Baoli CPDS15 Operation & Service Manual Download

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4. Electric system

4.1 General description

Electric system mainly consists of battery group, traction motor, lift motor,

multifunctional integration controller system, control switch, liquid crystal instrument,

harness and lighting device, etc.

Fig.4-1 Construction of electric system

1. Head lamp

2. Front combination lamp

3. Flash light

4. Inching relay

5. Meter assy

6. Start switch

7. Turning switch

8. Direction switch

9. Lamp switch

10. Hand brake

11. Main harness

12. Brake switch

13. Horn

14. Accelerator

15. Inching switch

16. Lift potentiometer

17. Socket assy

18. Battery assy

19. Controller assy

20. Rear working lamp

21. Rear tail lamp

22. Back-up buzzer

23. Fuse box

24. DC commutator

25. Steering potentiometer

26. Lift motor

27. Traction motor

28. Seat switch

29. Emergency switch

Summary of Contents for CPDS15

Page 1: ......

Page 2: ...OPERATION SERVICE MANUAL Three wheel Electric Forklift Truck KION Baoli Jiangsu Forklift Co Ltd...

Page 3: ...hydraulic AC motor with temperature and speed sensor and towing AC motor so they have a lot of advantages such as good performance easy operation wide vision flexible steering reliable braking powerfu...

Page 4: ...plates 14 Construction principle adjustment and maintenance of forklift truck 20 1 Transmission system 20 1 1 General description 20 1 2 Disassembly of drive system 22 1 3 Assembly of drive system 23...

Page 5: ...fication of battery 49 6 3 Usage and maintenance of battery 49 6 4 Troubleshooting 54 6 5 Charger 55 7 Hydraulic system 58 7 1 General description 58 7 2 Maintenance and adjustment of hydraulic system...

Page 6: ...1 External view and technical parameter External view of three wheel electric forklift truck...

Page 7: ...ing radius R mm 1500 Front overhang X mm 360 Min right angle stacking aisle width pallet 800 1200 1000 1200 RASA mm 2860 3060 2910 3110 Performance Full load no load Travel speed km h 14 15 5 13 5 15...

Page 8: ...ll 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 t...

Page 9: ...ts Charge the battery once a month 2 3 Precautions 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 batt...

Page 10: ...ods without tray 8 If the truck is equipped 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 b...

Page 11: ...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...

Page 12: ...oper 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 steering wheel with two hands meanwhile his body must inclin...

Page 13: ...87 m s2 44 Users select Lengthening fork in order to carry widening loads Pay much attention not to overload and observe the allowable load and the capacity chart on the truck Careful driving should...

Page 14: ...g lever is pulled to the bottom 5 Check the meters lamps connectors switches and electric circuit if they are running properly 2 5 3 Charging the battery 1 Please refer to Manual of Battery about the...

Page 15: ...ease 1000 2 Parking brake lever Add grease 200 3 Pin foot brake Add grease 200 4 Reduction box Replace gear oil 2400 5 Braking oil Add Whenever necessary 6 Pin tilting cylinder Add lubricating grease...

Page 16: ...claimed obeying the relevant laws and regulations Incorrect treatment will pollute water soil and atmosphere etc Wear safety guards such as helmet safety shoes and working clothes to avoid directly co...

Page 17: ...cover Lock the battery cover Press the rear button of battery cover to open the lock 14 Foot brake pedal Brake the truck Depress the pedal to brake 2 6 2 Operating manual 1 Start Before starting put...

Page 18: ...em During using the electric forklift truck it s necessary to maintain the control system periodically as follows 1 Check the contact terminal for wear status and contactor if works freely Check the c...

Page 19: ...orking state and aging different from rated capacity According to the common performance when capacity drops to 20 one cell charge the battery to prolong the life of battery 3 Using PC machine or hand...

Page 20: ...15 2 General information when operating 3 Nameplate of forklift truck 4 Lubrication system 5 Capacity chart...

Page 21: ...16 6 Inspections before starting 7 Add hydraulic oil 8 Sling decal 9 Sling point indication 10 Forbid entering into the rear space of the mast...

Page 22: ...17 11 Hand caution decal 12 Forbid conveying person 13 Routine battery use 14 Routine battery maintenance 15 Faulty starting decal electric forklift truck witch DC motor 16 Overturn caution decal...

Page 23: ...ction device brake friction device case cover and wheel axle The outer housing and case cover are of cast construction The reducer device and brake friction device are assembled in the case body which...

Page 24: ...19 Fig 1 1 Drive axle...

Page 25: ...el Loosen the wheel nuts and remove the drive wheel then loosen the 7 bolts fixing in the frame and remove the transmission case joint with traction motor from the frame Fig 1 2 1 2 2 Disassembly of t...

Page 26: ...seal gaskets and an O ring assembling separately on the flange of the motor and reduction box housing There is a hole in the motor flange for mounting the fixing ring of shaft The shaft of the motor i...

Page 27: ...m See it as Fig1 6 There are one inlet and one outlet separately below the transmission case frame Fig 1 6 1 3 3 Assembly of wheels Fig 1 7 The wheel axle of transmission case is fit for assembly of p...

Page 28: ...al ring if necessary b Unscrew the oil fill plug pos 2 with seal ring pos 4 c Inject the gear oil in transmission case When adding oil make sure that there is not air in the transmission case which wi...

Page 29: ...ake is assembled in reduction box eliminating the pollution extending the life of brake unit and descending the maintenance cost 2 1 1 Brake pedal The brake pedal assembly is of sling structure see th...

Page 30: ...wards This compresses or impacts the disc brake to slow or stop the truck Meanwhile the cavity caused behind the piston is filled with brake fluid led through the return port and inlet port When the b...

Page 31: ...brake fluid can be flowed b Press the brake pedal again and again then the pressure from brake fluid can exhaust the air mixed in brake system c When there is only brake fluid after exhausting the ai...

Page 32: ...gh and if the brake pedal can return to the original position by the spring c Brake fluid leakage inspection Press the brake pedal if not brake well check the assembly and tightness performance of tra...

Page 33: ...djust the brake switch Fig 2 5 a Loose the locking nut of the brake pedal after adjusting the height of brake pedal b Pull out the plug separate the lead c Turn the switch with the clearance A 1mm d M...

Page 34: ...s Fig3 1 The steering device is assembled on the rear of the frame with the gear turning pushed by the steering motor then the steering wheel can be turned to steering Main parameter of steering syste...

Page 35: ...y when turning the hand wheel right the truck will turn right When turning the hand wheel left the truck will turn left The rear wheels of the forklift truck are steering wheels which make the back of...

Page 36: ...g unit to the priority valve with the pressure the core of the check valve will be balanced to confirm the flow from CF port The steering circuit doesn t influence the other working circuits Main disp...

Page 37: ...mbled in the steering axle body with two tapered roller bearing In the inner of the bearing there is oil seal which makes the lubrication grease hold in the wheel hub and steering wheel axle chamber T...

Page 38: ...1kg m d 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 e Tighten the castle nut and align one of the notches with a c...

Page 39: ...re Air in steering oil circuit Exhaust air Steering unit fail to recover due to spring piece damaged or elasticity insufficient Replace spring piece Oil leakage in the steering motor Inspect the seal...

Page 40: ...Head lamp 2 Front combination lamp 3 Flash light 4 Inching relay 5 Meter assy 6 Start switch 7 Turning switch 8 Direction switch 9 Lamp switch 10 Hand brake 11 Main harness 12 Brake switch 13 Horn 14...

Page 41: ...36 Fig 4 2 Principle of electric system...

Page 42: ...controlling in real time The intense and feeble circuit in the instrument adopts light electricity separating with control relay 4 2 2 Outline and instructions of meter Traveling speed km h Hand brake...

Page 43: ...ing on this mode in general for saving 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...

Page 44: ...17 Main breaker 16 18 Watchdog timer alarm 20 Power inverter over heating 22 37 Alarm on 5V encoder voltage 38 Alarm on 12V output voltage 50 Pump motor commands active on start 61 Motor blocking over...

Page 45: ...r 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 Whe...

Page 46: ...re of controller Connector K1 control box Logic control box Main contactor Power module Power module Power module for right motor for lifting motor for left motor NOTICE The electric control device co...

Page 47: ...aged electronic components are indicated with alarm code replace them 3 When replacing or disassembling other parts it s necessary to reset the value after disassembling steering lifting potentiometer...

Page 48: ...plays save it h Enter MIDDLE menu i Turn the steering wheel left and right until zero value displays straight traveling direction save it j Quit the menu Do trial operation check if the position of st...

Page 49: ...r MIDDLE menu h Operate lift lever until indicating middle value between minimum value and maximum value save it i Quit the menu 4 5 AC microtron 4 5 1 Outline and port function 4 5 2 Sketch for conne...

Page 50: ...rator connects correctly the output voltage will change with the stroke of the pedal d Enter ACCELERATION PEDAL CALIBRATION menu e Press the pedal slowly until START lamp lights save it f Select MINIM...

Page 51: ...sor Structure of AC motor 1 Front cover 2 Bearing 3 Temperature sensor 4 Support cap 5 Stator 6 Rotor 7 Rear cover 8 Gear sensor 9 Speed sensor 5 2 Operating environment 1 Elevation is lower than 1200...

Page 52: ...e 1 280 g cm3 Unit quantity 24 Max weight 920kg Min weight 850kg Charging pressure 48V 6 3 Usage and maintenance of battery The correct using and daily maintenance is very important for the performanc...

Page 53: ...close the cap Keep the vent clear for prevent exploding and damage of battery 6 After using the battery charge it in time If not charging in time undercharge usually standing idle without charging fo...

Page 54: ...causing injury 6 3 3 Perfusing electrolyte 1 After assembling the battery twist pore plug and pour the electrolyte cooled down to 30 into the battery which will be absorbed by pole plates add electrol...

Page 55: ...ing 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 never exceed the appointed amount Add...

Page 56: ...ure 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 Char...

Page 57: ...rove 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 resistan...

Page 58: ...ging 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...

Page 59: ...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...

Page 60: ...80 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 te...

Page 61: ...85mm Oil tank Capacity 24L 7 1 1 Oil pump Oil pump is gear pump the type is SG05A20L224C Chinese brand The lift oil pump is driven by lift motor The oil from pump is distributed into two classes throu...

Page 62: ...h the neutral position Fig7 2 b Pushing in of spool valve Fig7 3 In this time the spool is pushed in to close the mid passage This causes the oil from the main oil inlet to push up the inlet check val...

Page 63: ...P The oil through lift valve C will act on the surface with diameter A and B then the check valve K and relief lift valve D will fall on the valve seat See Fig7 5 Fig 7 5 When the setting pressure of...

Page 64: ...ling the valve core out is referred to Fig 7 10 At this time the mast is in backward tilt position The following is the situation as pushing in the valve core Fig 7 9 a The core valve is pushed in Whe...

Page 65: ...evers are assembled together with a shaft and the shaft is assembled on the front guard with the bracket The valve levers operate the control valve with the joints See Fig 7 11 Fig 7 11 Operation of t...

Page 66: ...the measure method specified in JB T3300 it can be adjusted by specified servicemen as follows a Screw out the measured hole plug from the inlet port of control valve and install the oil pressure gau...

Page 67: ...on its outer periphery There is a cut off valve assembled on the bottom of the cylinder for protecting the cylinder if the high pressure hose is cranked suddenly when lifting the mast The bushing and...

Page 68: ...a pressure difference between two chambers As the pressure difference is smaller than the spring force so that the cut off valve spool won t move If the high pressure hose bursts the pressure differen...

Page 69: ...any regulation When the lift spool is placed in the down position the oil flows in the reverse direction When the oil passes the orifice plate 5 and a pressure difference generates between the chamber...

Page 70: ...uide sleeve is fitted with dust seal snap ring Yx ring and O ring to prevent oil leakage and keep dust off Fitted with them the guide sleeve is screwed into the cylinder body When the tilt lever is pu...

Page 71: ...is an inlet filter and a return filter separately in the oil tank and the tube 7 1 7 Hydraulic oil circuit See Fig 7 18 Fig 7 18 Hydraulic oil circuit Forklift truck 1 5t 1 8t Main relief pressure 14...

Page 72: ...pump in a vice by lightly clamping the flange section b Remove bolts 11 pump cover pump body Fig 7 9 c Remove lining plate driving gear and driven gear d Remove seal ring and ring from the front and r...

Page 73: ...ng plate inspection Fig 7 21 Inspect the contact surface of the lining plate If the surface is worn or its thickness is smaller than the specified value replace the lining plate Fig 7 20 Fig 7 21 c Fr...

Page 74: ...s with a specified torque of 9 to 10 kg m after all Fig 7 24 Lining plate Fig 7 25 Seal Notice The maintenance data of oil pump parts may be different because of the difference of manufacturers 4 Tria...

Page 75: ...wing tables and repair it 1 Control valve Problem Possible cause Remedy Lower oil pressure of the lifting oil circuit Spool is held up Disassembly and clean Oil hole is blocked Disassembly and clean V...

Page 76: ...surplus valve to specified value with pressure gauge Air entering into the pump Retighten loose connections for suction pipe Add oil into oil tank Replace oil seal Noisy gear pump Worn suction pipe o...

Page 77: ...er mast 91 5 Mast lifting system Hydraulic Mast tilting device Hydraulic Fork clearance adjustment Manual 8 1 1 Inner and outer masts Fig 8 1 The inner and outer masts are welded parts The bottom of o...

Page 78: ...nap ring 2 Pin 8 Bolt 14 Guide plate 20 Chain assy 3 Grease 9 Washer 15 Roller bearing 21 Short bolt 4 Mast bearing 10 Side roller bearing 16 Snap ring 22 Nut 5 Support cover 11 Side roller washer 17...

Page 79: ...verse loads Fig 8 2 Carriage 8 1 3 Fork pin The fork pin fastens the fork on the definite position When adjusting the clearance of the fork pull the fork pin turn 1 4 circle the fork clearance must be...

Page 80: ...in the upper beam of the inner mast without shims 2 Lift the mast slowly to the max stroke of the cylinder and check the two cylinders synchronize or not 3 Install shims between the top of the piston...

Page 81: ...ual Fig 8 6 Fig 8 5 Fig 8 6 8 2 3 Carriage rollers replace 1 Fork a tray on the fork and let the truck parking on the horizontal ground Fig 8 7 2 Make the fork and the tray down to the ground 3 Disass...

Page 82: ...ton rod carefully 5 Disassemble the connecting bolts for the lift cylinder and the bottom of the outer mast Disassemble the lift cylinders and the oil pipes between the two cylinders without loosen th...

Page 83: ...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 tempera...

Page 84: ..._______________________________ _______________________________________________________________________ _______________________________________________________________________ ________________________...

Page 85: ...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 FOLLOWI...

Page 86: ...1 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 t...

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