Hangcha Forklift Fault Codes 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.

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.

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.

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

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3,1

Main Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3,2

Coil2 Driver

Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3,2

EM Brake Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3,3

Coil3 Driver

Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3,4

Coil4 Driver

Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3,5

PD Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3,6

Encoder Fault

1. Motor encoder failure.

2. Bad crimps or faulty wiring.

3. See 1311 menu Monitor » Motor: Motor RPM.

3,7

Motor Open

1. Motor phase is open.

2. Bad crimps or faulty wiring.

3,8

Main Contactor

Welded

1. Main contactor tips are welded closed.

2. Motor phase U is disconnected or open.

3. An alternate voltage path (such as an external precharge resistor) is

providing a current to the capacitor bank (B+ connection stud).

3,9

Main Contactor Did

Not Close

1. Main contactor did not close.

2. Main contactor tips are oxidized, burned, or not making good contact.

3. External load on capacitor bank (B+ connection stud) that prevents capacitor bank from charging.

4. Blown B+ fuse.

LED code

PROGRAMMER LCD

DISPLAY

POSSIBLE CAUSE

4,1

Throttle Wiper High

1. Throttle pot wiper voltage too high.

2. See 1311 menu Monitor » Inputs: Throttle Pot.

4,2

Throttle Wiper Low

1. Throttle pot wiper voltage too low.

2. See 1311 menu Monitor » Inputs: Throttle Pot.

4,3

Brake Wiper High

1. Brake pot wiper voltage too high.

2. See 1311 menu Monitor » Inputs: Brake Pot.

4,4

Brake Wiper Low

1. Brake pot wiper voltage too low.

2. See 1311 menu Monitor » Inputs: Brake Pot.

4,5

Pot Low Overcurrent

1. Combined pot resistance connected to pot low is too low.

2. See 1311 menu Monitor » Outputs: Pot Low.

4,6

EEPROM Failure

1. Failure to write to EEPROM memory. This can be caused by

EEPROM memory writes initiated by VCL, by the CAN bus, by

adjusting parameters with the 1311, or by loading new software into the controller.

4,7

HPD/Sequencing Fault

1. KSI, interlock, direction, and throttle inputs applied in incorrect

sequence.

2. Faulty wiring, crimps, or switches at KSI, interlock, direction, or throttle inputs.

3. See 1311 menu Monitor » Inputs.

4,7

Emer Rev HPD

1. Emergency Reverse operation has concluded, but the throttle, forward and reverse inputs, and interlock have not been returned to neutral.

4,9

Parameter Change

Fault

1. This is a safety fault caused by a change in certain 1311 parameter settings so that the vehicle will not operate until KSI is cycled. For example, if a user changes the Throttle Type this fault will appear and require cycling KSI before the vehicle can operate.

6,8

VCL Runtime Error

1. VCL code encountered a runtime VCL error.

2. See 1311 menu Monitor » Controller: VCL Error Module and VCL Error. This error can then be compared to the runtime VCL module ID and error code definitions found in the specific OS system information file.

6,9

External Supply Out of

Range

1. External load on the 5V and 12V supplies draws either too much or too little current.

2. Fault Checking Menu parameters Ext Supply Max and Ext Supply Min are mistuned.

3. See 1311 menu Monitor » Outputs: Ext Supply Current.

7,1

OS General

1. Internal controller fault.

7,2

PDO Timeout

1. Time between CAN PDO messages received exceeded the PDO

Timeout Period.

7,3

Stall Detect

1. Stalled motor.

2. Motor encoder failure.

3. Bad crimps or faulty wiring.

4. Problems with power supply for the motor encoder.

5. See 1311 menu Monitor » Motor: Motor RPM.

8,7

Motor

Characterization Fault

1. Motor characterization failed during the motor characterization process.

8,8

Encoder

Characterization Fault

1. Encoder characterization failed during the motor characterization process.

2. Motor encoder pulse rate is not a standard value (32, 48, 64, 80 ppr).

8,9

Motor Type Fault

1. The Motor type parameter value is out of range.

9,2

EM Brake Failed to

Set

1. Vehicle movement sensed after the EM Brake has been commanded to set.

2. EM Brake will not hold the motor from rotating.

9,3

Limited Operating

Strategy(LOS)

1. Limited Operating Strategy (LOS) control mode has been activated, as a result of either an Encoder Fault (Code 36) or a Stall Detect Fault (Code 73).

2. Motor encoder failure.

3. Bad crimps or faulty wiring.

4. Vehicle is stalled.

9,4

Emer Rev Timeout

1. Emergency Reverse was activated and concluded because the EMR Timeout timer has expired.

2. The emergency reverse input is stuck On.