Hyundai 12 ES-X Service Manual
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Hyundai 12 ES-X Service Manual

Hyundai 12 ES-X Service Manual

Electric stacker
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12/16/20 ES-X
Electric Stacker
Service Manual
WARNING
Do not use the electric 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 for future reference.

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Summary of Contents for Hyundai 12 ES-X

  • Page 1 12/16/20 ES-X Electric Stacker Service Manual WARNING Do not use the electric 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 electric stacker, 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 stackers. When operating and servicing the truck, make sure, that it applies to your type.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS CORRECT APPLICATION ........................1.1 INTRODUCTION–MAINTENANCE SAFETY PRECAUTIONS ............. 1.2 MEASUREMENT CONVERSIONS ...................... DESCRIPTION OF THE STACKER ....................Overview of the main components ....................Main technical data ......................... Description of the safety devices and warning labels(Europe and other, excepting USA) ....Identification plate ...........................
  • Page 4 a. Electrical circuit diagram ........................b. Electrical circuit diagram (EN1175:2020) .................... c. Hydraulic circuit ........................... 11. Electrical Systems ..........................a. Overview ............................. b. Emergency switch ..........................c.Controller and related devices ......................d.Tiller head ............................12.Drive/Brake System ..........................a. Overview ............................. b.

  • Page 5: Correct Application

    CORRECT APPLICATION It is only allowed to use this electric stacker according to this instruction handbook. The trucks described in this handbook are self-propelled pedestrian controlled electric power stacker, with electrically powered low height lifting function. The trucks are designed for stacking operations in dedicated racking by lifting and lowering the palletized load up to the desired lifting height.

  • Page 6: Introduction-Maintenance Safety Precautions

    1.1 INTRODUCTION–MAINTENANCE SAFETY PRECAUTIONS Maintenance work may cause injuries. Always take care to perform work safe, at least observing the following. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves, others or damage to the equipment.
  • Page 7 It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system. Relieve system pressure by cycling the applicable control several times with the engine(motor) stopped and ignition on, to direct any line pressure back into the reservoir.
  • Page 8 Exhaust gas is dangerous provide ventilation when working in a closed space. Avoid breathing dust that may be generated when handling components containing asbestos fibers. Wear a gas mask if necessary. When working on top of the machine, be careful not to lose your balance and fall.

  • Page 9: Measurement Conversions

    Before making adjustment, lubricating or performing any other maintenance, shut off all power controls. When removing parts containing O-ring Gaskets or seal clean the mounting surface and replace with new sealing parts. Thoroughly clean the machine. In particular, be careful to clean the grease fittings and the area around the dipsticks.
  • Page 10 Volume Unit 0.000001 0.001 0.061024 0.000035 0.000001 1000000 1000 61024 35.315 1.30796 1000 0.001 61.024 0.035315 0.001308 16.387 0.000016 0.01638 0.000578 0.000021 28316.8 0.028317 28.317 1728 0.03704 764529.8 0.76453 764.53 46656 1gal(US)=3785.41 cm =231 in =0.83267gal(US) Pressure Unit kgf/cm Pa=N/m lbf/in lbf/ft kgf/cm...
  • Page 11 METER TABLE Classification 4T, 5T Bolt type 10.9 Bolt size Torque kgf ·m (lbf· ft) Torque kgf ·m (lbf ·ft) 0.2 ± 0.02 0.4 ± 0.04 0.3 ± 0.03 0.8 ± 0.08 0.5 ± 0.05 1.4 ± 0.14 1.2 ± 0.12 3.3 ±...
  • Page 12 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 1.2 ± 0.12 3.0 ± 0.3 5/16 2.0 ± 0.20 5.6 ± 0.5 3.2 ±...
  • Page 13 – ring PF THREAD Torque (kgf · m) Thread 1.1 ± 0.1 2.6 ± 0.2 4.6 ± 0.3 8.5 ± 0.4 19 ± 1.0 33 ± 2.0 TORQUE FOR SWIVEL NUT WITH O-RING hose O – ring Connector Swivel– nut Tube O.D (inch) Thread (in) Torque (kg f ·...
  • Page 14 APPROXIMATE CONVERSIONS Conv Conv Non– SI Unit Unit Factor Factor Unit Torque Newton meter (N · m) ln · in N · m × × 0.113 Newton meter (N · m) lb ·ft. N · m × × 0.74 1.36 Newton meter (N ·...

  • Page 15: Description Of The Stacker

    1. DESCRIPTION OF THE STACKER Overview of the main components Fig. 1: Overview main components Main cover Key switch Handle Load roller Safety (belly) button 10. Pallet Accelerator (butterfly button) 11. Load backrest Battery cover 12. Protective board Emergency button 13.

  • Page 16: Main Technical Data

    Main technical data Fig. 2: Technical data Table1: Main technical data for standard version Type sheet for industrial truck acc. to VDI 2198 12ES-X 16ES-X 20ES-X Manufacturer`s type designation (3600) (4600) (4600) Power (battery ,diesel, petrol, gas, manual) Battery Operator type Pedestrian Load Capacity / rated load Q(t)
  • Page 17 ∅xW Tire size, rear ∅84×70 (mm) ∅xW Additional wheels(dimensions) ∅150x54 (mm) Wheels, number front/rear(x=driven wheels) 1x+1/4 Track, front (mm) Track, rear (mm) Lowered mast height (mm) 2308 2108 2228 Free Lift height (mm) 1760 1520 1520 Lift height (mm) 3530 4530 4530 Extended mast height...
  • Page 18 Lowered mast height Free Lift height Lift height Extended mast height Designation h1(mm) h2(mm) h3(mm) h4(mm) 12ES-X 1958 2830 3380 — Two stage mast 2108 3130 3680 — 2308 3530 4080 — 1958 1410 2830 3380 Two stage mast FFL 2108 1560 3130...

  • Page 19: Description Of The Safety Devices And Warning Labels(Europe And Other, Excepting Usa)

    Description of the safety devices and warning labels Crane hook label Warning decal: Do not step under or on the forks Residual lift capacity sticker Never reach through Identification plate (ID-plate) Sticker to read and follow these instructions Sign of filling point The truck has an emergency button (6) which stops all lifting-, lowering-, driving- functions and engages the failsafe electromagnetic brake when it is pushed.

  • Page 20: Warnings, Residual Risk And Asfety Instructions

    2. WARNINGS, RESIDUAL RISK AND SFETY INSTRUCTIONS DO NOT • Drive outside the stacking operation with a lifted load higher than the lifting point. • Put foot or hand under or into the lifting mechanism. • Allow other person than the operator to stand in front of or behind the truck when it is moving or lifting/lowering.

  • Page 21: Commissioning, Transporting, Decommissioning

    3. COMMISSIONING, TRANSPORTING, DECOMMISSIONING Commissioning Table 2: Commissioning data (For different models, the commissioning weight is marked on the ID-plate) Type 12ES-X /3600 16ES-X /4600 20ES-X /4600 Commissioning weight 1082 1415 1660 [kg] 3600 4600 4600 Version/ Lift [mm] For different models, the commissioning weight is marked on the ID plate. After receiving your new truck or for re-commissioning you have to do following before (firstly) operating the truck: •...

  • Page 22: Decommissioning

    Transportation DURING TRANSPORTATION ON A LORRY OR TRUCK ALWAYS FASTEN THE TRUCK SECURELY Lower the forks and park the truck on the iron plate securely. Fixe the forks by the iron sheet with two screws. Fasten the truck by fixing dedicated lashing belts according to fig.

  • Page 23: Daily Inspection

    4. DAILY INSPECTION This chapter describes pre-shift checks before putting the truck into operation. Daily 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 24: Operating Instructions

    5. OPERATING INSTRUCTIONS BEFORE OPERATING THIS TRUCK, PLEASE FOLLOW THE WARNINGS AND SAFETY INSTRUCTIONS (CHAPTER 3). BEFORE OPERATING THIS TRUCK, ENSURE THAT THE LOAD OR OTHER EQUIPMENT NOT CAUSES INSUFFICIENT VISIBILITY! Fig.8: Key switch Fig.7: Tiller operating controls Make sure, that the load is palletized and stable and that the daily inspection is carried out. For starting, insert the key and turn it clockwise to the “ON”- position.

  • Page 25: Lifting

    Lifting DO NOT OVERLOAD THE TRUCK! THE MAXIMUM CAPACITY IS 1200/1600/2000kg WHEN THE LOAD CENTER IS 600MM. LIFT ONLY CAPACITIES ACCORDING TO THE RESIDUAL LIFT DIAGRAM. Travel with the lowered forks fully underneath the pallet and press the lifting button(fig.7,23) until you reached the desired lifting height.

  • Page 26: Steering

    If you move the accelerator button back to the neutral position, the controller decelerates the truck until the truck stops. If the truck stopped, the parking brake will be engaged. Drive carefully the truck to the destination. Watch the route conditions and adjust the travelling speed with the accelerator-button.

  • Page 27: Battery Maintenance, Changing And Replacement

    6. BATTERY MAINTENANCE, CHANGING AND REPLACEMENT Only qualified personnel are allowed to service or charge the batteries. The instructions of • this manual and from the battery- manufacturer must be observed. Lead-acid batteries and lithium batteries are allowed. • Recycling of batteries undergoes national regulations. Please follow these regulations. •...

  • Page 28: Replacement

    Replacement Park the truck securely and switch off the stacker with the key (8) and activate the emergency button (6). Open the battery cover and pull out the hinge, remove the battery cover. Unscrew and remove the battery baffle plate, pull out the battery plug (Fig.13), and take the batteries out with a crane.
  • Page 29 a-2. Side pulling installation mode 1.Open the lid of the battery box 2.Pull off the power plug 3.Unscrew bolts with 5 mm hexagon wrench 4.Pull out plugs 5.Pull the battery out in the direction indicated by the arrow and the installation process is the reverse of the removal process.

  • Page 30: Battery Indicator

    Battery indicator The discharge status is indicated by ten red LED segments. Only when the battery is properly charged, the most right LED lit as the battery’s state-of-charge decreases, successive LEDs light up, only one on at a time. • The 2 from left LED flashes, indicating “energy reserve”...

  • Page 31: Description Of The Lithium-Ion Battery

    Description of the lithium-ion battery The Lithium-ion battery is a battery with rechargeable cells, the battery is designed for industrial trucks and is able to withstand related vibrations during operation. The battery is equipped with special connections for charging and discharging operations. Avoid installing the improper battery or connecting the improper chargers to the battery.
  • Page 32 Item Description Item Description Manufacturer's mark in English Manufacturer's address Material Code electrical hazard marker Battery specifications Rechargeable logo Rated voltage Vertical upward packing, transportation and use Rated Capacity No putting into ordinary garbage bins Rated Energy Guide to use Weight Production date Battery information bar code...

  • Page 33: Technical Parameter

    Technical parameter Items Data(PS12/16L) Note Specification 24V100Ah Nominal voltage Nominal capacity 150Ah 0.5C discharge Weight 72kg Maximum continuous discharge current Maximum Pulse Discharge 180A Not exceeding 30 seconds Discharge Current Discharge cut-off voltage ≥20V Standard charge current Charge Max charge current Charge voltage 29.2V Between positive and...

  • Page 34: Safety Instructions, Warning Indications And Other Notes For Lithium-Ion Batteries

    Safety Instructions, Warning Indications and other Notes for lithium-ion batteries Safety regulations for handling lithium-ion batteries Do not try to make any repairs or maintenances of lithium-ion 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 35: Potential Hazards

    Potential hazards If the 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: Physical damage to the battery would be caused by falling or be deformed. Mechanical damages may •...
  • Page 36 Explosion and fire hazard Physical damage, thermal effects or incorrect storage of a defective battery can result in explosions or fire. Materials of the battery can be flammable. Particular hazard from combustion products The lithium-ion batteries may be damaged by a fire. When extinguishing a lithium-ion battery fire, the following information must be taken into consideration.

  • Page 37: Cleaning Measures

    Precautionary measures for personnel • Keep personnel away, avoid any contact with smoke or discharged materials. • Block off the affected area and ensure its reasonable ventilation. Wear personal protective equipment. If vapors, dust or aerosols are presented, use self-contained •...
  • Page 38 Failure to comply with these safety instructions can result in fire and explosion or the leakage of harmful materials. Faults If any damage is found to the battery or battery charger, contact the service provider immediately. Do not open the battery. Disposal and transportation of a lithium-ion battery Instructions for disposal Lithium-ion batteries must be disposed of in accordance with the relevant national environmental protection...

  • Page 39: Charger

    Charger Main product specification Outline dimension: L*W*H model CBZ3 CBZ3 CBZ3 CBZ3 CBZ3 CBZ3 CBZ3 CBZ3 CBZ3 CBZ3 item F-25 F-30 F-35A/ F-40A/ F-45A/ F-50A/ F-55A/ F-30A/ F-40A/ F-25A/ A/24 24 V 24 V 24 V 24 V 24 V 36 V 36 V 48 V...
  • Page 40 model CBZ3 CBZ3 CBZ3 CBZ3 CBZ3 CBZ3 CBZ3 CBZ3 CBZ3 F-30A F-35A F-25A F-30A F-65A F-45A F-55A F-65A F-85A item /48V /48V /72V /72V /24V /48V /48V /48V /48V Input Single phase 220-240V 50-60HZ Dual phase 380V ，50-60HZ voltage V，HZ Input power output...

  • Page 41: Regular Maintenance

    7. REGULAR MAINTENANCE Only qualified and trained personnel are allowed to do maintenance on this truck. • Before maintaining, remove the load and lower the forks to the lowest position. • If you need to lift the truck, follow chapter 4-b by using designated lashing or jacking •...
  • Page 42 Check the electric drive motor for noise and damages • Test the display • Check if correct fuses are used, if necessary replace. • Test the audio warning signal • Check the contactors • Check the frame leakage (insulation test) •...

  • Page 43: Lubricating Points

    Lubricating points Lubricate the marked points according to the maintenance checklist. The required grease specification is: DIN 51825, standard grease. Bearings in wheels Main frame post Chain Hydraulic system Steering bearing Fig. 16: Lubricating points Check and refill hydraulic oil It is recommended to use hydraulic oil in connection with average temperature: Environment –5℃~25℃...

  • Page 44: Checking Electrical Fuses

    Checking electrical fuses Remove the main cover. The fuses are located according to Table 5. Table 5: Size of the fuses Rate FU 01 350A Fig. 17: the size is according to table Replace fuse 1, fuse 2, fuse 01 (refer to 10.a circuit diagram) 1.

  • Page 45: Removing, Reattaching Guarding

    Fuse Fuse1 Fuse2 Fuse01 specifications 350A Fuse position 1.Unscrew the nut with a 13mm open-ended wrench, remove the fuse and replace it with a new one. The installation process and the reverse of the above process are described. Removing, reattaching guarding DO NOT USE THIS TRUCK, IF THE GUARDING IS DAMAGED OR NOT CORRECTLY ASSEMBLED! If the guarding needs to be removed, unbolt the fixing screws and remove the screen carefully.

  • Page 46: Trouble Shooting

    8. TROUBLE SHOOTING • If the truck has malfunctions follow the instructions, mentioned in chapter 6. Table 6: Trouble shooting TROUBLE CAUSE REPAIR Lift only max. capacity, Load weight too high mentioned on the ID-plate Battery discharged Charge the battery Check and eventually replace the Lifting fuse faulty lifting fuse...
  • Page 47 relating tiller cables Check the tiller cables and disconnected or damaged connections. Defective height sensor Check the sensor reduced speed at ∼300mm height Electric system overheated Stop using and cool down the truck Check and if necessary replace the Defective heat sensor heat sensor The controller is damaged.

  • Page 48: Wiring/ Circuit Diagram

    9. WIRING/ CIRCUIT DIAGRAM a. Electrical circuit diagram(EN1175:2020) FU1: 10A FU01: 350A Fig. 18: Circuit diagram (EN1175:2020)
  • Page 49 Table 7: Description of electrical diagram Code Item Code Item Battery Diode DC power switch Relay Controller Proximity switch Main contactor Tiller FU01 Fuse 350A Capacitor Fuse 10A Horn Indicator Magnetic switch Key switch Micro switch Lifting contactor Electromagnetic valve Pump motor Blue light Traction motor...

  • Page 50: Hydraulic Circuit

    c. Hydraulic circuit Fig. 19: Hydraulic circuit of PS12L Fig. 20: Hydraulic circuit of PS16/20L...

  • Page 51: Electrical Systems

    11. Electrical Systems a. Overview The model is equipped with an electrical system consisting of the following components: 1 The battery supplies power to the electrical system. 2 Press the power switch to turn off all DC and AC circuits in case of emergency. 3 Motors, controllers and associated equipment provide the necessary drive and pump power to the vehicle based on their interactions with sensors, switches, relays and actuators and many parameter settings.
  • Page 52 Replace the emergency stop switch 1.Use a Phillips screwdriver to unscrew the two 2.After removing the screws, the mushroom screws of the emergency stop switch head can be removed 3.Unscrew screw with crosshead 4.Separate the integrated blade panel from the screwdriver.

  • Page 53: C.controller And Related Devices

    7. Pull off the micro switch by holding the clips on both sides of the micro switch by hand. The installation process and the reverse process of the above process are described. Conversely, installing an emergency stop switch is the reverse process of the above steps. c.Controller and related devices 1) Controller Curtis ACF2-C (20 CE/EN1175)
  • Page 54 c-2 Functions The controller is connected via the following sensors, switches, relays and actuators. Key switch Power switch throttle tiller proximity switch Emergency reverse switch Hydraulic control switches c-3. Replacing Controller(example) 1. Remove the wiring on the electronic control in turn, pull out the plug-in and note the different ports corresponding to the different wiring...
  • Page 55 2.Unscrew the five screws V, U, W, -P, -B with a 10mm open-ended wrench and remove the wiring in turn 3.The controller can be removed by unscrewing the four fixing screws of the controller with a crosshead screwdriver. The installation process is the reverse process of disassembly. c-4.Replacing contactors 1.Unscrew two screws with a 13mm wrench.
  • Page 56 3 Remove copper bars 4.Unscrew bolts with a 13mm open-ended wrench 5.Remove copper bars 6.Unscrew screws with crosshead screwdriver 7.Remove contactor with mounting frame 8.Unscrew two screws with a screwdriver.

  • Page 57: D.tiller Head

    9.Remove mounting bracket and replace contactor. Installation reverse disassembly. d.Tiller head Function The tiller head controls some of the vehicle's movements through up and down buttons, belly switches, turtle buttons, throttle and combination locks and controller interplay Tiller Head disassembly and Installation 1).Remove 3 screws fixing the back cover of the handle with Philips screwdriver.
  • Page 58 2).Remove apart the front cover of handle 3).Remove the screws fixing the drive switch with Allen wrench. 4).Remove the drive switch and pull out the connectors 5).Unplug connector and then you can remove PCB and replace it.

  • Page 59: Drive/Brake System

    12.Drive/Brake System a. Overview The drive/brake system includes the following: 1) The drive motor controlled by the controller transmits the rotational force to the drive shaft (electric power mechanical power). 2) The drive shaft converts the rotational force transmitted from the drive motor into torque and speed suitable for driving through its gear set and sends them to the corresponding wheels (mechanical power).

  • Page 60: Operation

    Screw M10x20 Washer Washer Bolt M16x45 Screw M8x40 Driving wheel seat AC vertical drive assembly Operation The drive motor operates when the following conditions are met: 1 The key and the emergency stop switch are turned on to supply power to the controller, 2 Move the handle to the operating area, 3 Determine the direction of travel, 4 Twist the accelerator on the handle...

  • Page 61: Brake

    Remove screws，take off the connector Move 5 screws fixing the PU rim with 17mm wrench, and then you can remove and replace it b. Brake Appearance...
  • Page 62 Brake Disassembly Move 3 screws fixing the magnetic brake onto the drive wheel with 5mm Allen wrench and then you can remove the brake. Brake system circuit diagram Fig. 21: Brake circuit diagram...

  • Page 63: Hydraulic System

    13.Hydraulic System a. Overview The hydraulic system is composed of working oil pump, lifting cylinder and piping and other components. The hydraulic oil is supplied by the oil pump directly connected to the motor. The oil pump pumps the hydraulic oil to the cylinder. Description Qty.

  • Page 64: B.pump Station Assembly

    b. Pump station assembly b-1 Appearance and specifications The pump motor electrically transmits power to the main hydraulic pump to pump hydraulic fluid to operate the hydraulic system. b-2 Replacing Pump Station Note: When assembling and disassembling the hydraulic pump, do not apply any pressure to the motor Preliminary Steps 1.Drop the fork to the bottom and press the drop button several times to eliminate the residual...
  • Page 65 1.Unscrew the screw with a 13mm wrench and remove the wiring 2.Remove the hydraulic line with a 22m and 22mm 3.Pull plug-in off by hand. open-ended wrench, e.g. Note: Hydraulic oil will leak out when removing the oil pipe. It is recommended that the yarn or rag be backed up when removing.
  • Page 66 b-3 Replacement of hydraulic fluid and filter Preliminary steps 1.When the fork reaches the top, press the drop button several times to eliminate residual pressure in the hydraulic system 2.Open the case and disconnect the battery. 3.Prepare and oil pan. Danger Hot oil and components may cause personal injury.
  • Page 67 Checking and refilling hydraulic fluid The type of hydraulic oil required is: _H-LP 46, DIN 51524  _Viscosity is 41.4 - 47  Oil quantity is 6.0~9.5L according to model  Waste materials such as waste oil, waste batteries or other materials must be disposed of and recycled in accordance with national laws and regulations and sent to the recycling company for recycling if necessary.
  • Page 68 b-4 Replacement of Carbon brush for pump motor 1.Unscrew bolts with a 10mm open-ended wrench 2.Open the cover. 3.Unscrew the screw with a crosshead screwdriver and take out the carbon brush for replacement. Installation process and the reverse of the above process.
  • Page 69 b-5. Troubleshooting Pump motor...

  • Page 70: Lifting System

    Hydraulic pump 14.Lifting system a. Overview a-1. Component The lifting system is powered by the main hydraulic pump. Fork: Two fork-shaped objects to support the load Chain: the part that lifts the bracket and mast Lifting cylinder: single-acting cylinder pulls back the chain of the bracket Mast: the vertical structure at the front of the forklift, which extends and retracts to lift and lower the load...

  • Page 71: Mast

    b. Mast b-1. Appearance Lifting of mast The mast assembly uses two masts and a single acting oil cylinder to lift the load. Rollers mounted on the inside and outside of the cargo fork and mast, respectively, facilitate these up/down movements.
  • Page 72 b-2. Replacement of cylinder 1)Outer cylinder right 1.Remove the oil pipes at the lifting cylinders on both sides with a 19 mm open-ended wrench. Note that hydraulic oil will leak out when removing the oil pipes. It is recommended that the oil pipes be backed up or wiped.
  • Page 73 6.Remove cylinder, install process and reverse process of above process 2)Outer cylinder left 1.Remove the bottom line of the cylinder with a 2.Remove top oil line of cylinder with 22mm 22mm open-ended wrench open-ended wrench 3.Remove the two bolts on the top of the left and 4.Remove the four bolts on the pressure plate of right cylinders and the mast with a 12 mm hexagon.
  • Page 74 5.Remove the cylinder base retaining bolts with a 6. Remove the entire cylinder 12mm hexagon wrench 3)Middle cylinder 1.Knock off spring clip with punch and take off protective plate 2.Unscrew the oil line at the bottom of the 3.Remove cotter pin middle cylinder with a 22mm open-ended wrench...
  • Page 75 4.Take out the pin shaft and take off the chain. 5.Unscrew the bolt of the clamp and take off the clamp with a 13mm open-ended wrench. 6.Remove the middle cylinder 7.Remove the circlip with the circlip pliers...
  • Page 76 8. Remove sprocket shaft 9.Remove the side cover with a 12mm hexagon wrench and all parts can be removed for replacement and repair. The installation process is the reverse of the removal process. b-3. Replacement of cylinder sealing ring 1.Remove cylinder head with crescent tool...
  • Page 77 2.Remove the new O-ring with a small screwdriver 3.Remove the dust ring with a screwdriver 4.Remove sealing ring for shaft 5.The cylinder head sealing ring can be disassembled and replaced by removing the sturdy seal.

  • Page 78: Curtis Handheld Console

    15.CURTIS Handheld Console a. 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 79: Introduction

    b. INTRODUCTION The Curtis 1313 Handheld Programmer (1313 HHP) performs programming and troubleshooting tasks for Curtis programmable motor controllers, gauges, and control systems. The 1313 HHP connects to Curtis devices in one of two ways- specific to the device: Either directly via the device’s RS232 serial port, or through a Controller Area Network (CAN) connection which can have multiple devices on the CANbus.
  • Page 80 1)Power the console The handheld console can be connected to the controller by inserting its connection wire into the programming port of the controller, and will automatically power on and display the control information on the console after connecting to the controller. Once the 1313 HHP has uploaded the information from the controller, it displays the Main Screen DISPLAY FORMAT...

  • Page 81: Key Functions

    KEY FUNCTIONS The pushbutton keys on the 1313 HHP’s keypad allow rapid navigation through the apps. 2)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 82 3)Fault diagnosis menu In the main menu, Select the "Diagnostics" Fault diagnosis icon and press the corresponding function key to enter the Fault diagnosis menu, which includes two folders: "Present Errors" and "Fault History" Note: the fault caused by a temporary event captured in the circuit is not a real system fault in some cases. and you can determine if the fault really exists by restarting the system and observing the automatic fault indication.
  • Page 83 4)Programming edit menu In the main menu, Select the "Programming" programming icon and press the corresponding function key of "Select" to enter the menu. You can store and restore parameter setting files (.cpf files) through the programming menu. Save.cpf File Use the save.
  • Page 84 Parameters can be adjusted or modified in two ways: one is in the parameter list page as shown in the figure below; The other is through the parameter edit page as shown below...

  • Page 85: Troubleshooting For Each Fault Code

    16.Troubleshooting for Each Fault Code a. Countermeasures of fault codes for ACF2-C controller(20CE/EN1175:2020) Fault Set and Clear Fault name Possible cause Action code conditions Controller Overcurrent 1.External short of phase U, V, Set: Phase current Shutdown Motor; Fault type:1=U phase or W exceeded the current Shutdown Main...
  • Page 86 Severe B+ 1.Non-controller system Set: After the main No drive torque output Undervoltage consumes photocell contactor is closed Fault type:1 2.The internal resistance of the and the FET bridge battery is too high circuit is working, 3.The battery is not connected either the current when driving the motor output exceeds 64ms...
  • Page 87 Severe KSI 1.The battery voltage to the Set: KSI voltage Shutdown Motor; Overvoltage controller KSI (pin1) end exceeds the set value Shutdown Main Fault type:1 exceeds the critical high of severe high voltage Contactor; Shutdown voltage setting value Clear: reset the EMBrake;...
  • Page 88 Undervoltage e 1.The battery needs to be Set: After the FET Reduce drive torque Cutback charged, and the performance bridge circuit works, Fault type:1 of the controller is limited under the capacitance this voltage voltage is lower than 2.Controller battery parameter the limit value of setting error Under voltage Cut...
  • Page 89 Ext 5V Supply Failure 1.The external 5V load is too Set:1, 5V output Turn off 5V output Fault type: small (pin16) exceeds 5V±10%; 1.The output 5V 2.Check the voltage and 2, 5V current is voltage is out of range current of 5V output displayed limited by parameter The current of 2, 5V by Programmer System...
  • Page 90 Main Driver 1.The driver load is open or When Set: Main Shutdown Motor; Fault type: short circuited Enable=On, the main Shutdown Main 1.Driver short circuit 2.The pin of the connector or contactor drive is Contactor; Shutdown 2.Driver overcurrent the coil of the contactor is dirty open or EMBrake;...
  • Page 91 Main Contactor Welded 1.The contact of the main Set: Release the main Shutdown Motor; Fault type:1 contactor is stuck normally contactor after it is Shutdown Main open pulled in, and the Contactor; Shutdown 2.Motor V phase or U phase capacitor voltage EMBrake;...
  • Page 92 Memory data read and 1.Memory data read and write Set: Controller failed shutdown motor, main write failure (NV failure to read and write contactor, Memory Failure) 2.Controller internal failure EEPROM data electromagnetic brake, Fault type: Clear: Download the Throttle, interlock, drive 1.Invalid verification correct software and 1, drive 2, drive 3, drive...
  • Page 93 Pump HPD Wrong lifting /lowering Throttle Set: shutdown pump Fault type: input conditions (>25%) setting 1.Throttle output is 1.can only lift parameters wrong: high when starting up 2.can only drop 1.Hydraulic suppression type 2.Drop Throttle output 3.Lifting and lowering 2.HPD/SRO judgment time oil high when starting pump Throttle hardware failure 3.Throttle output is...
  • Page 94 Battery type mismatch USER 19 FAULT PDO Fault ECS 5-12 USER 20 FAULT Rema EMR SRO 5-13 USER 21 FAULT HYD SRO Fault 5-14 USER 22 FAULT Throttle ON Without Interlock 5-15 Fault USER 23 FAULT 6-10 USER 24 FAULT 6-11 USER 25 FAULT 6-12...
  • Page 95 Programmer/Application Clear: Receive CAN Setup/CAN Interface/PDO NMT information, or Setups reset the Controller 1.Motor stalled Set: no motor shutdown motor, motor stalled （Stall 2.Motor encoder failure shutdown EMbrake, encoder signal 3.Wrong crimping or wiring change detected shutdown Throttle, the Detected） 4.The power supply part of the Clear: Reset the control mode is...
  • Page 96 Throttle, Fullbrake Motor Characterization The motor matching failed Set: motor matching shutdown motor, on Error during the matching process failed in the process shutdown main Fault type: of matching motor contactor, shutdown 71.write memory RAM Clear: Reset EMbrake, shutdown failure Controller Throttle, Fullbrake 72.temperature sensor...
  • Page 97 match 102.Permanent magnet synchronous motor temperature sensor failure 103.permanent magnet synchronous motor high temperature reduction 104.permanent magnet synchronous motor controller temperature reduction 106.permanent magnet synchronous motor controller low voltage reduction 107.Permanent Magnet Synchronous Motor Controller High Voltage Reduction Encoder Pulse Error 1.The encoder step setting Set: Wrong encoder shutdown motor,...
  • Page 98 motor from rotating after detected that the after interlock activation braking vehicle is running Clear: 1.Activate Throttle (EM Brake Type=2); 2.Activate Interlock (EM Brake Type=1) Encoder LOS 1.Encoder 3-6 failure or 7-3 Set: Encoder 3-6 fault LOS mode Fault type:1 failure, enter LOS mode or 7-3 fault, if the 2.The motor encoder fails...
  • Page 99 Clear: battery charging Pump Hardware 1.External short circuit of pump Set: shutdown vehicle Fault type: motor 1.The pump duty operation 1.The duty cycle has 2.Controller failure cycle update failed; not changed 2.Input and output 2.The input and output duty cycles do not duty cycle of the pump match does not match...
  • Page 100 Setup/Emergency Supervision Reverse/Emergency Reverse Clear: Reset Supervision. Controller Driver 1 Fault 1.The driver load is open or Set: Driver 1 open shutdown driver1 10-1 Fault type: short circuited circuit or short circuit 1.Driver short circuit 2.The pin of the connector or or driver overcurrent 2.Drive overcurrent the coil of the contactor is dirty...
  • Page 101 be turned on Driver4 Fault 1.The driver load is open or Set: Drive open circuit shutdown driver 4 10-4 Fault type: short circuited or short circuit or 1.Driver short circuit 2.The pin of the connector or drive overcurrent, 2.Drive overcurrent the coil of the contactor is dirty exceeding the value 3.Open/short (high...
  • Page 102 Driver7 Fault 1.The driver load is open or Set: Driver 7 open Shutdown 10-7 Fault type: short circuited circuit or short circuit Driver7 1.Driver short circuit 2.The pin of the connector or or driver overcurrent 2.Drive overcurrent the coil of the contactor is dirty exceeds the value set 3.Open/short (high 3.Connector crimping error or...
  • Page 103 Low/Analog1 High range, and the Controller is reset Analog 2 Out of Range 1.The input voltage of analog 2 Set: None, unless VCL adds 11-2 Fault type: is higher than the setting value 1.The input voltage is special handling 1.Exceeded the upper of Analog2 High higher than the limit...
  • Page 104 2.The lower limit is is lower than the setting value parameter; limited to of Analog5 Low 2.The input voltage is 3.View Programmer/Controller lower than the Setup/Analog Inputs/Analog 5 threshold set by the 4.Check parameter; Programmer/Controller Clear: The input Setup/Analog voltage returns to the Inputs/Configure/Analog5 parameter setting Low/Analog 5 High...
  • Page 105 Programmer/Controller Clear: The input Setup/Analog voltage returns to the Inputs/Configure/Analog8 parameter setting Low/Analog 8 High range, and the Controller is reset Analog 9 Out of Range 1.The input voltage of analog 9 Set: None, unless VCL adds 11-9 Fault type: is higher than the setting value 1.The input voltage is special handling...
  • Page 106 limit value of Analog18 Low 2.The input voltage is 2.The lower limit is 3.View Programmer/Controller lower than the limited to Setup/Analog Inputs/Analog18 threshold set by the 4.Check parameter; Programmer/Controller Clear: The input Setup/Analog voltage returns to the Inputs/Configure/Analog18 parameter setting Low/Analog18 High range, and the Controller is reset...
  • Page 107 all faults related to the analog fault input are grouped into this fault Clear: resolves any and reported allocation conflicts, or input out of range, and resets the Controller...

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