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Noblelift RT16B Service Manual

Electric reach truck
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Service Manual
Electric Reach Truck
RT16B/RT20B
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.
 Keep it for future reference.
Version 03/2023
RTXXB-SM-003-EN

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  • Page 1 Service Manual Electric Reach Truck RT16B/RT20B 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 this forklift truck, please read this manual carefully and fully understand how to use this truck, improper operation may cause danger. This manual describes how to use different types of battery operated reach trucks, please make sure that this manual matches your model when operating and servicing the reach truck.

  • Page 3: Table Of Contents

    Contents 1.Correct application a.Introduction – maintenance safety precautions b.Measurement conversion 2. Truck Overview a. Overview components b.Main technical parameters c. Description of the safety devices and warning labels d.VIN Location e.Identification plate (ID-plate) 3. WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS 4.COMMISSIONING, TRANSPORTING, DECOMMISSIONING a.
  • Page 4 a.Battery replacement b. Battery testing c.Charging 10. Lithium battery a. Lithium battery specifications and introduction b.Charger 11. Hydraulic system a. General view b. Lifting oil pump assembly 12.mast system a. Overview b.Mast 13. Regular maintenance a. Maintenance checklist b. Lubrication points c.

  • Page 5: Correct Application

    1.Correct application In order to ensure the safety of personal equipment, drivers should observe the following precautions. 1. Only trained and licensed forklift drivers are allowed to drive; 2. This forklift is suitable for use on hard and flat indoor floors; 3.

  • Page 6: A.introduction - Maintenance Safety Precautions

    a.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  Battery should always be disconnected during replacement of electrical components.  Always use the grades of grease and oil recommended by NOBLELIFT choose the viscosity specified for the ambient temperature.  Exhaust gas is dangerous provide ventilation when working in a closed space.
  • Page 8  When changing the oil or fitter, check the drained oil and filter for any signs of excessive metal particles or other foreign materials.  Always use NOBLELIFT genuine parts for replacement. ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.

  • Page 9: B.measurement Conversion

    b.Measurement conversion length unit mile 0.01 0.00001 0.3937 0.03281 0.01094 0.000006 0.001 39.37 3.2808 1.0936 0.00062 100000 1000 39370.7 3280.8 1093.6 0.62137 2.54 0.0254 0.000025 0.08333 0.02777 0.000015 30.48 0.3048 0.000304 0.3333 0.000189 91.44 0.9144 0.000914 0.000568 mile 160930 1609.3 1.6093 63360 5280...
  • Page 10 Pressure Unit kgf/cm Pa=N/m lbf/in lbf/ft kgf/cm 0.98067 98066.5 98.0665 14.2233 2048.16 1.01972 100000 14.5037 2088.6 Pa=N/m 0.00001 0.001 0.001 0.00015 0.02086 0.01020 0.01 1000 0.14504 20.886 lbf/in 0.07032 0.0689 6894.76 6.89476 lbf/ft 0.00047 0.00047 47.88028 0.04788 0.00694 kgf/cm =735.56 Torr(mmHg)=0.96784atm Standard tightening torque The following tables give the standard tightening torques of bolts and nuts.
  • Page 11 Standard tightening torque The following table shows the standard tightening torque of bolts and nuts Meaurement table Classification 4T, 5T Bolt type Bolt size Torque kgf · m (lbf · ft) Torque kgf · m (lbf · ft) 0.2 ± 0.02 0.4 ±...
  • Page 12 Meaurement 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 13 The torque in above table shall not be applied to nylon or nonferrous bolts or washer. The same is valid for not standardized ones. H Newton meter : 1 Nm = 0.1kgfm TIGHTENING TORQUE OF SPLIT FLANGE BOLTS The following torque shall be applied to the split flange bo lts.
  • Page 14 Replacement tool for electrical plug-in connection Application Remove pin Install pin Loose lock Two-hole lock Four-hole lock Remove pin...

  • Page 15: Truck Overview

    2. Truck Overview a. Overview components Fig. 1: Overview of the main components 1. Seat assembly 13. up and down tilt operation tiller 2. Accelerator pedal 14. left and right side-shift operation tiller 3. brake pedal 15. emergency power off switch 4.

  • Page 16: B.main Technical Parameters

    b.Main technical parameters β α fig. 2: Schematic diagram of the structure...
  • Page 17 Table 1:Main technical parameters of the standard version Type RT16B RT20B Power battery battery Operator typr Seated Seated Load capacity Q (t) Load center distance c (mm) Load distance, center of drive axle to fork x (mm) Wheelbase y (mm)
  • Page 18 drive motor power S2 60min Lift motor power S3 15% 12.5 12.5 Battery acc. to DIN 43531/ 35/ 36 A,B,C, A,3Pzs A,4Pzs Battery voltage, rated capacity K5 V/ Ah 48/420 48/560 Battery weight Three-phase AC Three-phase AC Type of drive control System pressure (bar) System flow...

  • Page 19: Description Of The Safety Devices And Warning Labels

    c. Description of the safety devices and warning labels Warning labels: 前 移 式 叉 车 特 种设 备 制造 许 可 证编 号 ：TS2510350-2021 Tel:4008— 836115 型 号 X XX X X 额 定载 荷 重 量 X X XX 额...
  • Page 20 Safety devices: fig 4: Safety device 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 21: D.vin Location

    d.VIN Location Fig 5:VIN location The VIN is located on the body, mast and fork frame of the truck, and the corresponding frame number is also on the fork of the truck equipped with hook-type forks.

  • Page 22: E.identification Plate (Id-Plate)

    Max Lifting Height xxxx Serial Number Manufacturing Date Device Code Manufacturer Art.No This truck is only used in factories, tourist attractions and tourist sites. Noblelift Intelligent equipment co. LTD No.528 Changzhou Road, Taihu Sub-district, Changxing County, Zhejiang Province，China fig. 7: ID plate...

  • Page 23: Warnings, Residual Risk And Safety Instructions

    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 24: Commissioning, Transporting, Decommissioning

    4.COMMISSIONING, TRANSPORTING, DECOMMISSIONING a. 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); ...
  • Page 25 Table 2: Truck carriage weight and mast weight Type RT16B RT20B Truck carriage pack weight [kg] 2300 2600 Truck carriage pack size [mm] 1800x1300X2200 1800x1300X2200 Lift height H3 [mm] 5500 5500 5500 5500 5500 5500 Mast pack weight [kg] 1240...

  • Page 26: B.loading And Unloading/ Transporting

    b. Loading and unloading/ transporting When load and unload the truck, refer to the guide diagram below. The weight for chasis and mast is shown in table 2, for the whole truck weight, please the ID plate. Truck carriage lift Whole truck lift Whole truck lift fork position Fig 9: Loading and unloading guide diagram...

  • Page 27: Decommisioning

    Fig 10: Fixing points c. Decommisioning 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 Fig10 for long time storage. Grease all greasing points mentioned in this handbook (regular inspection), and eventually protect the truck against corrosion and dust.

  • Page 28: Regular Inspection

    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 29: Operational Instructions

    6.OPERATIONAL INSTRUCTIONS a.Operational control devices position Fig. 11 Operational control devices position...

  • Page 30: Power-On Operation

    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 (15), insert the key switch (6), and turn it clockwise to the "ON" position, then step on the safety switch (3). Before start the truck, please press the horn button (17) to start the horn to warn others if necessary.

  • Page 31: Steering

    The white mark on the mast indicates if the specific lifting limits reached. For instance with a load centre of gravity distance c of 600 mm and a maximum lift height of 9500 mm, the maximum capacity Q for RT16B is 600 kg. fig 12: Load curve diagram...

  • Page 32: I.mast Front Shift And Back Shift

    g.Lifting DO NOT OVERLOAD THE TRUCK! THE MAXIMUM CAPACITY IS 2000 KG AND 1600 KG WHEN THE LOAD CENTER IS 600MM. REFERRING TO THE ID PLATE. LIFT LOADS ALLOWED IN LOAD CURVE DIAGRAM ONLY OR DAMAGE THE TRUCK. Push backwards the lifting control stick (7) until reach the desired lifting height. When the lifting height without load is more than 3m or the lifting height with load is more than 1m, please reduce the speed of truck.
  • Page 33 l.Malfunctions If there are any malfunctions or the truck is inoperative, please stop using the truck and activate the emergency button (1) by pushing it. If possible, park the truck on a safe area, turn the key switch (2) counterclockwise and remove the key.

  • Page 34: Drive And Brake System

    7. Drive and brake system a.Drive assembly appearance Drive assembly Item Quantity Note Electromagnetic brakes Motor Motor 2.01 Encoder 2.01 Encoder Screw M8x40 Spring pad 8 Proximity switch Bolt M12x60 Spring pad 12 Flat pad12 Fixing plate Bolt M12x55 Fixing seat Bolt Reduction box Flat pad 8...
  • Page 35 On the electric side, the drive motors turn their drive wheels, allowing the trucks to move forward/backward Controlled by the Controller The drive motors are connected to the Controller via the U, V and W wires. The Controller runs the drive motors based on inputs from multiple switches and sensors as well as internal parameter settings.

  • Page 36: B.drive Motor Disassembly/Assembly

    b.Drive motor disassembly/assembly 1). After removing the electromagnetic brake, loosen the screws and remove the box cover. 2). Remove the encoder and U, V, W. 3). Remove the steering motor.
  • Page 37 4). Remove the drive motor fixing bolt. 5). Use the crane to lift the motor to remove it. 6). Installation is the reverse of disassembly.
  • Page 38 Stator test 1). Use a clean cloth moistened with alcohol to carefully wipe any contaminants from the stator surface. Note: Contaminants in the stator may cause damage to the coil and therefore to the stator itself. 2). Use a milliohmmeter to measure the resistance of each phase (UV, VW, WU). Rated resistance: 0.4Ω...
  • Page 39 Drive motor common fault analysis Possible causes Problem Switch not closed (battery connector, key switch, proximity Drive motor does not work switch). Turn off the switches. If it still does not work, use a voltmeter to test the power supply to the control panel and the current to each switch.
  • Page 40 eliminate the problem. Change to a tire with less friction After one work shift, the truck is working beyond its designed capacity and has no power available. Battery is dirty, electrolyte is on top of the battery and in Positive (+) or negative (-) battery contact with the frame.

  • Page 41: Braking System And Principle

    c. Braking system and principle Foot brake assembly...
  • Page 42 Item Quantity Note Rubber Mat Pedals Composite Sleeve Cotter pins Cushion pad Spring Bracket Foot switch Bolt M10x40 Nut M10 With trunnion Flat pad 6 Spring pad 6 Bolt M6x12 Cotter pin Flat pad 10 Spring pad 10 Brake master Bolt M10x30 cylinder Brake Assembly...
  • Page 43 Brake System Schematic fig 13: Brake schematic (travel brake)
  • Page 44 Fig. 14: Braking schematic CURTIS (parking brake) Fig. 15: Brake schematic INMOTION (parking brake)

  • Page 45: Electrical System

    8.Electrical system a. Electrical control components Item Quantity Note Controller Steerin Controller Traction Controller Pump Contactor Fuse 10A Fuseholder BD-2x10A Fuse 500A(Ceramic)

  • Page 46: B.instrumentation Components

    b.Instrumentation components CURTIS-3501 meter (1232SE configuration). Battery power is displayed on the right side of the meter, full charge shows full cell (10 cells), power shows 100%, when the power use remaining about 20%, the battery symbol indicator at the bottom of the meter lights up (the sixth from the left in the picture above), indicating the need to charge, when the remaining power in about 10%, the prohibition indicator lights up (the fourth from the left in the picture above), at this time can not be lifted, but can walk slowly.
  • Page 47 CURTIS-3401 meter (F4A configuration) The icons in the main screen of the 3401 instrument are shown below. Setback; Moving forward; The power level is below 10% and the lock indication is raised; Parking brake; Foot pedals; Seat instructions; Seat belt indication; Fault indication；...
  • Page 48 F1: Enter the number "1" for the password. F2: Enter the number "2" for the password. F3: Enter the number "3" for the password. F4: Enter the number "4" for the password. F5: Enter the number "5" for the password. ▲:switch user password/OEM password, H: high speed mode, full speed 10.5Km/h.
  • Page 49 Boost lock light: When the battery level is below 10%, the boost lock light will be on Seat light: illuminates when the driver leaves the seat Handbrake light: illuminates when the driver operates the handbrake Icon Name Function Move Up Move the cursor up, or add 1 to the selected number;...

  • Page 50: Electrical Diagram

    c. Electrical diagram -BATT 编程器接口 -BATT 编程器接口 -BATT fig 15: 1232SE Configuration Circuit Diagram...
  • Page 51 1232SE Symbol Description Code Item Code Item battery48V Battery displacement monitoring switch Emergency power off switch mast Limit Switches Traction motor mast speed limit switch Oil pump motor Front shift limit switch Steering motor Backward shift limit switch Traction Controller Front and rear shift speed limit switch Oil Pump Controller...
  • Page 52 fig 16: F4A Configuration Circuit Diagram...
  • Page 53 F4A Symbol Description Code Item Code Item battery48V Battery monitoring switch Emergency power off switch Lifting switch Traction motor Forward and backward shift switch Oil pump motor Tilt Switch Steering motor Side shift switch SteeringController Park switch Traction Controller mast limit switch Gauge mast speed limit switch 0°...
  • Page 54 fig. 17: Inmotion configuration circuit diagram...
  • Page 55 Inmotion Description Code Item Code Item battery48V Forward and backward shift switch Emergency power off switch Tilt switch Traction motor Left/right shift switch Oil pump motor mast forward-backward speed limit switch Steering motor Speed control switch SteeringController Diode Traction Controller Horn Gauge Warning light...

  • Page 56: Battery Changes And Replacement

    Attention: If the electrolyte level is not enough, must fill distilled water other than other liquid. After charging, the standard electrolyte proportion is 1.28g/ml. The truck is equipped with following acid traction battery-type: RT20B: 1x48V 4PzS 560AH(Standard) [1216x355x754 mm (LxWxH)] RT16B 1x48V 3PzS 420L(Standard) [1216x283x754 mm (LxWxH)] 1x48V300Ah1HR [1216x355x754 mm (LxWxH)] 1x48V400Ah1HR [1216x355x754 mm (LxWxH)]...

  • Page 57: A.battery Replacement

    Lead-acid batteries and lithium batteries are allowed. THE WEIGHT OF THE BATTERIES HAS AN INFLUENCE TO THE TRUCKS OPERATING BEHAVIOR. PLEASE CONSIDER THE MAXIMUM OPERATING TEMPERATURE OF THE BATTERIES. a.Battery replacement Park the truck securely, release the battery hook, move the mast and battery components forward, turn off the truck with key (2), and press emergency button(1), move the battery plug (15) and remove the battery with a crane.

  • Page 58: Battery Testing

    b. Battery testing A. Battery Status Check Weak batteries may cause or lead to problems with the Controller and power circuits. Make sure the battery is in good condition before troubleshooting other areas. Preliminary steps Verify the correct polarity on the battery connector and control panel. The positive cable should be located at the line fuse (fuse) and the negative cable should be located at the negative terminal of the control panel.
  • Page 59 c.Charging  Before charging ensure that you are using an appropriate charger for charging the installed battery!  Before using the charger, please fully understand the instructions of the charger instructions.  Please follow these instructions!  The room, where you are charging must be ventilated. Park the truck at a dedicated secured area with a dedicated power supply.

  • Page 60: Lithium Battery

    10. Lithium battery a. Lithium battery specifications and introduction Battery system technical parameters System rated voltage System rated capacity 300Ah&400Ah System rated energy 19.2kWh System operating voltage 40V~58.4V Number of battery boxes Continuous charging current 0.5C:150A&200A Continuous Discharge Current 200A Peak Discharge Current 500A/5s Power up...
  • Page 61 Interface Pin Definitions Discharge port Discharge terminal positive Discharge terminal negative Discharge start contact key1 key2 CAN-H CAN line H of the whole car CAN line L terminal of the whole car CAN-L Charging port Charging terminal positive Charging terminal negative CAN-H Charging CAN line H terminal Charging CAN line L terminal CAN-L...
  • Page 62 Debug port Debugging CAN H Debugging CAN L Complete Vehicle CAN H Complete Vehicle CAN L Charging CAN H Charging CAN L Empty Pin Caution 1). The battery should not be charged below 0℃. Otherwise, the performance of the battery will be seriously deteriorated, and even a safety accident will occur.
  • Page 63 b.Charger Concise operation guide for industrial battery high frequency intelligent charger (general version) Precautions for Safe Operation Preface Thank you for using this product. Please read this manual carefully before installation and use, and carefully check the product packaging and accessories for completeness according to the packing list.
  • Page 64  If the cable, connector or other accessories are found to be damaged, you must stop using the charger immediately and contact the technical service center for repair or replacement. Operating Environment Security  Prevent smoke, water, flame, corrosive gas, etc. from entering this charger. ...
  • Page 65 Installation Guide 1) AC input wiring method The AC input wiring of our factory charger is as follows. Specification Wiring method 3KW series Single-phase three-wire system 6KW series Three-phase four-wire system and above Three-phase five-wire system  The charger is equipped with industrial plugs and socket accessories, the plugs have been pre-assembled by our company, you need to install the socket accessories by yourself.

  • Page 66: Quick Setup

    Quick Setup  ♦ The charger is equipped with a circuit breaker, which is located on the side or rear of the housing, and you may see the following models. (1P: 3KW 系列) (2P: 6KW 系列) (4P: 9~30KW 系列) Check the AC input is connected, DC output is connected to the battery, turn the circuit breaker upward to ON position, then the charger will be energized.
  • Page 67 Charger display and simple trouble shooting ♦Depending on the model you purchase, the charger is equipped with an LCD display or LED digital tube display, both of which can show the charging status. (LCD display) (LED display) Status display. Description of the status. Self-testing (LCD) Detects whether the battery is defective, whether it allows charging, and whether the charger itself is defective, etc.

  • Page 68: Hydraulic System

    11. Hydraulic system a. General view The hydraulic system operates several actuators by means of pressurized oil from the main hydraulic pump and pumps out the oil discharged from these actuators. 1). The main hydraulic pump is driven by a pump motor controlled by the Controller. 2).
  • Page 69 Hydraulic schematic 前后移 倾斜 起升下降 侧移 reach tilt au× lift/lower Fig. 20: Hydraulic circuit...

  • Page 70: Lifting Oil Pump Assembly

    b. Lifting oil pump assembly Pump motor Disassembly of pump motor 1). Disconnect the cables from the U, V and W terminals and unplug the encoder and temperature sensor plug-in. 2). Disconnect the hose from the hydraulic pump.
  • Page 71 3). Remove the bolts securing the pump motor to the pump and remove the motor. Mounting torque:55±10 N-m (40±7 lb-ft). 4). Install the pump motor by following the above steps in reverse order. Replace the seal of the lifting cylinder 1) Use the crescent wrench to remove the cylinder cover 2) Pull out the piston rod and remove the shaft support ring from the bottom of the piston rod.
  • Page 72 3) Use a small screwdriver to remove the dust ring, retaining ring and Y-seal from the cylinder cover. 4) Take off the O-ring and retaining ring on the cylinder cover, you can repair the whole oil pipe, the installation process is the reverse process of disassembly.
  • Page 73 Common faults of hydraulic motor Fault Possible cause Bad connection or fuse burning. Check the battery connection. Check the key fuse. Check if hydraulic pump motor is likely to cause fuse burning. The key switch or pump station contactor is not turned off.
  • Page 74 Batteries have one or more defective battery cells, which may result in lower rated capacity and battery capacity. Test and identify defective cells. Replace defective cells. Battery units are connected in series. A bad battery causes high resistance in series with other batteries.
  • Page 75 Common faults of hydraulic pump Fault Possible cause Low oil level oil thick limit to the inlet line of the pump Pump noise 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 High temperature...
  • Page 76 Restrictions on the pump inlet pipeline air leakage in the inlet pipe. Loose bolts. Defects in the inlet pipe. viscosity of the oil is wrong Pump worn too much Pump can’t convey fluid pump shaft fault The bolts of the pump do not have the correct torque...

  • Page 77: Mast System

    12.mast system a. Overview The lifting system is powered by the main hydraulic pump. Fork: two fork-shaped objects to support the load Chain: the component that lifts the pallet and mast Lifting cylinder: single acting cylinder pulling back the chain of the pallet mast: a vertical structure at the front of the forklift that extends and retracts to lift and lower the load b.Mast Appearance...
  • Page 78 Auxiliary tools: wrench S24, pry bar Safety precautions. The installation operator must have received the appropriate operational training or be guided by a trained professional on site. The operator of the auxiliary lifting equipment must have the appropriate qualifications. If the mast is lifted by forklift directly on the mast beam, the mast must be tied to the fork frame of the forklift with a protective rope to avoid the danger of slipping off.
  • Page 79 1). Remove block #5 2). Lifting mast...
  • Page 80 3). Insert the lower roller into the guide slot 4). Link forward moving cylinder (red circle) 5). Connecting fuel line and harness Both have several numbers 1 to 1 2 to 2 6). Installation is complete, block back in...

  • Page 81: Regular Maintenance

    13. Regular maintenance Only qualified and trained personnel are allowed to carry out maintenance work on this vehicle Before maintenance, remove the load from the forks and lower the forks to the lowest position To lift the truck, use the specified lashing equipment or lifting equipment in accordance with Chapter 4.
  • Page 82  Check if the correct fuse is used, and replace it if necessary  Test buzzer  Check the current contactor  Check the frame for leakage (insulation test)  Check the function and wear of the gas pedal  Check the electrical system of the drive motor Brake system ...

  • Page 83: Special Warning

    Special Warning: For the new reach truck put into use or the forklift after replacing a wheel, the operator must check the fastening of the tire nut within the first 50 hours working and before starting work every day. If the nut is found to be loose, it must be tightened with a torque of 140Nm. It must be checked again after 50 hours of operation, and then every 50 hours until no loosening occurs after several consecutive checks (maintain the correct torque).

  • Page 84: Lubrication Points

    b. Lubrication points Lubricate the marked points according to the maintenance list. The required grease specification is: DIN 51825 standard grease. fig 21: Complete vehicle lubrication diagram c. Check and refill hydraulic pressure The required hydraulic fluid type is. - H-LP 32, DIN 51524 - Viscosity is 41.4 - 47 Waste materials such as used oil, used batteries or other materials must be disposed of and recycled in accordance with national regulations, and if necessary handed over to a recycling company for recycling.

  • Page 85: Check The Electrical Fuse

    d. Check the electrical fuse Remove the plastic cover, the fuse is located in the position shown in fig 22. See Table 4 for fuse specifications. fig 22: Fuse diagram Table 4:Fuse Specifications 1232SE Specification configuration Fuse 1 Fuse 2 Fuse 3 Fuse 4 Fuse 01...

  • Page 86: Trouble Shooting

    14. TROUBLE SHOOTING If the truck has malfunctions follow the instructions, mentioned in chapter 6. Table 5: Trouble shooting TROUBLE CAUSE MAINTENANCE 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 failure Load lifting failure lifting fuse...

  • Page 87: Self-Diagnosis And Common Fault Code Solution

    15. Self-diagnosis and common fault code solution a.1232SE Configuration The Controller detects a wide variety of faults or error conditions. Faults can be detected by the operating system or by VCL code. This section describes Diagnostic information can be obtained in 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 name.
  • Page 88 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 89 Shutdown Pump. Controller Severe Overtemp Controller Severe Undertemp Set: Heatsink temperature 1) Controller is operating in an Shutdown Motor; above +95° C extreme environment Shutdown Main Clear: Bring heatsink 2)Excessive load on vehicle Contactor; Shutdown temperature below +95° C, and 3) Improper mounting of controller EMBrake;...
  • Page 90 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 2 ， 3 Undervoltage limit Reduced drive torque 4) Battery resistance too high Clear: Bring capacitor voltage 5) Battery disconnected while below the undervoltage limit driving...
  • Page 91 Compensation and Temp Cutback should be programmed Off. Motor Temp Sensor 1) Motor thermistor is not Fault Set: Motor thermistor input is connected properly MaxSpeed reduced at the voltage rail (0 or 10V) 2) If the application doesn't use a (LOS, Limited Clear: Bring the motor motor thermistor.
  • Page 92 Set: Driver 3 (pin 4) is either 1) Open or short on driver load Coil4 Driver Open/Short open or shorted 2) Dirty connector pins ShutdownDriver4 Clear: Correct open or short 3) Bad crimps or faulty wiring and cycle driver Set: Proportional driver (pin 2) 1) Open or short on driver load PD Open/Short is either open or shorted.
  • Page 93 Set: Throttle pot wiper (pin 16) voltage is lower than the low fault threshold (can be Throttle Wiper Low changed with the VCL function Throttle pot wiper voltage too low Shutdown Throttle; Setup_Pot_Faults()) Clear: Bring throttle pot wiper charge above the fault threshold Set: Pot2 wiper (pin 17) voltage is higher than the high...
  • Page 94 2) Faulty wiring, crimps, or inputs Clear: Reapply inputs in switches at KSI, interlock, correct sequence direction, or throttle inputs Set:At the conclusion of the Emergency Reverse operation Emergency Reverse,the fault has concluded, but the throttle, was set because vaious inputs Emer Rev HPD forward and reverse inputs, and were not returned to the...
  • Page 95 Set: The external supply current (combined current used by the 5V supply [pin 26] and the 12V supply [pin 25]) is 1) External load on the 5V and either greater than 12V supplies draws either too the upper current threshold or External Supply Out of much or too little current lower than the lower current...
  • Page 96 Motor characterization failed during characterization process. 0 = none 1 = encoder signal seen, but step size not determined; set Encoder Motor Characterization Step Size manually Fault 2 = motor temp sensor fault Shutdown Motor; 3 = motor temp hot cutback fault Set: Motor characterization Shutdown Main 4 = controller overtemp cutback...
  • Page 97 Set: Encoder Fault (Code 36) or Stall Detect Fault (Code 73) was activated, and Brake or Interlock has 1) Limited Operating Strategy been applied to activate LOS (LOS) control mode has been control mode, allowing limited Encoder LOS (Limited activated, as a result of either an motor control Operating Strategy) Encoder Fault or Stall Detect Fault...
  • Page 98 1222 Steering motor controller troubleshooting table STEER TRACTIO FLASH CLEAR NAME POSSIBLE CAUSE FAULT N FAULT CODE CONDITION ACTION ACTION An internal hardware error has Hardware Fault been detected; controller Cycle KSI Shutdown. 1 = Stop. defective. 1. External short of phase U, V, Controller or W motor connection.
  • Page 99 1. Battery or battery cable resistance too high for a given Severe regen current. Cycle KSI Shutdown. 1 = Stop. Overvoltage 2. Battery disconnected while regen braking. 1. Improper mounting or cooling of controller. Controller 2. Excessive load on vehicle. Heatsink Warning 1 = Stop.
  • Page 100 1. Motor phase is open. Warning 2. Bad crimps or faulty motor Motor Open Cycle KSI then 1 = Stop. cable wiring. shutdown 3. Controller defective. 1. Steer contactor tips are welded closed. Contactor 2. An alternative voltage path Cycle KSI Shutdown.
  • Page 101 1. New software loadedinto EEPROM memory. EEPROM CRC 2. Try using function "Restoreto Cycle KSI Shutdown. 1 = Stop. Fault Factory Defaults" to clear fault. 3. Controller defective. Sin/Cos 1. Sin/Cos Sensor defective. Hold then command 2. Sin/Cos Sensor parameters Cycle KSI 1 = Stop.
  • Page 102 1.Home switch defective. Home Reference 2. For 360° degree steering, the Hold then Cycle KSI 1 = Stop. Tolerance Fault parameter Homing Cam Angle Shutdown. (deg) is not set correctly. Steer Command Supervision Command input device Hold then Cycle KSI 1 = Stop.
  • Page 103 Hardware 1. New software loaded. Software 2. Controller hardware cannot Cycle KSI Shutdown. 1 = Stop. Mismatch use the loaded software. 1. Parameter settings arein Parameter conflict with each other. Cycle KSI Shutdown. 1 = Stop. Conflict 2. Parameter setting out of range.

  • Page 104: B.f4A Configuration

    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 105: Summary Of Led Display Formats

    Summary of LED display formats The two LEDs have four different display modes, indicating the type of information they are providing: 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 Controller is in Flash program mode.
  • Page 106 For a dual drive truck, the fault screen is displayed as follows. Language is set to English...
  • Page 114 Shutdown Motor; Shutdown The accelerator signal VCL HPD Main Contactor; Shutdown comes first, operate in the Controller Fault EM Brake; Shutdown Faults correct order Throttle; Full Brake. Shutdown Motor; Shutdown The switch signal comes VCL SRO Main Contactor; Shutdown first, operate in the correct Controller Fault EM Brake;...
  • Page 115 Shutdown Motor; Shutdown Display Main Contactor; Shutdown Config Check display configuration Controller EM Brake; Shutdown Faults Fault Throttle; Full Brake. Shutdown Motor; Shutdown BMS Fault Main Contactor; Shutdown Grade Non check battery Battery EM Brake; Shutdown Faults Zero Throttle; Full Brake. Shutdown Motor;...
  • Page 116 Shutdown Motor; Shutdown BMS Temp Main Contactor; Shutdown Check battery Battery LOW fault EM Brake; Shutdown Faults Throttle; Full Brake. Shutdown Motor; Shutdown Redundanc Main Contactor; Shutdown e Check Controller EM Brake; Shutdown Faults Fault Throttle; Full Brake. Shutdown Motor; Shutdown Battery Main Contactor;...
  • Page 119 Controller hardware is incorrect 1, CRC or Controller OS does Contro Bad Firmware cannot be fully not match ller started 2. An incompatib le OS is used 1. The Shutdown EM truck is Brake, operating shutdown when the throttle, EM brake Trigger the is set.
  • Page 120 mode 2. The motor encoder fails Crimping or wrong wiring 4. The truck stalled 1. The emergency reverse triggers and ends because Shutdown emergency Contro Emer Rev Timeout Throttle ,EMBr reverse ller time expires 2. The emergency reverse input is stuck 1.
  • Page 121 Shutdown application Throttle; Full Brake 2. The dual drive function is turned on in the torque mode 3. The dual drive function is turned on when the single Controller is applied 1. During interlock braking process, the motor speed exceeds parameter s set under Interlock Braking Supervision...
  • Page 122 Braking / Interlock Braking Supervisio 1. During emergency reverse, the motor speed exceeds parameter Shutdown s set under Motor; Emergenc Shutdown EM y Reverse Contro EMR Supervision Brake; Supervisio ller Shutdown Main 2. Check Contactor Programm er / Application Setup / Emergenc y Reverse / Emergenc...
  • Page 123 4. The driver is overcurren exceeding the value set by Driver 1 Overcurren 5. Check Programm er / Controller Setup / Outputs / Driver 1 / Driver 1 Overcurren 1. The driver load is open or short circuited 2. The pin of the connector or the coil...
  • Page 124 5. Check Programm er / Controller Setup / Outputs / Driver 2 / Driver 2 Overcurren 1. The driver load is open or short circuited 2. The pin of the connector or the coil of the contactor is dirty Connector Driver 3 Fault crimping Fault Type:...
  • Page 125 Overcurren 1. The driver load is open or short circuited 2. The pin of the connector or the coil of the contactor is dirty Connector Driver 4 Fault crimping Fault Type: error or 1. Driver short circuit wiring error 2. driver overcurrent 4.
  • Page 126 5. Disconnection 2. The pin 6. Output limited with no current of the Fault Type 3-5 connector Requires driver failure detection to be turned on or the coil of the contactor is dirty Connector crimping error or wiring error 4. The driver is overcurren exceeding...
  • Page 127 error or wiring error 4. The driver is overcurren exceeding the value set by Driver 6 Overcurren 5. Check Programm er / Controller Setup / Outputs / Driver 6 / Driver 6 Overcurren 1. The driver load is open or short circuited 2.
  • Page 128 Overcurren 5. Check Programm er / Controller Setup / Outputs / Driver 7 / Driver 7 Overcurren 1, One driver used as 2 or more functions 2. View Programm er / Controller Setup / IO Driver Assignment Shutdown Contro Assignmen Fault Type: 5 The serial number of the driver caused the Driver ller...
  • Page 129 crimping error or wiring error Controller failure 1.the input voltage of analog 1 is higher than the setting value of Analog 1 High 2. Analog 1 input voltage is lower than Analog 1 Settings Analog 1 Out of Range None, unless 3.
  • Page 130 Analog 2 High 2. The input voltage of analog 2 is lower than the setting value of Analog 2 3. Check Programm er / Controller Setup / Analog Inputs / Analog 2 4. Check Programm er / Controller Setup / Analog Inputs / Config /...
  • Page 131 3. Check Programm er / Controller Setup / Analog Inputs / Analog 3 4. Check Programm er / Controller Setup / Analog Inputs / Config / Analog 3 Low/Analo g 3 High 1. The input voltage of analog 4 is higher than the setting value of...
  • Page 132 Setup / Analog Inputs / Config / Analog 4 Low/Analo g 4 High 1. The input voltage of analog 5 is higher than the setting value of Analog 5 High 2. The input voltage of analog 5 is lower than Analog 5 Analog 5 Out of Range None, unless...
  • Page 133 2. the lower limit is limited to higher than the setting value of Analog 6 High 2. The input voltage of analog 6 is lower than Analog 6 Settings 3. Check Programm er / Controller Setup / Analog Inputs / Analog 6 4.
  • Page 134 Settings 3. Check Programm er / Controller Setup / Analog Inputs / Analog 7 4. Check Programm er / Controller Setup / Analog Inputs / Config / Analog 7 Low/Analo g 7 High 1. The input voltage of analog 8 is higher than the setting value of...
  • Page 135 er / Controller Setup / Analog Inputs / Config / Analog 8 Low/Analo g 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 Analog 9 Out of Range...
  • Page 136 1. The input voltage of analog 14 is higher than the setting value of Analog 14 High 2. The input voltage of analog 14 is lower than the setting Analog 14 Out of Range value of None, unless Analog 14 Fault Type ：...
  • Page 137 input is out of range 3. Check Programm er / Controller Setup / IO Assignmen ts / 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...
  • Page 138 Low/Analo g 18 High 1. The input voltage of analog 19 is higher than the setting value of Analog 19 High 2. The input voltage of analog 19 is lower than the setting Analog 19 Out of Range value of None, unless Analog 18 Contro...
  • Page 139 Contactor, brands do Shutdown not match EMBrake, Shutdown 2. Contact Throttle, local Curtis Full Brake technical support to handle the fault BMS Cutback Solve None, unless 1. Battery current decreases battery or Batter VCL adds 2. The battery cell voltage is reduced battery special 3.
  • Page 140 Analog 31 4. Check Programm er / Controller Setup / Analog Inputs / Config / Analog 31 Low/Analo g 31 High 1. CAN parameter s of detuned dual driver Contro Invalid_CAN_Port None 2. CAN ller node ID conflicts due to dual drive Kick_ Watchdog(...
  • Page 141 every 16 millisecond s, the input considered to be disconnect 2. Offset parameter 3. Wiring error 1. The fault diagnosis execution cycle is every 4 millisecond s. If no PWM Input 29 Out of Range signal is 1. Input disconnection generated 2.
  • Page 142 3 = PRIMARY_DEVICE_STARTUP_VALID, 4 = PRIMARY_INITIALIZE_PARAMETERS, 5 = PRIMARY_WAIT_FOR_FIRST_SIGNALS, 6 = PRIMARY_WAIT_FOR_SUPERVISOR, 7 = PRIMARY_RESTORE_PARAMETER_FAIL, 8 = PRIMARY_SUPERVISOR_FIRST_SIGNALS_ERROR, 9 = PRIMARY_SUPERVISOR_STARTUP_ERROR, 10 = 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.
  • Page 143 tdown EM measured Brake;Shutdo phase PWM duty Throttle;Full cycle and Brake;Shutdo wn Pump measured phase PWM duty cycle is greater than the allowable value. Clear: Reset Controller OS and Controller Shutdown Motor;Shutdo incompatib wn Main Contactor;Shu tdown EM downloade Contro Hardware Compatibility Brake;Shutdo d software...
  • Page 144 related to the analog input will collected reported Clear: Resolve assignmen t conflicts, or enter out of range, and then reset Controller This fault detects dangerous movement when the motor is required to move. Hazardous Movement The first 1=The motor speed is opposite to the direction required by danger is the speed, and the motor cannot accelerate in the correct that if the...
  • Page 145 wrong direction or too fast. Note: This fault only occurs when the control mode is selected at Speed_ Mode、 Speed_ Mode_ Express or Servo_ Occurs in Mode Clear: Reset the controller. discover ous_ direction_ Response _ Time=0 will disable these checks Check whether...
  • Page 146 1222 Steering motor controller troubleshooting table: FLAS STEER TRACTIO CLEAR NAME POSSIBLE CAUSE FAULT N FAULT CONDITION CODE ACTION ACTION An internal hardware error has Hardware Fault been detected; controller Cycle KSI Shutdown. 1 = Stop. defective. 1. External short of phase U, V, Controller or W motor connection.
  • Page 147 1. Battery or battery cable resistance too high for a given Severe regen current. Cycle KSI Shutdown. 1 = Stop. Overvoltage 2. Battery disconnected while regen braking. 1. Improper mounting or cooling of controller. Controller 2. Excessive load on vehicle. Heatsink Warning 1 = Stop.
  • Page 148 1. Motor phase is open. Warning 2. Bad crimps or faulty motor Motor Open Cycle KSI then 1 = Stop. cable wiring. shutdown 3. Controller defective. 1. Steer contactor tips are welded closed. Contactor 2. An alternative voltage path Cycle KSI Shutdown.
  • Page 149 1. New software loadedinto EEPROM memory. EEPROM CRC 2. Try using function "Restoreto Cycle KSI Shutdown. 1 = Stop. Fault Factory Defaults" to clear fault. 3. Controller defective. Sin/Cos 1. Sin/Cos Sensor defective. Hold then command 2. Sin/Cos Sensor parameters Cycle KSI 1 = Stop.
  • Page 150 1.Home switch defective. Home Reference 2. For 360° degree steering, the Hold then Cycle KSI 1 = Stop. Tolerance Fault parameter Homing Cam Angle Shutdown. (deg) is not set correctly. Steer Command Supervision Command input device Hold then Cycle KSI 1 = Stop.
  • Page 151 Hardware 1. New software loaded. Software 2. Controller hardware cannot Cycle KSI Shutdown. 1 = Stop. Mismatch use the loaded software. 1. Parameter settings arein Parameter conflict with each other. Cycle KSI Shutdown. 1 = Stop. Conflict 2. Parameter setting out of range.

  • Page 152: Inmotion Configuration

    c. Inmotion Configuration...

  • Page 164: Handheld Programmer

    16. Handheld programmer Operating Precautions. The handheld unit is designed to facilitate truck inspection and maintenance. Adjustment of the controller parameters is not permitted without the approval of the truck manufacturer to avoid truck and personal safety accidents. After the handheld unit is modified, it will automatically save the parameters, just turn off the key switch and restart. The CURTIS handheld unit can be connected to the controller with or without power.
  • Page 165 Programmer power on Plug the handheld programmer cable into the Controller's programming port to connect to the Controller. After connecting to the Controller, the handheld programmer will automatically power up and display the control information on the programmer.
  • Page 166 Function keys The three keys will be blank because the function of the three keys is based on the specified content. At given time, the functions of the buttons are displayed on screen above. Directional arrow key The information displayed can be selected by pressing up, down, or left or right through 4 directional keys.
  • Page 167 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 168 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.
  • Page 169 Programming menu In the main menu, select the "Programming" icon and press the corresponding "Select" function key to enter the menu. The programming menu allows you to store and restore the parameter settings file (.cpf file) Save.cpf File Use the Save.cpf File function in the programming menu to make a backup of the currently set parameters.

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