 7/16 - 12 21 ± 2.1 14 Disassembly/assembly instructions a. Replacement tool for electrical plug-in connection Application Remove pin Install pin...
  • Page 121 Two-hole lock Four-hole lock Remove pin b. Drive motor disassembly/assembly 1. After removing the electromagnetic brake, loosen the screws and remove the lid 2. Remove encoder and U V W...
  • Page 122 3. Remove steering motor. 4 Remove the drive motor retaining bolt. 5 Remove the motor by hoisting it flat with the crane. 6 Installation is the inverse of disassembly.
  • Page 123 c. Stator Test 1.Carefully wipe the contamination on the stator surface with a clean cloth dipped in alcohol. Note: contamination in the stator can cause coil damage and therefore damage to the stator itself. 2.Use a milliohmmeter to measure the resistance of each phase (UV, VW, Wu). Rated resistance: 0.4 Ω...
  • Page 124 Common Faults Analysis of Drive Motor Problem Possible cause Drive motor does not work Switch not off (battery connector, key switch, seat switch, f / R switch or parking brake switch): Turn off the switch. If it still fails to operate, use a voltmeter to test the power supply of the control panel and the current of each switch.
  • Page 125 Check all cells for one or more defective cells. Check the specific gravity of each cell. The maximum density difference from the highest battery to the lowest battery shall not exceed. 020 SG (specific gravity) Incorrect operation of the control panel: Drive motor does not work Encoder failure.
  • Page 126 Check the brake adjustment. Check the wheel bearing, axle and other mechanical parts for correction to eliminate the fault. Change to a tire with less friction After a work shift, the forklift's working capacity exceeds its designed capacity without available power: The battery is dirty and the electrolyte is on the Battery positive (-) or negative (-) in direct contact...
  • Page 127 f. Hydraulic System The hydraulic system operates a plurality of actuators by pressurized oil from the autonomous hydraulic pump and draws oil discharged from these actuators. 1. The pump motor which is controlled by the controller drives the main hydraulic pump. 2.
  • Page 128 tank and conveys the oil to the lifting cylinder. 3. The hydraulic tank stores the hydraulic oil returned from the cylinder. The stored oil is suncted by the main hydraulic pump for reuse. The pump motor is connected to the pump motor controller through the pump contactor and (B-)line. The controller runs the pump motor according to the input of the lifting switch and sensor.
  • Page 129 Remove the fastening bolts and take out the motor. Mounting Torque：55±10 N·m（40±7 lb·ft） 4. Install the pump motor in reverse orders. h. Replacing the Seal Rings of the Lifting Cylinder 1.Remove the cylinder head using the crescent wrench...
  • Page 130 2. Pull out the piston rod, remove the support ring on the shaft 3. Take out the dust ring, baffle ring and Y-ring from the cylinder head with a flat-head screwdriver.
  • Page 131 4. Remove the O-ring and retaining ring from the cylinder cap, then do the maintenance. The installation process is the reverse process of disassembly. i. Common Faults of Pump Motor Problem Possible reasons Bad connection or fuse burning. Check the battery connection. Check the key fuse.
  • Page 132 Check for one or more defective battery cells in battery. Check cable terminals are tightly aligned with battery terminals and control panel connectors. Check cable internal wires are broken. The lift and drive system is not operating correctly. The battery installed on the vehicle is too small. According to the working hours, choose the appropriate battery capacity.
  • Page 133 j. Common Faults of Hydraulic Pump Problem Possible reasons Low oil level oil thick Pump noise limit to the inlet line of the pump Worn parts in the pump. Oil dirty Air leaks into the inlet line Low oil level oil channel limited Safety valve settings are too low Oil thin...
  • Page 134 k. Appearance of a lithium battery Battery System Parameters Rated Voltage 51.2V Rated Capacity 300Ah & 400Ah Total Voltage Range 43.2V 58.4V power on Press and hold the power switch for 1 second power off Press and hold the power switch for 3 seconds STD.
  • Page 135 l. Port definition Discharge Port Positive discharge terminal Negative discharge terminal key1 Start of discharge key2 CAN-H Vehicle CANH CAN-L Vehicle CANL...
  • Page 136 Charge Port Positive charge terminal Negative charge terminal CAN-H Charge CANH CAN-L Charge CANL 12V+ in 12V power supply of Chaeger for battery BMS 12V- in Debug Port Debug_CANH Debug_CANL Vehicle_CANH Vehicle_CANL Charge_CANH Charge_CANL No Pin Attentions 1.Batteries are forbidden to charge below 0 ℃. Otherwise, the performance of batteries willdeteriorate seriously, and even safety incidents will occur.
  • Page 137 of the battery. Unpredictable hidden dangers. After taking it out of the cold environment, it should be kept at room temperature for at least4 hours before use. 3.The battery protection level is IP54. Do not flush the battery directly with water. 4.The battery should not be used in the marine salt spray environment, and should not beused in the humid environment for a long time (in the aquatic market, cold storage, icemaking plant, bathroom, acid plant, etc.).
  • Page 138 n. Industrial Battery High-Frequency Charger 1).Cautions for safe operation Preface Thank you for using this product, Please ensure read the guide carefully before installing the product, and check the completeness of packing and attach-ment based on packing list. In order to keep the operator safe and charger run normally, please follow the guide strictly. Caution: We will not take any responsibility for those who operate the charger not follow the opera-tion guide.
  • Page 139 Operating Condition Safety ♦ Smoke, water, flame and corrosive gas should be pre-vented from entering the charger. ♦ In case any liquid intrusion, please turn off the charger immediately and send it to the designated professional and technical personnel for maintenance.
  • Page 140 Need to be installed by a professional electrician.  Single phase Three phase Three phase Y Terminal three wire four wire five wire system system system phase color Brown Black Gray Blue PE / Yellow Green...
  • Page 141 DC Output Connecting The connectors you use for the chargers may be the-se: Which ever connector you choose,be sureconnect the charger correctly according to guidance on the connectors . Cautions Make sure checking the input and output connected 3).Quick Setup ♦...
  • Page 142 ♦ The charger is equipped with an touch screen displayer or LED displayer depends on different model, which shows charging status. （Touch Screen Displayer） （LED Displayer） DESCRIPTION Touch Screen : LED Self-checking Check if battery good, allow charging, or any problem Ready External condition normal, charging available...
  • Page 143 Charging completed SOC is equal to 100% or the charging voltage reaches 98% of the set voltage, and BMS sends the instruction to stop charging Battery over-voltage BMS detects battery abnormality and sends overvoltage command Battery overcurrent BMS detects battery abnormality and sends overcurrent instruction BMS communication Communication between the BMS and the...
  • Page 144 15. CURTIS SE Handheld Console Operation Cautions ： The prompt function of the console is designed for the convenience of vehicle inspection and maintenance, Adjustments to the controller parameters are not allowed without the approval of the vehicle manufacturer， so as to avoid vehicle and personal safety accidents. After modifying the parameters, the handheld unit will automatically save the parameter settings, and the only thing you need to do is just close the key switch and restart.
  • Page 145 The programmer has two interfaces with a battery box and a memory card slot, of which one is used to communicate with electric control, and the other is used to communicate with PC. SD card slot Battery box position USB Connector (on the back) Controller Connector Connectors...
  • Page 146 Function keys The three keys will be blank because the function of the three keys is based on the specified content. At any given time, the functions of the buttons are displayed on the LCD screen above. Directional arrow key. The information displayed can be selected by pressing up, down, or left or right through 4 directional keys.
  • Page 147 Menu structure The main menu consists of nine submenus, each of which is displayed with a specific icon, and each item of the submenu is arranged in a hierarchy. Some menus contain one item only, but most menus contain more than one item, and you can access the next level of submenus through each folder.
  • Page 148 and you can determine if the fault really exists by restarting the system and observing the automatic fault indication. In the history failure folder, the failures listed are all failures encountered after the last history failure was cleared, which can be restarted by clearing the fault content in the entire folder. "Clear All"...
  • Page 149 Parameter Settings Select "Parameters" from the main page and press "Select" to enter the parameter setting page, in which you can adjust or modify the parameters of the controller. Save.cpf File Use the save. cpf file function in the programming menu to back up the currently set parameters.
  • Page 150 The other is through the parameter edit page as shown below...
  • Page 151 16. CURTIS F handheld unit The 1313 HHP has two connectors, one for communicating with the devices and one for interfacing with a PC. The 1313 HHP also has a battery compartment and a memory card slot. Controller (Vehicle System) Connector Use the cable with the DB9 connector for connecting to CAN-port programmable devices.
  • Page 152 Vehicle Harness Wiring for CAN Connected 1313 HHP USB Connector Use this connector with the supplied USB cable to connect the 1313 HHP to a PC. Windows Explorer will display the 1313 HHP as a removable drive. If an SD card is inserted in the 1313 HHP, Windows Explorer will display the 1313 HHP’s “Internal”...
  • Page 153 If the 1313 HHP hasn’t previously connected to a selected device, it will sequence through four steps uploading information. The 1313 HHP will automatically remember this device. All subsequent connections to this device, even on a different system, will be much faster, only requiring the final current-data upload step.
  • Page 154 KEY FUNCTIONS The pushbutton keys on the 1313 HHP’s keypad allow rapid navigation through the apps. MAIN SCREEN AND APPS ORGANIZATION The Main Screen contains 8 apps that are each identified by a specific icon. To select an app, scroll using the arrowkeys ( ) until the app is highlighted.
  • Page 155 DEVICES Device Details and Connection To use the 1313 HHP, a device must be compatible and then a CAN connection established. TheDevice app is where devices (CAN nodes) discovered during the startup CANbus-scan are listed*. After the 1313 powers up and completes the start-up scan, the Main Screen is displayed with theDevices app highlighted.
  • Page 157 PROGRAMMER ADJUSTING/EDITING PARAMETERS Within Programmer, use the down ( ) or up ( ) arrows to navigate between parameters, monitor- items, or sub-menus. If the menu contains more than the 8 items shown on the screen, a scrollbar appears at the right edge of the screen. When a scrollbar is present, the lines wrap around so that navigating up from the top line/item navigates the screen to the last line/item on the list and vice versa.

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