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HANGHCA Forklift Trucks Fault Codes DTC list

LED code — PROGRAMMER LCD DISPLAY — EXPLANATION — POSSIBLE CAUSE

1, 2 HW FAIL SAFE1-2-3 Self-test or watchdog fault Controller defective.

1, 3 M-SHORTED internal M- short to B-

1．Controller defective.

FIELD OPEN .Field winding fault

1. Motor field wiring loose.

1,2. Motor field winding open.

ARM SENSOR armature current sensor fault 1．Controller defective.

FLD SENSOR Field current sensor fault 1．Controller defective.

2, 1 SPEED CONTROL

FAULT VSC signal exceed range

1．VSC input wire open.

2．VSC input wire shorted to B + or B-.

3. Throttle pot defective.

4. Wrong throttle type selected.

2, 3 START LOCKOUT starting sequence wrong

1. Improper seq. of direction and throttle inputs.

2. Wrong START LOCKOUT type selected.

3. Misadjusted throttle pot.

4. Sequencing delay too short.

3, 1 CONT DRVR OC cont. driver output over current

1. Contactor coil shorted.

3, 2 MAIN CONT WELDED welded main contactor

1. Main contactor stuck closed.

2. Main contactor driver shorted.

3, 3 PRECHARGE FAULT internal voltage too low at startup

1. Controller defective.

2. External short, or leakage path to B- on external B + connection.

3, 4 MISSING CONTACTOR missing contactor

1 Any contactor coil open or not connected.

CONTINC main contactor did not close 1 Main contactor missing or wire to coil open.

4, 2 OVERVOLTAGE overvoltage

1. Battery voltage> overvoltage shutdown limit.

2. Vehicle operating with charger attached.

3. Battery disconnected during regen braking.

4, 3 THERMAL CUTBACK Over- / under-temp. cutback

1.Temperature> 85 or < -25 ℃.

2. Excessive load on vehicle.

3. Improper mounting of controller.

4. Operation in extreme environments.

HANGCHA Forklift Fault table of lift (oil pump) controller

LED code — PROGRAMMER LCD DISPLAY — EXPLANATION — POSSIBLE CAUSE

off

NO voltage or controller is not working, error (such as MCII defective)

0,1 ■ ¤ controller work normally, no error

1,1 ¤ ¤ EEPROM defective

1. EEPROM miss data

2. EEPROM data check error，use programmer 1311 to change any parameter can delete the error.

1,2 ¤ ¤¤ Hardware defective

1. MOSFET short down.

2. Motor circuit is an open circuit.

2,1 ¤¤ ¤ Low voltage Battery voltage is too low.

2,2 ¤¤ ¤¤ Lifting lock.

The function of lifting lock of the controller is touch off.

2,3 ¤¤ ¤¤¤ Order fault （Startup lockout）

Any switch of SS1-SS4 closes earlier than KSI or INTERLOCK.

3,2 ¤¤¤ ¤¤ Contact err

1. Main contact bonded。

2. The set of parameter ―CONTACT CNTRL‖ is wrong.

3,3 ¤¤¤ ¤¤¤ Pre-charge fault

1. Pre-charge circuit work with err.

2. Motor short down.

3,4 ¤¤¤ ¤¤¤¤ Contact has not been installed or is not close.

1. The connection of main contact coil loose.

2. Main contact works abnormally.

4,1 ¤¤¤¤ ¤ Low -voltage protect. The voltage of battery is lower than the set value of ―LOVOLT CUTBACK‖

4,2 ¤¤¤¤ ¤¤ Over-voltage protect. The battery voltage is too high.

4,3 ¤¤¤¤ ¤¤¤ temperature protect (over / under-temp）

1. The temperature of controller is too high or too low.

2. Temperature sensor works abnormal.

Источник

When faults happen, try to restart by resetting the key switch after confirmed that faults are not

caused by faulty wiring connection or mechanical failure. If the faults are still on, shut down the

key, check for incorrect connection or corruption of the pin 35 connecter, reconnect after repaired

and cleared, and then restart again.

The controller provides diagnostics information to assist technicians in troubleshooting drive

system problems. The diagnostics information can be obtained in two ways: by reading the

appropriate display on the programmer or by observing the fault codes issued by the status LED.

Led Diagnostics

During normal operation, with no faults present, the status LED is steadily on. If the controller

detects a fault, the status LED flashes a fault identification code continuously until the fault is

corrected. Refer to the troubleshooting chart for suggestions about possible causes of the various

faults. Faults are listed alphabetically.

Note: The status LED can only indicate one fault at a time. If multiple faults are detected, the

highest priority fault code flashes until it is cleared.

Programmer Diagnostics

The programming devices present complete diagnostic information in plain language. Faults are

displayed in the Faults/Diagnostics menu, and the status of the controller inputs/outputs is

displayed in the Monitor menu.

Additionally, the fault history file in the Faults/Diagnostics menu provides a list of the faults that

have occurred since the file was last cleared. Checking (and clearing) the fault history file is

recommended each time the vehicle is brought in for maintenance.

Refer to the troubleshooting chart for suggestions about possible causes of the various faults.

Faults are listed alphabetically.

Fault Handling

When a fault is detected, the controller operates in a manner that is safe in the presence of that

fault. Depending on the severity of the fault, the response can range from reduction of current to

complete shutdown of drive. The status LED uses a 2-digit code. For example, code

«1,4»—undervoltage—appears as:

¤ ¤¤¤¤

（1,4）

¤ ¤¤¤¤

（1,4）

Источник

CPD10/15/20/25/30/35J C1, CPD10/15/18/20/25/30/35J C2, CPD40/45/50J C2

Fault table of tow controller

LED code	PROGRAMMER LCD DISPLAY	EXPLANATION	POSSIBLE CAUSE
1,2	HW FAIL SAFE1-2-3	self-test or watchdog fault	Controller defective.
1,3	M-SHORTED	internal M- short to B-	1.Controller defective.
FIELD OPEN	.Field winding fault	1. Motor field wiring loose. 1, 2. Motor field winding open.
ARM SENSOR	armature current sensor fault	1.Controller defective.
FLD SENSOR	Field current sensor fault	1.Controller defective.
2,1	SPEED CONTROL FAULT	VSC signal exceed range	1.VSC input wire open. 2.VSC input wire shorted to B+ or B-. 3.Throttle pot defective. 4. Wrong throttle type selected.
2,3	START LOCKOUT	starting sequence wrong	1..Improper seq. of direction and throttle inputs. 2. Wrong START LOCKOUT type selected. 3. Misadjusted throttle pot. 4. Sequencing delay too short.
3,1	CONT DRVR OC	cont. driver output over current	1. Contactor coil shorted.
3,2	MAIN CONT WELDED	welded main contactor	1. Main contactor stuck closed. 2. Main contactor driver shorted.
3,3	PRECHARGE FAULT	internal voltage too low at startup	1. Controller defective. 2. External short, or leakage path to B- on external B+ connection.
3,4	MISSING CONTACTOR	missing contactor	1 Any contactor coil open or not connected.
CONT DNC	main contactor did not close	1 Main contactor missing or wire to coil open.
4,2	OVERVOLTAGE	overvoltage	1. Battery voltage >overvoltage shutdown limit. 2. Vehicle operating with charger attached. 3. Battery disconnected during regen braking.
4,3	THERMAL CUTBACK	Over-/under-temp. cutback	1.Temperature >85°C or < -25°C. 2. Excessive load on vehicle. 3. Improper mounting of controller. 4. Operation in extreme environments.

LED code

PROGRAMMER LCD

DISPLAY

EXPLANATION

POSSIBLE CAUSE

off On		NO voltage or controller is not working, error (such as MCII defective)
0,1	■ ¤	controller work normally, no error
1,1	¤ ¤	EEPROM defective	1. EEPROM miss data 2. EEPROM data check error, use programmer 1311 to change any parameter can delete the error.
1,2	¤ ¤¤	Hardware defective	1. MOSFET short down. 2. Motor circuit is an open circuit.
2,1	¤¤ ¤	Low voltage	Battery voltage is too low.
2,2	¤¤ ¤¤	Lifting lock.	The function of lifting lock of the controller is touch off.
2,3	¤¤ ¤¤¤	Order fault ( Startup lockout)	Any switch of SS1-SS4 closes earlier than KSI or INTERLOCK.
3,2	¤¤¤ ¤¤	Contact err	1. Main contact bonded。 2. The set of parameter “CONTACT CNTRL” is wrong.
3,3	¤¤¤ ¤¤¤	Pre-charge fault	1. Pre-charge circuit work with err. 2. Motor short down.
3,4	¤¤¤ ¤¤¤¤	Contact has not been installed or is not close.	1. The connection of main contact coil loose. 2. Main contact works abnormally.
4,1	¤¤¤¤ ¤	Low -voltage protect.	The voltage of battery is lower than the set value of ―LOVOLT CUTBACK‖
4,2	¤¤¤¤ ¤¤	Over-voltage protect.	The battery voltage is too high.
4,3	¤¤¤¤ ¤¤¤	temperature protect (over-/under-temp)	1. The temperature of controller is too high or too low. 2. Temperature sensor works abnormal.

There are two LEDs including a yellow LED and a red LED. The two LEDs have four different display modes, indicating the type of information they are providing.

DISPLAY	STATUS
Neither LED illuminated	Controller is not powered on, has a dead battery, or is severely damaged.
Yellow LED flashing	Controller is operating normally.
Yellow and red LEDs both on solid	Controller is in Flash program mode.
Red LED and yellow LED flashing alternately	Controller has detected a fault.

TOWING CONTROLLER ERROR CODE TABLE

LED code	PROGRAMMER LCD DISPLAY	POSSIBLE CAUSE
1,2	Controller Overcurrent	1. External short of phase U, V, or W motor connections. 2. Motor parameters are mis-tuned. 3. Controller defective.
1,3	Current Sensor Fault	1. Leakage to vehicle frame from phase U, V, or W (short in motor stator). 2. Controller defective.
1,4	Precharge Failed	1. External load on capacitor bank (B+ connection stud) that prevents the capacitor bank from charging. 2. See 1311 menu Monitor » Battery: Capacitor Voltage.
1,5	Controller Severe Undertemp	1. Controller is operating in an extreme environment. 2. See 1311 menu Monitor » Controller: Temperature.
1,6	Controller Severe Overtemp	1. Controller is operating in an extreme environment. 2. Excessive load on vehicle. 3. Improper mounting of controller. 4. See 1311 menu Monitor » Controller: Temperature.
1,7	Severe Undervoltage	1. Battery Menu parameters are misadjusted. 2. Non-controller system drain on battery. 3. Battery resistance too high. 4. Battery disconnected while driving. 5. See 1311 menu Monitor » Battery: Capacitor Voltage. 6. Blown B+ fuse or main contactor did not close.
1,8	Severe Overvoltage	1. Battery Menu parameters are misadjusted. 2. Battery resistance too high for given regen current. 3. Battery disconnected while regen braking. 4. See 1311 menu Monitor » Battery: Capacitor Voltage.
2,1	Controller Undertemp Cutback	1. Controller is performance-limited at this temperature. 2. Controller is operating in an extreme environment. 3. See 1311 menu Monitor » Controller: Temperature.

2,2	Controller Overtemp Cutback	1. Controller is performance-limited at this temperature. 2. Controller is operating in an extreme environment. 3. Excessive load on vehicle. 4. Improper mounting of controller. 5. See 1311 menu Monitor » Controller: Temperature.
2,3	Undervoltage Cutback	1. Normal operation. Fault shows that the batteries need recharging. Controller is performance limited at this voltage. 2. Battery parameters are misadjusted. 3. Non-controller system drain on battery 4. Battery resistance too high. 5. Battery disconnected while driving. 6. See 1311 menu Monitor » Battery: Capacitor Voltage. 7. Blown B+ fuse or main contactor did not close.
2,4	Overvoltage Cutback	1. Normal operation. Fault shows that regen braking currents elevated the battery voltage during regen braking Controller is performance limited at this voltage. 2. Battery parameters are misadjusted. 3. Battery resistance too high for given regen current. 4. Battery disconnected while regen braking 5. See 1311 menu Monitor » Battery: Capacitor Voltage.
2,5	+5V Supply Failure	1. External load impedance on the +5V supply (pin 26) is too low. 2. See 1311 menu Monitor » outputs: 5 Volts and Ext Supply Current.
2,6	Digital Out 6 Overcurrent	1. External load impedance on Digital Output 6 driver (pin 19) is too low.
2,7	Digital Out 7 Overcurrent	1. External load impedance on Digital Output 7 driver (pin 20) is too low.
2,8	Motor Temp Hot Cutback	1. Motor temperature is at or above the programmed Temperature Hot setting, and the requested current is being cut back. 2. Motor Temperature Control Menu parameters are mis-tuned. 3. See 1311 menus Monitor » Motor: Temperature and Monitor » Inputs: Analog2. 4. If the application doesn’t use a motor thermistor, Temp Compensation and Temp Cutback should be programmed Off.
2,9	Motor Temp Sensor Fault	1. Motor thermistor is not connected properly. 2. If the application doesn’t use a motor thermistor, Temp Compensation and Temp Cutback should be programmed Off. 3. See 1311 menus Monitor » Motor: Temperature and Monitor » Inputs: Analog2.

3,1

Coil 1 Driver

Open/Short