Baoli CPD10 Operation & Service Manual Download

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2. Brake system

2.1 General description

The brake system is the front two-wheel braking interior extended hydraulic type

consisting of a master cylinder, wheel brakes and brake pedal.

2.1.1 Brake pedal

The structure of the brake pedal which is assembled on meter rack with bracket is

indicated in Fig.2-1.

With the push rod of mast cylinder, the pedal converts the force acting on pedal to

brake oil pressure force.

Fig.2-1 Brake pedal

2.1.2 Master cylinder

The cylinder contains a valve seat, a check valve, a return spring, primary cup, piston

and secondary cup, which are all kept in place with a stop washer and a stop wire. The

exterior of the cylinder is protected from dust by means of a rubber dust cover. The piston

is actuated through the push rod by operation of the brake pedal. As the brake pedal is

pressed, the push rod pushes the piston forwards. The brake fluid in the cylinder flows

Summary of Contents for CPD10

Page 1: ......

Page 2: ...CPD10 30 DC CPD10J 30J AC Balanceweight Type Electric Forklift Truck OPERATION SERVICE MANUAL KION Baoli Jiangsu Forklift Co Ltd 1 3T ...

Page 3: ... system can control the torque intelligently the standard soft provides a complete toolkit to meet the demands of users and it optimizes the operation and reduces the producing cost of trucks It adopts imported motors and electric controllers improving the reliability of trucks and making the performance more superior The combination meter based on User Interface makes the operation more easily an...

Page 4: ... plates 20 Ⅲ Construction principle adjustment maintenance of electric forklift truck 26 1 Transmission system 26 1 1 General description 26 1 2 Assembly of wheel hub 31 2 Brake system 32 2 1 General description 32 2 2 Disassembly assembly and adjustment of wheel brake 39 3 Steering system 45 3 1 General description 45 3 2 Adjustment and maintenance 49 4 Electric system 51 4 1 General description ...

Page 5: ... 85 6 2 Specification of battery and charger 85 6 3 Usage and maintenance of battery 86 6 4 Troubleshooting guide 90 6 5 Charger 91 7 Hydraulic system 94 7 1 General description 94 7 2 Maintenance and adjustment of hydraulic system 104 8 Lifting system 109 8 1 General description 109 8 2 Maintenance and adjustment of lifting system 112 Charging record card of electric forklift truck 115 NOTE 116 E...

Page 6: ...1 Ⅰ External view and specification External view of electric forklift truck ...

Page 7: ...42 4038 Overhead guard height H2 mm 2162 2162 Min turning radius R mm 1820 1820 Min right angle stacking aisle width RAX A mm 3370 3370 Performance No load full load Travel speed km h 13 5 11 5 13 11 Lifting speed mm sec 400 300 390 285 Max grade ability 15 15 Service weight kg 2900 3120 Max pull force full load KN 6 6 5 Chassis Tyre Front mm 6 50 10 10PR 6 50 10 10PR Rear mm 5 00 8 8PR 5 00 8 8PR...

Page 8: ...xtended height H3 mm 4042 Overhead guard height H2 mm 2162 Min turning radius R mm 1820 Min right angle stacking aisle width RAXA mm 3370 Performance No load full load Travel speed km h 15 13 Lifting speed mm sec 400 300 Max grade ability 15 Service weight kg 3120 Max pull force full load KN 6 5 Chassis Tyre Front mm 6 50 10 10PR Rear mm 5 00 8 8PR Tread Front B2 mm 890 Rear B3 mm 920 Wheelbase Y ...

Page 9: ...3 mm 4040 Overhead guard height H2 mm 2159 Min turning radius R mm 2050 2100 Min right angle stacking aisle width RAXA mm 3715 3755 Performance No load full load Travel speed km h 12 5 11 12 5 10 5 Lifting speed mm sec 400 260 390 250 Max grade ability 10 15 Service weight kg 4160 4360 Max pull force full load KN 8 Chassis Tyre Front mm 7 00 12 12PR Rear mm 18 7 8 14PR Tread Front B2 mm 960 Rear B...

Page 10: ...nded height H3 mm 4240 Overhead guard height H2 mm 2125 Min turning radius R mm 2050 2100 Min right angle stacking aisle width RAXA mm 3715 3755 Performance No load full load Travel speed km h 14 12 Lifting speed mm sec 420 310 420 300 Max grade ability 10 15 Service weight kg 4160 4360 Max pull force full load KN 8 Chassis Tyre Front mm 23 9 10 16PR Rear mm 18 7 8 14PR Tread Front B2 mm 1040 Rear...

Page 11: ... 2040 Mast extended height H3 mm 4273 Overhead guard H2 mm 2125 Min turning radius R mm 2230 Min right angle stacking aisle width RAXA mm 3915 Performance No load full load Travel speed km h 13 12 Lifting speed mm sec 380 250 Max grade ability 10 Service weight kg 4850 Max pull force full load KN 10 Chassis Tyre Front mm 23 9 10 Rear mm 18 7 8 Tread Front B2 mm 1040 Rear B3 mm 980 Wheelbase Y mm 1...

Page 12: ...t extended height H3 mm 4273 Overhead guard height H2 mm 2125 Min turning radius R mm 2230 Min right angle stacking aisle width RAXA mm 3915 Performance No load full load Travel speed km h 14 5 12 Lifting speed mm sec 420 280 Max grade ability 10 Self weight kg 4850 Max pull force full load KN 10 Chassis Tyre Front mm 23 9 10 Rear mm 18 7 8 Tread Front B2 mm 1040 Rear B3 mm 980 Wheelbase Y mm 1630...

Page 13: ... disassembling the mast and balance weight 2 1 2 Load and unload the forklift truck 1 Use the plate with enough length width and strength 2 Pull the parking brake and use jacks to stop the wheel 3 Fasten the plate on the center of the cabin there must be no grease on the plate 4 The left and right height of the plate must be equal to make the loading and unloading smooth 5 Don t change the directi...

Page 14: ...ions before operation 1 Check all the instruments 2 Check the tyre inflation pressure 3 Check all the levers and pedals 4 Check if the voltage of the battery is in normal limit Check if the density and level of the electrolyte is appropriate 5 Check for all the terminals and plugs 6 Check hydraulic oil electrolyte and brake fluid for leakage 7 Check all connectors and fasteners for looseness 8 Che...

Page 15: ...quipped with a load handling attachment its usage sphere will be wider but its allowable load and stability is reduced The attachment and special device is not to be diverted to any other purpose It s very dangerous to rebuild the attachment Please read the additional instruction we supplied and operate the truck following it strictly 9 Fork can not be used to pull out any embedded goods if necess...

Page 16: ...ackward It s also necessary to tilt forward slowly so as to prevent the goods from slipping off the rack 21 Tilt the mast of the high lift forklift truck as backward as possible when the truck works Use minimum forward and backward tilt when loading and unloading It is dangerous to travel or turn at high levels 22 On the high lift forklift truck with lifting height more than 3m it is noted that th...

Page 17: ... of the truck should be done smoothly When steering on the humid or slippery road the truck should be decelerated 34 Operate the controls smoothly don t jerk the steering wheel Avoid sudden stop acceleration stop or turn In the case of improper operation the truck will turn over In case of this the driver must keep calm don t jump off the truck The driver must hold tightly the control wheel with t...

Page 18: ...depends on the working condition etc road operation method so the actual vibration frequency must be determined according to environment condition when necessary Model The noise pressure level at the operator s position The vertical direction acceleration mean value from the seat to the operator EN 12053 EN 13059 CPD10 15 69 1dB A 1 10 m s2 CPD20 25 78 3dB A 1 08 m s2 CPD30 63 9dB A 1 11 m s2 45 U...

Page 19: ... piping joints pumps and valves 3 Check the traveling brakes The free stroke of brake pedal is 20 30 mm when achieving effective brake the clearance between the front floor and the pedal should be more than 20mm 4 Check the parking brake The unload truck can park on stated ramp when the parking lever is pulled to the bottom 5 Check the meters lamps connectors switches and electric circuit if they ...

Page 20: ...t of photoelectric coupler of the hydraulic motor switch 8 Clean and dry the surface of the battery usually 9 Periodic maintenance must be done according to the following list after using the forklift truck No Item Contents Period hrs Remark 1 Bearing steering wheel Replace grease 1000 2 Bearing drive wheel Replace grease 1000 3 Steering link lever Replace grease 1000 4 Parking brake lever Add gre...

Page 21: ...0 SAE85W 90 3L 6L 6L To the oil level Brake fluid DOT3 Compound brake fluid 0 4L 0 4L 0 4L Lubricant grease 3 Lithium base grease drop point 170 JISK2220 2 Right amount Adding oil grease and coolant should follow relevant automobile standard The waster of the forklift truck must be reclaimed obeying the relevant laws and regulations Incorrect treatment will pollute water soil and atmosphere etc We...

Page 22: ...nds when pushing forward 11 Operating lever tilt cylinder Operate tilt cylinder Tilt backward when pulling backward it s forward oppositely 12 Accelerator pedal Control output voltage Press and accelerate 13 Seat adjust handle Adjust seat position 14 Lock battery cover Lock the battery cover Press the rear button of battery cover to open the lock 2 6 2 Electric forklift truck with DC motor 1 Start...

Page 23: ...lift truck can t start Turn the start switch clockwise to shift Ⅰ to turn on the power meter indicator and electric control circuit release the hand brake switch Push the shift direction switch forward press down the accelerator pedal then the truck goes forward If pull the direction switch backward the reverse lamps light and the back up buzzers sound If having operational errors or others the me...

Page 24: ... Measure the voltage drop between the contact terminals with multimeter to make sure there is no resistance between terminals Make sure that the sound of turning on or off the micro switch is slivery The inspections of micro switch should be done every three months 3 Check the connecting lines of primary circuit and make sure good insulation and connecting tightness of cables of the battery contro...

Page 25: ...en capacity drops to 20 one cell charge the battery to prolong the life of battery 3 Using PC machine or hand hold device connecting with control device the users can enter into software setting interface with powerful functions within certain limits You can measure and know the working condition of truck more intuitively for example as follows working current and rotating speed of AC drive motor ...

Page 26: ...21 2 General information when operating 3 Nameplate of forklift truck 4 Lubrication system ...

Page 27: ...22 5 Capacity chart 6 Inspections before starting 7 Adjust parking brake 8 Add hydraulic oil ...

Page 28: ...23 9 Tyre safety decal charging tyre 10 Sling decal 11 Sling point indication 12 Forbid entering into the rear space of the mast ...

Page 29: ...24 13 Tyre pressure decal charging tyre 14 Hand caution decal 15 Forbid conveying person 16 Routine battery use ...

Page 30: ...25 17 Routine battery maintenance 18 Faulty starting decal electric forklift truck witch DC motor 19 Overturn caution decal ...

Page 31: ...housing The differential case is of splitting type with two half shaft gears and four planet gears Refer to Fig1 3 2 Drive axle The driving axle assembled on the front of frame mainly consists of housing wheel hubs and wheels The axle housing is of integrally casting construction The tyre with rim is fixed to the hub with stubs and nuts The power is transmitted through the differential to the half...

Page 32: ...ar 3 Gear shaft 4 Differential housing 5 O ring 6 Cover 7 Bearing 8 Reducer housing 9 Bearing 10 Bearing seat 11 Bearing 12 Nut 13 Adjust shim 14 Adjust shim 15 Oil seal 16 Drivel gear shaft 17 Shim 18 Gear shaft 19 Bevel gear 20 Bearing 21 Bearing seat 22 Lock washer ...

Page 33: ...28 Fig 1 2 Gear box and differential 2 3t ...

Page 34: ...29 Fig 1 3 Differential ...

Page 35: ...30 1 Housing 2 Half shaft 3 Wheel brake 4 Brake drum 5 Oil seal 6 Taper bearing 7 Wheel hub 8 Taper bearing 9 Oil seal 10 Tyre 11 Rim 12 Hub nut 13 Lock nut Fig 1 4 Drive axle ...

Page 36: ... that pull the lock plates up to lock the bolts 5 Wheel assembly Install the inner rim and gasket inside the outer rim and assemble the outer rim and inner rim Pay attention to the following points a Put the air valve rod in the notch of the rim and make it face outside b Make the tops of the rim mounting bolts face outside c Don t stand near the tyre when inflating air d When the tyre pressure re...

Page 37: ... pedal converts the force acting on pedal to brake oil pressure force Fig 2 1 Brake pedal 2 1 2 Master cylinder The cylinder contains a valve seat a check valve a return spring primary cup piston and secondary cup which are all kept in place with a stop washer and a stop wire The exterior of the cylinder is protected from dust by means of a rubber dust cover The piston is actuated through the push...

Page 38: ...ginal position the brake fluid in the master cylinder flows into the reserve tank through the return port The brake fluid in the brake pipelines and operating master has a residual pressure proportioned to the set pressure of the check valve which makes each operating cylinder piston cup securely seated to prevent oil leakage and eliminates a possibility of air locking when the truck is sharply br...

Page 39: ...ce See Fig 2 3 On the other hand the braking operation in the truck s reverse travel is performed in reverse order but the braking force is the same as that being in the case of the truck s forward travel See Fig 2 4 2 Parking brake Built in the wheel brake the parking brake device consists of pull rod and push rod Assembled on the side of primary brake shoe by pin the operation of the pull rod tr...

Page 40: ...gs that the brake pull rod turns right round point A then point B is lifted On the other hand as the brake is released the lever turns left actuated by the spring point B descends The descending distance of point B becomes further with enlarging of clearance between friction pieces and brake drum This cause adjusts lever get long and clearance decrease See Fig 2 6 Fig2 7 Range of adjustable cleara...

Page 41: ... spring 15 Dust ring 2 Primary brake shoe 9 Secondary brake shoe 16 Cylinder body 3 E retainer 10 Spring 17 Piston 4 Operating cylinder 11 Ratchet pawl 18 Spring 5 Return spring 12 Clearance self adjuster 19 Cup 6 Parking push rod 13 Spring 7 Spring 14 Push rod ...

Page 42: ...perating cylinder 6 Parking push rod 11 Spring 2 Spring 7 Pressure spring 12 Parking pull rod 3 Push rod 8 Spring 13 Primary brake shoe 4 Secondary brake shoe 9 Ratchet pawl 14 Return spring 5 Backing plate 10 Clearance self adjuster ...

Page 43: ...nt of control lever Fig 2 10 1 Position of releasing the brake 2 Pull the lever point B with 15 30Kg force it can be pulled to diagrammatic position When the force is great the point A turns to right on the contrary turns to left Fig 2 10 Parking brake Adjustment of switch Fig 2 11 1 Loose two mounted bolts 2 Pull the parking brake lever 3 Mount the roller on the bracket of control lever after hea...

Page 44: ...ring See Fig 2 12 2 Remove return springs of two shoes See Fig 2 13 3 Remove three hold down springs of primary brake shoe See Fig 2 14 Fig 2 12 Fig 2 13 Fig 2 14 4 Remove the primary and secondary shoes At the same time remove the adjuster and adjuster spring See Fig 2 15 5 Remove the brake line from the operating cylinder then remove the mounting bolts of operating cylinder and detach the operat...

Page 45: ... the periphery surface of the piston for rusting Then measure the clearance between the piston and pump body Fig 2 19 Specified clearance 0 03 0 10mm Maximum clearance 0 15mm 2 Visually check the piston cup for damage or deformation If unsatisfactory replace with new one 3 Check the free length of the spring of operating cylinder If unsatisfactory replace it Fig 2 19 4 Check the friction piece for...

Page 46: ...urface between backing plate and brake shoes b Anchor pin c Contact surfaces between brake shoe and spring seat d Supporting pin of parking pull rod e The screw of the adjuster and other rotating parts Fig 2 22 5 Install the brake cable assembly on the backing plate with an E retainer 6 Install shoes on the backing plate with hold down springs See Fig 2 23 7 Put the spring on the parking push rod ...

Page 47: ...r 11 Measure the inner and outer diameter of brake drum Adjust the adjuster to obtain the difference needed between the drum inner diameter and the friction piece outer diameter Specified difference 1mm Fig 2 25 Fig 2 26 2 2 4 Operation test of clearance self adjuster 1 Make the brake shoe diameter approach the specified mounting size and pull the adjusting level with your finger along the arrow m...

Page 48: ...nd also check the adjuster gear for rotating condition and meshing section for undue wear or damage Check if lever and gear is contacted If above mentioned condition occurs replace the damage parts with new ones 2 2 5 Brake pedal adjustment see Fig 2 28 1 Push the master cylinder lever 2 Adjust the pedal height with the stopper bolt shown as Fig 2 28 3 With the brake pedal pressed and pull the rod...

Page 49: ...oreign matter mixed in brake fluid Check brake fluid 7 Maladjustment of brake pedal inching valve Adjust Noisy brake 1 Hardened friction piece surface or foreign matter adhered there Repair or replace 2 Deformed backing plate or loose bolts Repair or replace 3 Deformed shoe or incorrect installation Repair or replace 4 Worn friction piece Replace 5 Loose wheel bearing Repair Uneven braking 1 Oil c...

Page 50: ...xle consists of one steering knuckle separately on the left and right The steering cylinder piston pushes the steering knuckle to steer through lever then the steering wheel will be deflected and carry out steering Fig 3 1 Steering control device 3 1 1 Hand wheel Hand wheel is operated in normal way that is to say when turning the hand wheel right the truck will turn right when turning the hand wh...

Page 51: ...nd a combination valve The hole on the cover of combination valve is relief valve In the valve body there is a bipartite over load warning valve which protects the parts from damage when the truck wheels suffer unexpected impact and cause high pressure for hydraulic system We have adjusted the relief valve and bipartite over load warning valve the users can t adjust them without permission Fig 3 2...

Page 52: ...ectively The rear wheel hubs are fitted to the knuckle shafts through tapered roll bearings with oil seals keeping the grease in the chambers of the hubs and the knuckles The wheels with rims are bolted on the hubs The steering tyre rim and the pressure of the steering wheel Fig 3 3 Steering axle Truck model 1 1 5t 2 2 5t 3t Tyre size 5 00 8 8PR 18 7 8 14PR 18 7 8 Rim size 3 50D 4 33R 4 33R Tyre p...

Page 53: ...nder The steering cylinder is of double action piston type Both end of the piston rod are connected with steering knuckles through connection rod Left or right steering of the truck is achieved with the help of the left or right travel of the piston rod driven by the pressure oil from the powered steering unit The piston seal adopts combination seal of support ring and O ring The Yx ring seal is a...

Page 54: ...ft 3 Fit a flat washer and tighten a castle nut with torque of 206 235N m 21 24kg m and loosen it and then tighten it again with torque of 9 8N m 1kg m 4 To ensure firm installation of the hub slightly knock at it with a wooden hammer and in the meantime rotate the hub for 3 4 turns 5 Tighten the castle nut and align one of its notches with a cotter pin hole drilled in the steering knuckle 6 Again...

Page 55: ... air Steering unit fail to reposition due to spring piece damaged or elasticity insufficient Replace spring piece Oil leakage in the steering cylinder Inspect the seal of the piston Truck s snaking or moving with oscillation Spring damaged or elasticity insufficient Replace Excessive noise Too low oil level in the oil tank Refill oil Suction pipeline or oil filter blocked Clean or replace Oil leak...

Page 56: ...2 Fig 4 3 Electric forklift truck with AC motor Fig 4 4 Fig 4 5 1 Fuse box 2 Horn 3 Head lamp 4 Front combination lamp 5 Harness front overhead guard 6 Dashboard assy 7 Hand brake switch 8 Flasher unit 9 Direction switch 10 Turn lamp switch 11 Brake lamp switch 12 Harness dashboard 13 Harness meter 14 Battery socket assy 15 Rear combination lamp 16 Lift switch 17 Back buzzer 18 Separately excited ...

Page 57: ...52 Fig 4 2 Principle of electric system DC CPD10 25 ...

Page 58: ...53 Fig 4 3 Principle of electric system DC CPD30 ...

Page 59: ...Direction switch 8 Hand brake 9 Horn 10 Horn absorber 11 Foot horn switch 12 DC convertor 13 Microrelay 14 Back up buzzer 15 Foot brake switch 16 Seat switch 17 Warning lamp 18 Rear combination lamp 19 Steering potentiometer 20 Controller assy 21 Battery assy 22 Socket and connector 23 Flasher 24 Fuse box 25 Accelerator 26 Traction motor 27 Lifting motor ...

Page 60: ...55 Fig 4 5 Principle of electric system AC ...

Page 61: ...d technology it has the advantages as follows independently controlling the armature and excitation circuit the best attributes of both the series and the shunt motors can be combined it has high torque at low speed a plug braking regeneration control thermal protector and battery protector etc 2 The accelerator is composed of start switch and potentiometer The potentiometer converts the degree of...

Page 62: ...57 Fig 4 7 Controller assy DC CPD30 Red Start switch Orange Start switch Blue Potentiometer Brown Potentiometer Fig 4 8 Accelerator ...

Page 63: ...pection for the forklift firstly cut off the key switch for one minute then discharge the capacitance completely by process control 4 4 Distribution and setting of sensor AC 4 4 1 General description The electric forklift truck embodies many superior features such as infinitely variable lifting speed steering speed adjuster and pedal setting which can be adjusted and set in real time by EYE softwa...

Page 64: ...etween 0 KΩ and 5 KΩ when locating on 900 900 position b Connect PC machine with controller connector c If electric potentiometer installs correctly the output voltage value will be changed with hand wheel s turning d Enter STEERING SENSOR CALIBRATION menu e Select ANTICLOCK parameter turn hand wheel left until minimum steering value displays save it f Enter CLOCK menu g Turn hand wheel right unti...

Page 65: ... 2 Adjustment a Install potentiometer on the first level lift of multi way valve make sure that the top lever of potentiometer runs freely b Connect PC machine with controller connector c Enter LIFT CALIBRICATION menu d Select MINIMUM parameter the minimum value will be indicated in lift calibration value frame save it e Enter MAXIMUM menu f Operate lift lever until the maximum potentiometer outpu...

Page 66: ...ontact Capacity 2A 100V 3 Setting for accelerator a Install potentiometer on front backing plate make sure the accelerator pedal on initial state b Connect PC machine with controller connector c If accelerator connects correctly the output voltage will change with the stroke of the pedal d Enter ACCELERATION PEDAL CALIBRATION menu No Definition Color 1 Switch output1 Yellow 2 Switch output2 Blue 3...

Page 67: ...enu 4 6 LED instrument DC The electric forklift truck adopts newly displaying with combination of LED and LCD Control circuit adopts micro computer technology sampling displaying and controlling in real time The intense and feeble circuit in the instrument adopts light electricity separating with control relay It has under voltage warning and high automatic supporting function Refer to Fig4 9 4 6 ...

Page 68: ...arm code on the left of meter will show the working hours and disappear after several seconds 4 Signal of normal battery voltage When turn off the key switch this lamp lights meaning working state is normal 5 Warning of under voltage battery The lamp lights when the battery is in a state of under voltage in the meantime the controlling power of lift switch negative pole is cut the lifting is prohi...

Page 69: ...V Blue A5 Forward signal Brown A6 Backward signal Gray A7 Input left turning signal Yellow A8 Input right turning signal Green A10 Input short signal Pink B1 12V key switch Grown B2 Output 12V key switch Red B3 Input 48V Input 80V Yellow and green B4 Output 48V Output 80V Purple B5 Power negative Black B6 Voltage measuring pump output Light blue B7 Backing buzzer output 12V Green ...

Page 70: ... when start up in the reverse direction 24 Motor field current is high when start up in the forward direction 27 Control s power supply is less than 10 Volt DC 28 Motor field current is too high during the run mode 41 Open thermal protector TP or transistor over temperature 42 Motor armature offset voltage is too high 43 Motor armature offset voltage is too low 44 Armature transistor can not turn ...

Page 71: ...ication standard The EYE software obtains allowable landing and upgrade panel with functions of detailed upgrade diagnosis and adjustment The control circuit adopts SCM technology sampling displaying and controlling in real time The intense and feeble circuit in the instrument adopts light electricity separating with control relay 4 7 2 Structure of meter 1 Panel body 2 Wick 3 Key switch 4 Lamp sw...

Page 72: ...on for SME meter connector Display type Specification Operating voltage 12V Supply current 150A MAX Operating temperature 30 50 Protection IP54 Connections lin bus 1 Input1 2 Input2 3 Input3 4 Input4 5 Lin bus 19 2 KBIT S 6 7 GND 8 12V ...

Page 73: ...tactor can t be connected and truck can t travel until seat switch closes Time meter Odometer Turning angle indicating the position of rear wheel Maintenance time indication Remind the users to maintain and service the forklift truck Slow speed operating With the lamp on the traveling speed and lifting speed will be reduced in slow speed mode Traveling speed Indicated by 0 9 forms Overheated motor...

Page 74: ...ing electricity 1 Start the key switch press ENTER button for 3 seconds enter into adjust and diagnosis mode 2 When operating press for 3sec enter into diagnose mode 3 Quit when pressing ENTER under diagnosing mode the enter key is used for setting new parameter 1 Reduce the parameter in adjusting mode when pressing this key 2 The parameter can be reduced in adjusting mode 3 Press the key for 1sec...

Page 75: ...eter is not working lamp lights No alarm code and the alarm indication lights off when the truck works normally 3 Move the turning switch forward and backward the left and right turning signals flash When turn on the headlamp lamp indication lights up 4 Brake indication Operating the hand brake indication as P lights up pull the hand brake the signal turns off Note When the electric quantity is be...

Page 76: ...nt offset alarm 17 Main breaker 16 18 Watchdog timer alarm 20 Power inverter over temperature 22 37 Alarm on 5V encoder voltage 38 Alarm on 12V output voltage 50 Pump motor commands active on start 61 Motor blocking over temperature 62 65 63 Seat switch open on start 64 Wrong star 74 Encoder alarm 77 Motor thermal sensor alarm 75 78 80 Inverter temperature alarm 83 CRC fault alarm 81 84 Bank CRC r...

Page 77: ...72 4 8 Harness Fig 4 10 Harness DC CPD10 30 ...

Page 78: ...73 Fig 4 11 Harness AC CPD10J 15J ...

Page 79: ...74 Fig 4 12 Harness AC CPD20J 30J ...

Page 80: ...40A 45kg XQD 8 6 3D Series 8 6kw a quarter 45V 248A 47kg XQD 10 3D Series 10kw a quarter 75V 160A 90kg 5 1 2 Drive motor Installed on reduction box of drive device the rotation of the drive motor is controlled by low power transistor H axle circuit in the controller Rotation status of the motor is determined by the current direction that flows through motor excitation coils 5 1 3 Lifting motor Lif...

Page 81: ...76 Fig 5 1 Assembly diagram of lifting motor Fig5 2 Lifting motor ...

Page 82: ... 5 Stator 6 Rotor 7 Rear cover 8 Gear sensor 9 Speed sensor 5 2 1 Operating environment Operate normally under the following conditions 1 Elevation is lower than 1200 meters 2 Air temperature ranges between 25 and 40 3 Relative humidity is 100 5 2 2 Daily inspection and maintenance 1 Always keep clean and no water oil pollution or dust in the motor 2 Check the bearing for heat or leakage 3 The loa...

Page 83: ...Motor frame 80 Bearing 55 Return to normal Vibration Motor frame bearing board or others Compare with normal vibration Check and troubleshoot Abnormal noise Ear measurement compare with normal noise Check and troubleshoot 5 3 2 Maintenance and service when stopping Item Part Judgment Remedy Assembly part Assembly screws etc Visualization Looseness dust or rust Tighten clean and spray paint Termina...

Page 84: ...face Visualization high roughness because of damage rustiness Clean correct Screw Visualization looseness rustiness and dust Tighten antirust replace Terminal Surface Visualization high roughness because of damage rustiness Clean correct Connection Visualization connection looseness insulating treatment Tighten replace Wire Visualization damage of covering protection Professional repair Resistance...

Page 85: ... than 1MΩ 8 Check if the bolts are loose and tighten them 9 Please refer to the fifth item Inspection and maintenance of bearing 10 When the paint has discolored or peeled off antirust treatment or repaint is necessary 11 Tighten the terminals securely The pontes must be insulated completely with insulating rubberized fabric 12 After assembling check carefully for any residual parts and if the scr...

Page 86: ...ry 9 Open the shutter regularly to check if the inner parts out of shape and the commutator operating normally 10 Usually clean the dirt on the casing to help radiating heat 11 Check the motor every half a year as follow methods a Check and clean the dust of the motor b Clean or replace the bearing Pay attention to the abnormal noise of the bearing when operating c Check the electric brush for wea...

Page 87: ...specially at thick dust place or the place that butter may flow for deterioration because of harmful gas or solvent adding inspection frequency is necessary Operation time More than 12 hours everyday Less than 12 hours everyday Check frequency Once every year Once every two years 2 Disassembly and assembly of bearing If the bearing has abnormal noise or firing disassemble the bearing from the shaf...

Page 88: ...ith airer then measure it again If the measured value is still abnormal replace the motor 7 Inspection of rectifier Rectifier is the most important part of the motor If oil or foreign matter adhered on it it will cause electric brush excessive roughness and weaken the efficiency of the rectifier Clean it with compressed air or dry cloth Polish up the roughness of the rectifier surface with 500 or ...

Page 89: ...nd commutator surface is too large The mica between commutator sheets sticks out The electric brush materials isn t fitting The trademark of electric brush is not correct Spark is great The motor is over capacity The commutator is not clean The commutator is not plat or round Mica sheets or some commutator pieces stick out The electric brush is badly grinded The pressure of electric brush is not l...

Page 90: ...ft truck Battery Capacity 440AH 5h 700AH 5h 500AH 5h Name D 440BS 7DB700 55VBS500 Voltage 48V 48V 80V Density of electrolyte 1 280g cm3 1 280g cm3 1 280g cm3 Weight 940kg 1160kg 1242kg Charger Form Intelligent control single phase AC steady voltage charger Rated power 4 5KVA 5 5KVA 9 5 KVA Voltage 220V 50HZ 380V 50HZ 380V 50HZ Appropriate battery capacity 570AH 1000AH 600AH Output voltage 72V 72V ...

Page 91: ...attery must charge for about 12 hours 4 When operating the battery avoid over discharging mean the voltage of single battery is lower than 1 80V and over charging for it will effect the usual life and performance of battery 5 When charging open the cap for pouring liquid After finishing charging close the cap Keep the vent clear for prevent exploding and damage of battery 6 After using the battery...

Page 92: ...tainers When compounding the electrolyte first put measured distilled water or deionizer water in clean container then put measured thick sulphuric acid into water at last mix them with vitriol stick Note Don t put water into thick sulphuric acid against spattering and causing injury 6 3 3 Perfusing electrolyte 1 After assembling the battery twist pore plug and pour the electrolyte cooled down to ...

Page 93: ...with a graduated container 2 Open all pouring caps of battery units 3 Absorb distilled water with ball type injector to charge the battery When electrolyte is over 15 20mm upper the plate stop charging 4 After charging tighten the pouring cap 5 Clean the surface of battery unit with a wet cloth Note 1 Wear eyes protect glasses rubber overshoes and rubber gloves 2 When adding the distilled water ne...

Page 94: ...o leave the battery idle for a period of time not until the temperature come down can it be charged g Overcharging or over discharging could make the temperature of electrolyte go up When charging the battery open the battery cover to radiate heat and ventilate 2 Characteristics of full charging battery a The battery voltage of is about 52V 1 2 5t forklift truck with 24 groups batteries or 86 8V 3...

Page 95: ... improve the operating way Density of electrolyte is too low Adjust the density of electrolyte The connecting line isn t clear too high resistance Unblock the outer connection line and reduce the resistance 2 Capacity drops gradually Pole plates are sulphated Charging repeatedly to exhaust the condition of sulphating There is harmful matter in electrolyte Check electrolyte replace it if necessary ...

Page 96: ...harging current or exhaust the short circuit 2 Some batteries temperature is higher than others Pole plates are sulphated Exhaust the condition of sulphating Color and density of electrolyte is abnormal 1 Density rises less or stays Pole plates are sulphated Exhaust the condition of sulphating 2 After charging the density drops heavily when storage Quick self discharging Much matter is in electrol...

Page 97: ... on OFF position and connect the battery When replace the battery sling it from the truck as rules b Confirm the input voltage and frequency of the charger select appropriate the switch socket matched with the battery c The minimum quantity of electrolyte should be kept the level of the electrolyte must be higher than guide plate for 15 20mm or be in the scale range ruled by vent plug d Correctly ...

Page 98: ...280 15 1 287 35 1 273 2 Balanced charging After the battery fully discharging measure the specific gravity when charged distilled water and that of all batteries then converse the values setting the temperature 25 come out the difference When the difference is over 0 02 and other performance ruled balanced charging is necessary Charging equally according to these procedures After operating by the ...

Page 99: ...ect with motor Control valve Type Pommel type Model CBT F15D CBT F15D CBT F15D Setting pressure 14 5MPa 17 5MPa 17 5MPa Lift cylinder Type Single action piston type with cut off valve Bore diameter Ф45mm Ф50mm Ф56mm Outer diameter Ф36mm Ф40mm Ф45mm Stroke 1495mm lifting height is 3000mm Tilt cylinder Type Dual action piston type Bore diameter Ф63mm Ф70mm Ф70mm Outer diameter Ф30mm Ф32mm Ф32mm Stro...

Page 100: ...95 2 Diagram of hydraulic system Principle diagram of hydraulic system Model CPD10 CPD15 CPD20 CPD25 CPD30 Primary pressure hydraulic system P1 Mpa 14 5 17 5 17 5 Steering pressure P2 Mpa 7 5 9 9 ...

Page 101: ...96 3 Hydraulic oil circuit ...

Page 102: ...lve installed upon control valve inlet can control the pressure of system and the self locking valve set on the tilting valve pieces is used for preventing serious results happening of tilting cylinder because of misoperation when there is no pressure source The retaining valve is separately installed between inlet and lift valve inlet port and between lift valve inlet port and tilt valve inlet po...

Page 103: ...ls through the linking rod Fig 7 2 Operation of control valve Install the inching switch Make the inching switch bulb and camshaft keep identical center with the tangency of bulb surface and reel then press the inching switch bulb with control valve rod make the stroke no less than 0 8 0 1mm make the inching switch keep ON position which can be opened or closed freely by adjusting the clearance pr...

Page 104: ...n the oil pressure is different from the specified value loosen the lock nut of the surplus valve adjust the adjusting screw left and right to achieve the specified value Turn the screw left when pressure is high and turn right when it is low d After having adjusted tighten up the lock nut Fig 7 3 Setting pressure of relief valve 7 1 2 Lift cylinder The lift cylinder is of single action piston typ...

Page 105: ...el backed bearing and oil seal assembled on cylinder head to support the piston rod and prevent the dust The diagram of lift cylinder is referred to Fig7 4 Fig 7 4 Lift cylinder 1 Upper beam 2 Adjust shim 3 Dust ring 4 Oil seal 5 Guide sleeve 6 O ring seal 7 Cylinder head 8 Steel backed bearing 9 Cylinder body 10 Piston rod 11 Piston 12 Oil seal piston 13 Oil seal 14 Ring 15 Snap ring 16 Cut off v...

Page 106: ... a pressure difference between two chambers As the pressure difference is smaller than the spring force as result of passing the holes so that the cut off valve spool won t move If the high pressure hose bursts the pressure difference will be big enough to overcome the spring force causing the spool to move until the holes on the circumference of the spool are blocked up and allowing only a small ...

Page 107: ...the control valve flows through the oil chambers A and B oil holes C D E and F and the chamber G to the lift cylinder without any regulation When the lift spool is placed in the down position the oil flows in the reverse direction When much oil passes the orifice plate the pressure difference overcomes the force of the spring and moves the valve core right thus the oil flow being decreased by narr...

Page 108: ...x ring and O ring to prevent oil leakage and keep dust off Fitted with them the guide sleeve is screwed into the cylinder body The construction of tilt cylinder is referred to Fig 7 8 When the tilt lever is pushed forward the high pressure oil enters into the cylinder body from the cylinder tail moving the piston forward and causing the mast assembly to tilt forward until 6 degrees When the tilt l...

Page 109: ...eturn pipe 4 Remove the oil tank board 5 Remove the return filter replace new filter 6 Remove the inlet filter replace new filter 7 Remove the old gasket replace new one and smear sealant Three Bood 400 or equivalence 8 Install the oil tank board connect the inlet pipe and the return pipe 7 2 Maintenance and adjustment of hydraulic system 7 2 1 Maintenance of gear pump Fig 7 9 Gear pump 1 Pump bod...

Page 110: ...arts should be washed with gasoline a Pump body inspection Fig 7 10 If the scraping trace is up to 1 2 long of the inner periphery it indicates that the bearing and gear shaft are subject to excessive wear replace the pump body b Lining plate inspection Fig 7 11 Inspect the contact surface of the lining plate If the surface is worn or its thickness is smaller than the specified value replace the l...

Page 111: ...side of the gear with groove aiming gear point don t confuse the inlet oil port and the outlet oil port Fig 7 14 e Install a new seal ring and a new ring on the groove of the rear cover Fig 7 15 f Install the rear cover on the pump body don t confuse the inlet oil port and the outlet oil port g Tighten up the connecting bolts with a specified torque of 9 to 10 kg m after all Fig 7 14 Lining plate ...

Page 112: ...e pressure to 175 kg cm2 Each circuit works for five minutes and then renews the return filter During the increase of the pressure observe the change of oil temperature and pump body surface temperature and working voice If the oil temperature or pump body surface temperature is excessively high decrease the load to reduce the oil temperature then go on doing the test e After the trial run measure...

Page 113: ... cause Remedy Less exhausting oil Lower oil level of oil tank Add oil up to specified level Blocked pipe line or oil filter Clean or replace oil Lower pressure of gear pump Lining plate seal ring bushing seals or snap ring broken down Replace Misadjusted surplus valve Adjust the pressure of surplus valve to specified value with pressure gauge Air entering into the pump Retighten loose connections ...

Page 114: ...outer mast is assembled on the drive axle with support The outside middle of outer mast is connected with the frame by tilt cylinders The mast assembly can be tilted forward and backward by operating tilt cylinders The outer mast has C shaped cross section fixed with main rollers and side rollers on the top of it The inner mast has J shaped cross section fixed with main rollers and side rollers at...

Page 115: ...110 Fig 8 2 Inner and outer mast 2 3t ...

Page 116: ...t the clearance when moving make two immovable side rollers move along the outside of inner mast wind plate Main rollers sustain the longitudinal loads And side roller sustains the transverse loads When forks reach the maximum height the upper pair of main rollers will come out from the top of the inner mast Fig 8 3 Fig 8 4 Fig 8 3 Lift bracket 1 1 5t Fig 8 4 Lift bracket 2 3t 8 1 3 Fork pin The f...

Page 117: ... shims between the upper beam of the inner mast and the piston rod head which reaches to its height firstly The shims thickness is 0 2mm or 0 5mm 4 Adjust the tightness of lift chains NOTICE Please pay more regard to safety when adjusting the lift cylinder at an elevated height Fig 8 5 Adjust lift cylinder 8 2 2 Adjust the height of lift bracket 1 The truck should be stopped on horizontal ground A...

Page 118: ... ground 2 Make the forks and salver descend to the ground 3 Take down the top joint of the chains And take out chains from sheave 4 Lift the inner and outer mast Fig 8 8 5 The forklift will be reversed when the lift bracket is disengaged from the outer mast Fig 8 8 6 Replace main rollers Take apart all the snap rings from the lift bracket and take out main rollers except the adjust shims Make the ...

Page 119: ...fully 5 Take apart bolts which jointed lift cylinders and the bottom of outer mast and take apart the oil pipe between two lift cylinders without loosing the nipple 6 Main rollers on the upper outer mast will be showed on the top of the inner mast as soon as main rollers were taken apart from bottom of the inner mast after laying down the inner mast 7 Replace main rollers Take apart the upper roll...

Page 120: ...ater ml Density of electrolyte St It must be charged when the density of electrolyte is lower than 1 160g cm 3 S25 St 0 0007 t 25 S25 The density when the temperature is 25 St The density when the temperature is t measured value t The temperature of liquid measured value Final voltage about 52V 1 2 5t about 86 8V 3t Charged electricity 130 150 of battery ration Liquid level Higher than the shield ...

Page 121: ... _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _________________________________________________...

Page 122: ...ing year COMPLIES WITH THE PROVISIONS OF THE FOLLOWING EUROPEAN DIRECTIVES 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 2006 95 EC LVD Directive COMPLIES WITH THE PROVISIONS OF THE FOLLOWING HARMONIZED STANDARDS EN 1726 1 1998 Safety of industrial trucks Self propelled trucks up to and including 10000 kg capacity and industrial tractors with a drawbar pull up to and including 20000 N A...

Page 123: ...61 6126 P C 214500 Add No 8 Xinzhou Road Economic Development Zone Jingjiang Jiangsu China www baoli mh com We reserve the right to make any changes or modifications of pictures and specifications in this manual without giving previous notice and without incurring any obligation Edition ME07 03 2010 ...

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