EP Equipment CPD30L1-B Service Manual Download Page 58

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REV. 05/2020

DRIVE SYSTEM

5.4 Drive Axle

5.4.1 Removal and Installation

See Section 5.3.1

5.4.2 Component

For CPD30L1-B

No.

Name

No.

Name

No.

Name

1 Bolt

7 Wheel Nut

13 Sector Plate-R

2 Lock Washer

8 Wheel Bolt

14 Bridge

3 Round Nut

9 Bearing

15 Plug

4 Rotary Shaft Lip Seal

10 Break Drum

16 Plug

5 Half Axis Washer

11 Rotary Shaft Lip Seal

17 Gearbox Mounting Pad

6 Half Axis

12 Wheel Brake-R

Summary of Contents for CPD30L1-B

Page 1: ...Service Manual Electric Forklift Truck CPD30 35L1 B CPD30 35L1 S ...

Page 2: ...Service Manual Electric Forklift Truck CPD30 35L1 B CPD30 35L1 S ...

Page 3: ...ome sections of the manual only involve certain model please refer to the manual according to the actual configuration of the vehicle If there are any changes revised version will be published once every 12 months if there is no change please follow the most recent version Please refer to the corresponding version of the service manual against the purchase time of your vehicle If you need the late...

Page 4: ...the complete operation and maintenance information in this Manual for vehicle maintenance Before using please check if the pages of the Manual are clear and complete so as not to affect your normal use because of incomplete information If the contents of the Manual have been illegible or damaged which may affect reading please contact our company or dealer for replacement With the constant update ...

Page 5: ... 21 3 1 2 Emergency Stop Switch 21 3 1 3 Warning Light Switch 21 3 1 4 Horn Button 21 3 1 5 Key Switch 22 3 1 6 Lighting Combination Switch 22 3 1 7 Reversing Buzzer 22 3 1 8 MDI Instrument 22 3 1 9 Accelerator Pedal 23 3 1 10 Brake Pedal 23 3 1 11 Horn 23 3 1 12 Control Switch 23 3 1 13 Warning Light 24 3 1 14 Combination Light 24 3 1 15 Headlight 24 3 1 16 Main Contactor 24 3 1 17 Pump Controlle...

Page 6: ...on 38 5 1 2 Faults and Causes 38 5 2 Drive Motor 39 5 2 1 Removal and Installation 39 5 2 2 Faults and Causes 40 5 2 3 Checking and Testing 41 5 2 4 Control Circuit Troubleshooting 42 5 3 Gearbox 44 5 3 1 Removal and Installation 44 5 3 2 Faults and Causes 44 5 3 3 Component 45 5 4 Drive Axle 46 5 4 1 Removal and Installation 46 5 4 2 Component 46 5 4 3 Drive Axle Oil 48 5 4 4 Faults and Causes 48...

Page 7: ...al and Installation 60 6 6 2 Faults and Causes 60 6 6 3 Checking and Testing 60 6 6 4 Control Circuit Troubleshooting 60 6 7 Emergency Switch 61 6 7 1 Removal and Installation 61 6 7 2 Faults and Causes 61 6 7 3 Checking and Testing 61 6 7 4 Control Circuit Troubleshooting 61 6 8 Parking Brake Switch 62 6 8 1 Removal and Installation 62 6 8 2 Faults and Causes 62 6 8 3 Connection Mode 62 6 8 4 Che...

Page 8: ...moval and Installation 81 7 6 2 Faults and Causes 81 7 6 3 Checking and Testing 81 7 7 Tilt Cylinder 82 7 7 1 Cylinder Removal Precautions 82 7 7 2 Cylinder Installation Precautions 83 7 7 3 Removal and Installation 84 7 7 4 Cylinder Maintenance 85 7 8 Hydraulic Troubleshooting 86 7 9 Hydraulic Symbol 87 8 STEERING SYSTEM 89 8 1 Steering Bridge 92 8 1 1 Removal and Installation 92 8 1 2 Faults and...

Page 9: ...ng 113 9 5 DC DC Converter 115 9 5 1 Removal and Installation 115 9 5 2 Faults and Causes 115 9 5 3 Checking and Testing 115 9 5 4 Control Circuit Troubleshooting 115 9 6 Combination Light Headlight Warning Light 116 9 6 1 Removal and Installation 116 9 6 2 Faults and Causes 116 9 6 3 Checking and Testing 116 9 6 4 Control Circuit Troubleshooting 117 9 7 Seat Switch 118 9 7 1 Removal and Installat...

Page 10: ...BLESHOOTING 175 10 1 Preparation Before Troubleshooting 177 10 1 1 Check the Voltage of Battery 177 10 2 Troubleshooting Solutions of Common Faults 178 APPENDIX 183 A SERVICE MANUAL MAST 185 A1 Wide View Two stage Mast 187 A1 1 Removal and Installation 187 A1 2 Lifting Chains 188 A1 2 1 Chain Adjustment 188 A1 2 2 Chain Replacement 189 A1 3 Mast Tubing 190 A1 4 Lift Cylinder 191 A1 4 1 Cylinder Re...

Page 11: ...lation 205 A3 2 Lifting Chains 206 A3 2 1 Chain Adjustment 206 A3 2 2 Chain Replacement 207 A3 2 2 1 Mast Chains 207 A3 2 2 2 Fork Carriage Chains 207 A3 3 Mast Tubing 209 A3 4 Lift Cylinder 211 A3 4 1 Cylinder Removal 211 A3 4 2 Cylinder Maintenance 212 A3 4 3 Cylinder Installation 213 A3 5 Built in Side Shifter 213 A3 6 External Side Shifter 213 B SERVICE MANUAL BATTERY 215 B1 Lithium ion Batter...

Page 12: ...ng device or jack leg is secure Park your vehicle in a safe and secure area Never use an open flame to check level of electrolyte other oils or fluids for leaks Keep the parking lot clean well ventilated and dry Regular checks and maintenance should be conducted to braking steering control warning and safety devices to keep them in good condition All nameplates and safety signs on the truck should...

Page 13: ...1 1 1 INFORMATION SPECIFICATIONS ...

Page 14: ...2 NOTE ...

Page 15: ...t Parts Service Platform In order to provide you with a fast and efficient after sales service when you claim order spare parts or after sales service upon maintenance please provide accurate truck model vehicle body serial number and part number After sales Maintenance Service Platform i NOTE ...

Page 16: ...TIONS 1 4 No Name 1 Drive wheel 2 Battery Cover 3 Chassis 4 Steering wheel 5 Counterweight 6 Rear Combination Lights No Name 7 Driver Seat 8 Warning Light 9 Overhead Guard 10 Headlight 11 Mast 12 Operate Lever 13 Forks 1 2 Introduction ...

Page 17: ...only be operated by single operator other personnel is forbidden from riding 1 3 Common Tools No Name Remark 1 Hex Head Socket Wrench 8 27 One Set 2 Phillips Screwdriver 2 One Piece 3 Slotted Screwdriver 2 One Piece 4 Sockets and Knobs One Set 5 Circlip Pliers One for holes and one for shaft 6 Hammer One Piece 7 Spreader Crane One Pair 8 Cylinder Wrenches For removal and installation of cylinders ...

Page 18: ... 10 9 8 8 5 8 1 4 General Tightening Torques Screws or bolts used on the truck are of 8 8 grade or higher performance level When you are conducting truck maintenance you can refer to Table 1 4 1 and Table 1 4 2 to select the suitable screws or bolts for replace ment CAUTION The performance levels of screws or bolts are marked on the heads of the screws or bolts If you find the screws or bolts used...

Page 19: ... 186 219 294 353 406 481 481 570 M18 1 5 210 247 331 397 457 541 541 641 M20 264 312 417 500 576 683 683 808 M20 1 5 294 345 463 555 640 758 758 897 M22 360 431 568 680 786 941 918 1099 M22 1 5 395 473 624 747 803 1034 1009 1208 M24 457 547 722 864 998 1195 1167 1397 M24 2 497 595 785 940 1086 1300 1269 1520 M27 669 801 1056 1264 1461 1749 1707 2044 M27 2 723 865 1141 1366 1578 1890 1845 2208 M30 ...

Page 20: ...REV 05 2020 INFORMATION SPECIFICATIONS 1 8 ...

Page 21: ...9 2 2 MAINTENANCE ...

Page 22: ...10 NOTE ...

Page 23: ...n wedges disconnect the key switch and disconnect the battery connections When lifting the truck the lifting tools can only be installed on the fixed positions as specified When jacking up the truck appropriate tools such as wedge blocks wooden blocks and so on must be used to secure the truck to pr event the occurrence of accidental rolling or tipping over Without the supplier s consent it is str...

Page 24: ...e vapor steam to clean the equipm ent 2 2 2 Inspection Regular inspection and maintenance under normal conditions of use Operating Hours h Requirements 50 At least once per 7 days 250 At least once per 60 days 500 At least once per 90 days 1000 At least once every 6 months 2000 At least once per year When the truck is at running in phase after approximately 100 hours of operation the equipment use...

Page 25: ...celerator pedal functions A Check fault information records and operating hours A Power Supply Drive System Check the battery cables for damage and replace if necessary A Check the battery charge connector A Check if the cable connections between battery mon omers are secure apply some grease to electrodes if necessary A Check electrolyte fluid level A Check electrolyte density A Check battery tem...

Page 26: ...hoses pipes and interfaces are fastened or sealed securely and check if there is damage A Check the connections of pump motor connectors A Check and tighten pump motor mounting bolts A Check the gear pump fixation and check for leaks A Check the cylinders for leaks A Check the cylinders for damages and check the fixation A Check the oil tank fixation and check for leaks A Check the hydraulic oil l...

Page 27: ...xation of lift mast A Check the tubing on mast for connections and leaks A Check the side shifter functions A Check and lubricate the chains A L Check the lifting chains and chain guides for wear adjust and grease A Check the fork carriages for wear and damage A Visual inspection of rollers sliders and stoppers A Check the lifting and lowering speed A Other Check if the signs are clear and complet...

Page 28: ...Check the seat fixation and adjustment functions A Check the seat belt and functions A Check the overhead guard and cabin A Checking covering parts for damages A Check if the optional features are functioning properly A A Check Adjust Please refer to Inspection Maintenance List for regular inspection and maintenance of the vehicles L Lubrication Under harsh conditions the lubrication intervals sho...

Page 29: ...se clean containers It is strictly forbidden to mix different types and specifications of lubricants with each other except for those can be mixed under clear statement The use and disposal of lubricants must be carried out in strict accordance with the manufa cturer s regulations Lubricant Please see Table 2 2 for the lubricants used in this truck CAUTION L1 L2 L3 L4 C C D A B B B B Fig3131 00004...

Page 30: ...y gear oil 85W 90GL 5 0 5L Align with oiling port Gearbox D Brake fluid ZSM207DOT3 After the gas within the system is completely discharged add to 2 3 of the oil cup Brakes Table 2 3 Application Amount of Hydraulic Oil Mast Series Lifting height mm Amount L 2 stage Mast 2000 11 2500 13 2700 13 5 3000 14 5 3300 16 3500 16 5 3600 17 0 4000 18 5 4300 19 5 4500 20 0 Table 2 4 Sliding Surface Lubricati...

Page 31: ...19 3 3 STRUCTURE FUNCTIONS ...

Page 32: ...20 NOTE ...

Page 33: ...ncy braking Description under normal circumstances switch cover is at high position and the circuit is connected when pressing this switch the circuit is disconnected Note Unserviceable 3 1 3 Warning Light Switch 3 1 4 Horn Button Location on the left of control panel Function to control the on and off of warning light Description warning light switch is normally open Note Unserviceable Location o...

Page 34: ...lay the battery power working hours travel speed and other basic information as well as fault code and so on Description 80V operating voltage Note Unserviceable 3 1 6 Lighting Combination Switch Location bottom right of steering wheel Function switch on left right steering light headlights Description 12V operating voltage Note Unserviceable 3 1 7 Reversing Buzzer Location on the right of the cha...

Page 35: ...ltage Note Unserviceable 3 1 11 Horn Location on the left support of front plate Function can provide sound alarm through the operation to horn switch operation Description 12V operating voltage Note Unserviceable Brake Pedal Accelerator Pedal Horn Control Switch 3 1 12 Control Switch Location at the end of operating lever Function to provide the controller with lift lower forward retract tilt for...

Page 36: ...keep clear of it Description 12V operating voltage Note Unserviceable 3 1 15 Headlight Location on the front of overhead guard Function to provide lighting for operator Description 12V operating voltage Note Unserviceable 3 1 16 Main Contactor Location electrical mounting plate of the chas sis Function to connect and disconnect circuit and to control the power transmission of drive motor Descripti...

Page 37: ...p motor through the signal input by the control switch Description 80V operating voltage to control the pump motor circuit Note Unserviceable 3 1 19 Fuse on Controller 3 1 20 DC DC Converter Location on the controller Function overcurrent protection Description fusing current is 400A Note Unserviceable Location on the front frame of the truck Function to provide 12V voltage for lights horn and acc...

Page 38: ... controller to control the power transmission of pump motor Note Unserviceable 3 1 23 Gear Pump Location near the pump motor Function to provide pressure for hydraulic system of the lifting and tilting Description N A Note Unserviceable Pump Motor Gear Pump 3 1 21 Multi way Manual Valve Location on the right of chassis Function connection and disconnection of oil passage Description manual valve c...

Page 39: ...27 4 4 CHASSIS SYSTEM ...

Page 40: ...28 NOTE ...

Page 41: ... Installation and Commissioning Install according to the reverse order of rem ova WARNING WARNING CAUTION Switch off the truck power and place the jack under the chassis near steering wheel make the wheel off the ground see Fig3131 10002SM Unscrew the eight nuts 1 on the steering wheel assembly 2 Remove the steering wheel assembly 2 from the steering bridge 3 Turn the wheel to see if it is rotatin...

Page 42: ...onnect the connection between the seat and main wiring harness Loosen the two nuts 2 and remove the two gas cylinder 3 Unscrew the two screws 4 and remove the battery cover 5 from the chassis Remove the cushion then unscrew the ten screws 1 Remove the left floorboard 2 Disconnect the connection between brake pedal and main wiring harness then remove the right floorboard 3 Unscrew the three screws ...

Page 43: ...r Install according to the reverse order of rem oval Remove the parking brake cover see section 4 2 1 Disconnect the connection between the parking brake switch and main wiring harness Loosen the three nuts 1 then remove the parking brake assembly 2 from the chassis Unscrew the two screws 3 and remove the parking brake switch 4 from the parking brake assembly Install according to the reverse order...

Page 44: ...pin shaft 6 then remove the brake master cylinder 7 Remove the sping 8 then unscrew one nut 9 and one bolt 10 Remove the shaft 11 and remove the brake pedal 12 Loosen the nut 13 and remove the pedal switch 14 Installation Install according to the reverse order of rem oval After replacing the brake master cylinder or tubings the air within the entire brake pipeline must be discharged Air Discharge ...

Page 45: ...tes that the air discharge is completed release the brake pedal and close the vent During the entire process of operation there must always be brake fluid in the oil cup Add brake fluid into the oil cup until it fills 2 3 of the cup Please apply as specified see Section 2 2 3 for specifications CAUTION 4 5 2 Faults and Causes 1 Fault Brake performance weakened or failure Cause a Insufficient brake...

Page 46: ...34 REV 05 2020 CHASSIS SYSTEM 4 ...

Page 47: ...35 5 5 DRIVE SYSTEM ...

Page 48: ...36 NOTE ...

Page 49: ...37 REV 05 2020 DRIVE SYSTEM 5 Drive System No Name 1 Drive Wheel 2 Gearbox 3 Drive Motor ...

Page 50: ...g or degumm ing Cause Improper use 3 Fault Vehicle sways while running Cause Drive wheel lock nut loosening WARNING Jack up the vehicle with lifting equipment 1 make the drive wheels off the ground Unscrew the six nuts 2 and remove the drive wheel assembly 3 Tyre wear can affect the stability of the truck replace the drive wheel with heavy wear Quality of tyres directly affects the stability and d...

Page 51: ... connection between the drive motor and main wiring cables Remove the tubings on the brake Wrap the sling around the overhead guard slightly lift the truck with crane Loosen the eight nuts 1 Fig3131 20006SM and remove the bolts 2 then remove the motor gearbox drive bridge assembly 3 from the chassis Unscrew the five screws 4 Fig3131 20007SM then remove the motor 5 from the assembly Make sure the l...

Page 52: ...noise or vibration Cause a Uneven clearance between stator and rotor b Bearing failures c Loosening fixing screws on motor housing 4 Fault Motor smoking or burning smell Cause Stator winding short circuit motor burnt 5 Fault Motor temperature too high controller failure Cause a Stator winding short circuit b Motor U V and W terminals with surface c Bearing failure resulting in severe heating d Mot...

Page 53: ...5 2 3 Checking and Testing U V W Terminals Identify if the motor windings are normal through measuring the resistance of U V V W and U W respectively if there is short circuit or breakage as shown in the following table Due to the small size of windings when measu ring with a multimeter put it on a low resistance range Resistance Measurement Judgment With readings but very low Normal 0 Ω Winding i...

Page 54: ...troller won t report for failure but the travel speed of the vehicle may slow down Testing 5 2 4 Control Circuit Troubleshooting Drive Motor Control Circuit For CPD30 35L1 B see Fig3131 20011SM Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 19 20 30 31 circuit circuit between motor encoder and controller is conducted Check if 39 20 circuit circuit betwe...

Page 55: ...43 REV 05 2020 DRIVE SYSTEM 5 For CPD30 35L1 S see Fig3131 20012SM ...

Page 56: ...e ten bolts 1 Fig3131 20013SM and remove the gear box 2 from the drive bridge Installation Install according to the reverse order of rem oval 5 3 2 Faults and Causes 1 Fault Gearbox Abnormal Noise Cause a Supporting bearing wear b Gear wear the gap is too big c Foreign objects in gear oil 2 Fault Gearbox Oil Leaks Cause Oil seal wear or aged 3 Fault Gearbox Stuck Cause a Gear fastening screws or n...

Page 57: ...t 11 Snap Ring For Hole 20 Differential Case 3 Housing Cover 12 Sealing Oil 21 Washer 4 Bearing 13 Bearing Cover 22 Axle shaft gear 5 O ring 14 O ring 23 Washer 6 Shaft 15 Washer 24 Planet Gear 7 Seal Cover 16 Housing 25 Universal Joint Pin 8 Dual Gear 17 Bearing 26 Gear Ring 9 Gear Shaft 18 Nut 27 Bearing Seat ...

Page 58: ...4 2 Component For CPD30L1 B No Name No Name No Name 1 Bolt 7 Wheel Nut 13 Sector Plate R 2 Lock Washer 8 Wheel Bolt 14 Bridge 3 Round Nut 9 Bearing 15 Plug 4 Rotary Shaft Lip Seal 10 Break Drum 16 Plug 5 Half Axis Washer 11 Rotary Shaft Lip Seal 17 Gearbox Mounting Pad 6 Half Axis 12 Wheel Brake R ...

Page 59: ...Wheel Brake R 2 Lock Washer 8 Bearing 14 Sector Plate R 3 Round Nut 9 Break Drum 15 Bridge 4 Rotary Shaft Lip Seal 10 Wheel Hub Nut 16 Plug 5 Half Axis Washer 11 Wheel Hub Bolt 17 Plug 6 Half Axis Bolt 12 Rotary Shaft Lip Seal 18 Gearbox Mounting Pad For CPD35L1 B CPD30 35L1 S ...

Page 60: ...thin the gearbox Remount the oil drain plug and add the gear oil of same specification with tubing through oiling port gear oil specification 85W 90GL 5 Gear oil filling amount 0 5 L Add Replace Drive Axle Oil 5 4 4 Faults and Causes 1 Fault Drive Axle Abnormal Noise Cause a Supporting bearing wear b Gear wear the gap is too big c Foreign objects in gear oil 2 Fault Drive Axle Oil Leaks Cause Oil ...

Page 61: ...49 6 6 OPERATING SYSTEM ...

Page 62: ...50 NOTE ...

Page 63: ...between the key switch 9 and main wiring harness then remove the back cover plate 7 Cut off the connection between the combina tion switch 12 13 and the main wiring harness Pull out the rubber sleeve 10 from the com bination switch Unscrew the adjusting handle 5 remove the front cover plate 6 Unscrew the four screws 11 remove the travel combination switch 12 and lighting combination switch 13 from...

Page 64: ...steering shaft 20 Fig3131 30001SM and bearing 19 from the bracket 16 Remove the five tubings on the redirector 21 Unscrew the four bolts 22 and remove the redirector 21 from the bracket 16 Unscrew the four nuts 2 Fig3131 30002SM and four bolts 3 remove the redirector bracket 16 Fig3131 30001SM from the chassis 1 Fault Operate the horn switch but the vehicle responds with no action Cause a Horn swi...

Page 65: ...plug connection is secure Check the horn switch guide rods and springs for abnormalities and deformation Testing 6 2 4 Control Circuit Troubleshooting Control Circuit Fig3131 30004SM Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 13 circuit circuit between press button and power supply positive electrode is conducted Check if 14 circuit circuit between ...

Page 66: ...itch and its wiring harness are in good con dition and if the connectors are connected securely 6 3 3 Checking and Testing Carry out ON OFF test to combination switch with a multimeter Travel combination switch should be at 0 position N of the lever Test Interface Status of Conduction 25 21 Broken Circuit 24 21 Broken Circuit 13 15 Broken Circuit Check if the combination switch circuit is connecte...

Page 67: ...y using a multi meter Set the multimeter to ON OFF Check if 13 circuit circuit between switch and DC DC converter is conducted Check if 15 circuit circuit between switch and light is conducted Check if 22 circuit circuit between switch and power supply positive electrode is con ducted Check if 24 25 circuit circuit between switch and controller is conducted ...

Page 68: ...56 REV 05 2020 OPERATING SYSTEM 6 For CPD30 35L1 S Fig3131 30008SM ...

Page 69: ...g harness are in good con dition and if the connectors are connected securely 6 4 3 Checking and Testing Carry out ON OFF test to combination switch with a multimeter Lighting combination switch should be at 0 position F of the lever Test Interface Status of Conduction 11 9 Broken Circuit 10 9 Conducted Circuit Check if the combination switch circuit is connected Testing Lighting combination switc...

Page 70: ...tch and turn signal is conducted Check if 5 9 circuit circuit between switch and power supply positive electrode is con ducted Check if 117 circuit circuit between switch and headlight relay is conducted Check if 6 circuit circuit between switch and outline marker light is conducted Lighting combination switch should be at the position of the knob Test Interface Status of Conduction 117 5 Conducte...

Page 71: ...d condition and if the connectors are connected securely 6 5 3 Checking and Testing Testing Check if the key switch circuit is conducted Carry out ON OFF test to the key switch with a multimeter key switch at OFF position open circuit place the key switch at ON position the circuit is conducted 6 5 4 Control Circuit Troubleshooting Control Circuit Fig3131 30012SM Check if the circuit is broken by ...

Page 72: ...and Testing Testing Check if the switch circuit is conducted Carry out ON OFF test to press button switch with a multimeter Press button switch at original position circuit breakage press the button circuit conducted 6 6 4 Control Circuit Troubleshooting Unscrew the two screws 1 and remove the multi way valve plate 2 of control panel 4 Unscrew the two screws 3 and remove the control panel 4 from t...

Page 73: ...rgency switch its wiring harness are in good condition and if the connectors are connected securely 6 7 3 Checking and Testing Testing Check if the emergency switch circuit is con ducted Carry out ON OFF test to emergency switch with a multimeter Emergency switch in pulled out status circuit conducted press the emergency switch the circuit is opened 6 7 4 Control Circuit Troubleshooting Control Ci...

Page 74: ...s connector to switch base Checking Check if the appearance of control switch is in good condition also check for deformation of handwheel Check if the handwheel is working smoothly and if there is foreign body blockage 6 8 4 Checking and Testing Enter the TESTER Menu to check the status of switches press the handwheel of switch to check the ON OFF status If the display does not change it indicate...

Page 75: ...8SM Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 27 109 circuit circuit between parking brake switch and controller is con ducted Set the multimeter to ON OFF Check if 27 circuit circuit between parking brake switch and controller is conducted Check if 18 circuit circuit between parking brake switch and battery is conducted ...

Page 76: ...n action Cause Remote control switch failure Checking Check if the appearance of control switch is in good condition also check for deformation of magnet buckle Check if the magnet buckle is working smoot hly and if there is foreign body blockage 6 9 3 Checking and Testing Enter the TESTER Menu to check the status of switches toggle each control switch separately to check the ON OFF status If the ...

Page 77: ...y using a multi meter Set the multimeter to ON OFF Check if 52 53 56 circuit circuit between control switch and controller is conducted Lift Switch Control Circuit For CPD30 35L1 S Fig3131 30021SM Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 56 122 123 circuit circuit between control switch and controller is conducted ...

Page 78: ...f 52 53 57 circuit circuit between control switch and controller is conducted Tilt Switch Control Circuit For CPD30 35L1 S Fig3131 30023SM Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 65 122 123 circuit circuit between control switch and controller is conducted Check if 21 circuit circuit between control switch and key switch is conducted ...

Page 79: ...52 53 58 circuit circuit between control switch and controller is conducted Left Shifting Right Shifting Switch For CPD30 35L1 S Fig3131 30025SM Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 61 62 122 123 circuit circuit between control switch and controller is conducted Check if 21 circuit circuit between control switch and key switch is conducted ...

Page 80: ...68 REV 05 2020 OPERATING SYSTEM 6 ...

Page 81: ...69 7 7 HYDRAULIC SYSTEM ...

Page 82: ...70 NOTE ...

Page 83: ...aulic oil is becoming less please tho roughly check the hydraulic system for leaks Disassembly of cylinder needs to be perfor med in a clean environment Before removing the cylinder the stains on the cylinder must be removed first Carefully remove the piston rod to prevent the cylinder wall from being scratched by its end surface or damaged part Every time when replacing the cylinder also replace ...

Page 84: ...72 REV 05 2020 HYDRAULIC SYSTEM 7 7 1 1 Hydraulic Schematic Diagram ...

Page 85: ...bolts 5 and remove the gear pump 4 from the motor 7 Unscrew the four bolts 6 and remove the pump motor 7 from the chassis Removal For CPD30 35L1 S For CPD30 35L1 B Installation Install according to the reverse order of rem oval When removing the tubing and gear pump the system will lose some hydraulic oil please refer to Section 2 2 3 for supplementary adding of hydraulic oil CAUTION 1 3 Fig3131 4...

Page 86: ...circuit motor burnt 5 Fault Motor temperature too high controller failure Cause a Stator winding short circuit b Motor U V and W terminals with surface c Bearing failure resulting in severe heating d Motor cooling duct blockage with foreign body e Overload 6 Fault On load motor speed is turning slow Cause a Insufficient voltage of battery b Overload c U V W terminals with abnormal voltage input d ...

Page 87: ...lues measured at U V V W and U W shall not be greater than 2 Identify if there is leakage current through measuring the resistance between U V W and motor housing respectively as shown in the following table Resistance Measurement Judgment 0 Ω Leakage current replace the motor Ω Normal For normal motor U V and W terminals are insulated from motor housing Temperature Sensor For CPD30 35L1 S For CPD...

Page 88: ...and controller is conducted Check if 64 73 circuit circuit between motor temperature sensor and controller is conducted Checking Speed Encoder Speed encoder is used to detect the speed of the motor and covert the speed into fixed signals Check if the motor encoder and the appear ance of cables are in good condition and if the plug connection is secure Remove the speed encoder and check its sensing...

Page 89: ...77 REV 05 2020 HYDRAULIC SYSTEM 7 ...

Page 90: ...y valve is at original position adjust the control lever 14 to a vertical position As some hydraulic oil will be lost when removing the manual multi way valve please add appropriate amount of hydraulic oil after the replacement is completed see Section 2 2 3 for specifications and adding amount CAUTION Unscrew the four screws 16 and remove the multi way valve and the mounting plate Remove the cott...

Page 91: ... Tank ø25 7 4 3 Faults and Causes 1 Fault The vehicle cannot perform the hydraulic control instructions Cause a Valve failure b Valve seat blocked by large impurities c External leakage sealing damaged poor threaded connection valve body defects d High viscosity of hydraulic oil e High frequency of use service life has expired already 2 Fault Slow pace of actuator Cause a Overflow valve in the con...

Page 92: ... noise Cause a Pump body defects b Gear pump inlet tubing diameter is too small c Oil filter clogging or motor speed is too high d Motor and oil pump shaft misalignment 7 5 1 Removal and Installation See Section 7 2 1 4 Fault Oil leaks Cause a Pump body defects b Seal skeleton spring off c Shaft sealing surface scratched 5 Fault Pump is not functioning properly or blocked Cause a Pump body defects...

Page 93: ...nstallation See Section 6 1 Checking Check the redirector body for leakage and damage Check if the connection of redirector and tub ings is normal 7 6 3 Checking and Testing If the redirector is found with failure it is recom mended to replace the redirector directly CAUTION Symbol Interface Function Connection Terminals Interface Size T Drainback Tank M18 1 5 P Oil Inlet Gear Pump M20 1 5 L Left ...

Page 94: ...t do not hammer forcefully it such case cannot be avoided please lay a copper rod to avoid damage to the parts special tools must be used for the parts having such requirements do not hammer forcefully or pry Fine pitch threaded cylinder cap after being shaken loose loosen it with cylinder wrench with even force copper rod can be used to hammer the part that cannot easily deform do avoid violent s...

Page 95: ...y attention if it is moving without blocking and if there is uneven resistance during the moving Upon the pressure testing raise the pressure slowly and observe carefully for leaks 7 7 2 Cylinder Installation Precautions All parts should be cleaned up before asse mbly then to be assembled after being dried during assembly apply appropriate amount of hydraulic oil for lubrication The tools used to ...

Page 96: ...chassis and outer mast Hydraulic oil may damage truck parts and con taminate the environment When removing joints or tubings place a clean container under it for discharge of hydraulic oil Unscrew the anchor bolt 1 from the outer mast with socket wrench and pull out the pin shaft 2 Unscrew the anchor bolt 4 from the chassis with socket wrench and pull out the pin shaft 5 Remove the tilt cylinder 3...

Page 97: ...ear 1 from the piston rod 12 Remove the nut 4 and unscrew the cylinder cap 9 with cylinder wrench Remove the dust ring 5 check ring 6 seal 7 bushing 8 O ring 10 and check ring 11 from the cylinder cap 9 Pull out the piston rod 12 from cylinder block 21 Remove the seal 13 and support ring 14 on the piston rod Remove the pin of the nut 20 and remove the nut from the bottom of the piston then separat...

Page 98: ...l 3 Pump or oil temperature is too high a Oil is too thin b Pump cavitation c Valve body internal relief 1 Discharge and clean and add new hydraulic oil 2 Check the oil inlet piping for air leaks 3 Replace the valve body 4 Low System Pressure a Insufficient oil b Relief valve failure c Pump wear internal leakage 1 Check the hydraulic oil level 2 See Fault 6 3 Replace the gear pump 5 On load declin...

Page 99: ...e liquid level Check valve Filter Cylinder Single acting direction Service line Supply line or return line Cylinder Double acting direction Control line Drain line Relief valve Connecting pipe Solenoid valve Two way two pass Port Test port Solenoid valve Three way four pass Motor Balancing valve Hydraulic pump Check valve 7 9 Hydraulic Symbol ...

Page 100: ...0 HYDRAULIC SYSTEM 7 Symbol Description Symbol Description Manual valve Three way six pass Brake valve Speed requlating valve Explosion proof valve Solenoid valve Three way four pass Solenoid valve Two way two pass ...

Page 101: ...89 8 8 STEERING SYSTEM ...

Page 102: ...90 NOTE ...

Page 103: ...REV 05 2020 STEERING SYSYTEM 8 91 Steering System No Name 1 Steering Wheel 2 Displacement Sensor 3 Steering Bridge ...

Page 104: ...sure that the truck won t tilt WARNING WARNING Remove the steering wheels See Section 4 1 Remove the two tubings 2 Fig3131 70003SM from the steering bridge Remove the steering displacement sensor See Section 8 2 Unscrew the four bolts 3 and remove the steering bridge from the frame Unscrew the four bolts 4 and remove the rubber 5 from the steering bridge Installation Install according to the rever...

Page 105: ...REV 05 2020 STEERING SYSYTEM 8 93 P l e a s e a d d g r e a s e see Section 2 2 3 for specification 8 1 3 Component Be sure to bend a cotter pin ...

Page 106: ...he sensor from the sensor bracket 7 Install according to the reverse order of rem oval Installation 8 2 2 Faults and Causes 1 Fault Truck does not travel the controller reports for error and fault information is displayed on the meter STEER SENSOR KO Cause Displacement Sensor or its circuit failure 8 2 3 Checking and Testing Checking Check if the displacement sensor and the appearance of cables ar...

Page 107: ...REV 05 2020 STEERING SYSYTEM 8 95 ...

Page 108: ...ing rings 1 then knock out the bearing 12 Unscrew the cylinder cap 17 with cylinder wrench Remove the collar 3 snap ring 4 dust ring 5 O ring 6 7 retaining ring 8 9 and seal 11 from the cylinder cap 17 Pull out the piston rod 18 from cylinder block 19 Separate the piston 20 from the piston rod Remove the spacer bush 2 O ring 13 seal 14 support ring 15 and ball 16 from the piston 15 Clean with hydr...

Page 109: ...97 9 9 ELECTRICAL SYSTEM ...

Page 110: ...98 NOTE ...

Page 111: ...DC converter seat switch etc 9 1 1 Removal and Installation For CPD30 35L1 S Fix the wheels with triangular wooden wedge Turn the switch lock to STOP and remove the key pull up the emergency stop switch Remove the battery cover see Section 4 2 1 Disconnect the connection between the batte ry and main wiring harness Remove the battery box from the truck Unscrew the two screws 1 Fig3131 50006SM and ...

Page 112: ... the chassis Unscrew the bolts on copper 3 and copper 4 remove the coppers from the controller Remove the wiring harness cables on the controller Unscrew the eight screws 5 then remove the pump controller 6 and traction controller 7 from the electrical mounting plate 2 For CPD30 35L1 B Unscrew four screws 1 Fig3131 50008SM and remove the flashing 2 Unscrew four screws 3 and remove the electrical m...

Page 113: ...REV 05 2020 ELECTRICAL SYSTEM 9 101 9 1 2 Controller Interface Function CPD30 35L1 B Traction Controller ACE2 Pump Controller ACE2 ...

Page 114: ...kward A 6 CBRK2 Input of the switch DI3 The input is activated when it is connected to Batt The default function is the controller SEAT input A 7 ENC A Channel A of an incremental encoder A 8 PENC Positive supply for encoder or for another speed sensor 12 or 5 V 150 mA maximum A 9 NAUX Output of auxiliary coil driver driving to Batt PWM voltage controlled 2 A maximum continuous current A 10 CBRK1 ...

Page 115: ...terface 1 A 22 THMOT Positive terminal for the motor thermal sensor The internal pull up is a fixed 2 mA current source max 5 V A 23 NTHMOT Negative terminal for the motor thermal sensor Terminal stud Pin No Signal Name Description B Negative battery termination B Positive battery termination U V W Connection bars of the three motor phases follow this sequence and the indication on the motor CNB I...

Page 116: ...REV 05 2020 ELECTRICAL SYSTEM 9 104 9 1 3 Controller Interface Function CPD30 35L1 S Traction Controller ACE3 Pump Controller ACE3 ...

Page 117: ...ted to the SEAT microswitch it is active when connected to BATT A 7 ENC A Incremental encoder phase A input A 8 PENC Incremental encoder positive supply 12 V 5 V A 9 BATT Negative power supply It is used as NPOT without PEDAL WIRE KO diagnosis for acceleration potentiometer and brake potentiometer A 10 CPOTBR Brake potentiometer wiper A 11 PB Brake request input It must be connected to the brake p...

Page 118: ...ltage I O A 22 NCAN CAN Bus negative supply A 23 PTHERM Input for motor temperature sensor It is possible to use a digital or analogue PTC sensor Terminal stud Pin No Signal Name Description B Negative battery termination B Positive battery termination U V W Connection bars of the three motor phases follow this sequence and the indication on the motor CNB Interface handheld unit communication inte...

Page 119: ...ent Ο Ο Ο Ο 5 Turn Signal Ο Ο Ο 6 Horn Ο Ο Ο 7 Headlight Ο Ο Ο 8 Reversing Light and Buzzer Ο Ο Ο 9 Warning Light Ο Ο Ο 10 Seat Interlock Ο Ο Ο Ο 11 Brake Brake Light Ο Ο Ο Ο Failure Ο Normal 9 2 Fuse The entire vehicle is installed with eight fuses altogether When there is fuse failure the truck may not be able to run properly due to that 9 2 1 Location of Fuses Main fuse installed in fuse box Fu...

Page 120: ...to OFF remove key pull out the battery plug and disconnect the power supply Set the multimeter to resistance measure ment with black probe connected to one end of the fuse red probe connected to another end of the fuse Identify if the fuse is normal according to the readings of resistance on the multimeter As shown in the following table Resistance Measurement Judgment 0 Ω Normal Ω Failure replace...

Page 121: ...e is released along with the release of spring and the contact recovers normally opened contact disconnected so the circuit is disconnected 9 3 1 Removal and Installation Removal For CPD30 35L1 S Remove the controller cover from the chassis see Section 9 1 1 Remove the cables on the main contactor Unscrew the two screws 3 Fig3131 50014SM and remove the mounting plate 4 from the chassis Unscrew the...

Page 122: ...observe if the contact can absorb If the surface is uneven or the contact does not absorb replace the main contactor 9 3 2 Faults and Causes 1 Fault Contact adhesion or slow release Cause a Contact fusion welding b Contact spring pressure is too low c Mechanical moving parts blocked shaft rusted or crooked d Anti force spring damaged 2 Fault Contact not absorbed or not fully absorbed Cause a Insuf...

Page 123: ...cuit is broken by using a multi meter Set the multimeter to ON OFF Check if 41 42 circuit circuit between con tactor and traction controller is conducted For CPD30 35L1 S Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 21 42 circuit circuit between con tactor and traction controller is conducted ...

Page 124: ...with wrench and remo ve the accelerator pedal from the pedal Installation Install according to the reverse order of rem oval See Section 3 1 for mounting position of acce lerator pedal 9 4 2 Faults and Causes 1 Fault Press the accelerator pedal operate travel switch the vehicle cannot go forward or backward Cause a Accelerator pedal failure b Accelerator pedal circuit not conducted 2 Fault Press t...

Page 125: ...od condition and if the connectors are connected securely Accelerator pedal at original position Connection interface Voltage Measurement A C 12 V A B 0 V A E 12 V B C 0 V Press the accelerator pedal Measure the vol tage between the interfaces with a multimeter as shown in the following table Press the accelerator pedal Connection interface Voltage Measurement A C 12 V A B Changing within the rang...

Page 126: ...M 9 114 For CPD30 35L1 S Fig 3131 50019SM Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 21 26 36 120 121 circuit circuit between accelerator pedal and traction con troller is conducted ...

Page 127: ...the converter 2 Install according to the reverse order of removal Checking Check if the appearance of converter and its wiring harness are in good condition and if the connectors are connected securely 9 5 3 Checking and Testing Check if the converter circuit is conducted Provide a voltage of 80V between converter interfaces 3 and 18 if there is voltage output of 12V between interfaces 4 and 17 th...

Page 128: ...al Disconnect the combination light headlight warning light connector Remove the combination light headlight warning light from the vehicle Installation Install according to the reverse order of rem oval Checking Check if the appearance of combination warning light headlight warning light and its wiring harness are in good condition and if the connectors are connected securely 9 6 3 Checking and T...

Page 129: ...REV 05 2020 ELECTRICAL SYSTEM 9 117 9 6 4 Control Circuit Troubleshooting Light Control Circuit Fig3131 50026SM Check if the circuit is broken by using a multi meter ...

Page 130: ...ng harness are in good condition and if the connectors are connected securely Repeatedly press the seat switch to check if it can reset properly 9 7 3 Checking and Testing Press the seat switch if the seat signal on the display does not change then it indicates the seat switch or its circuit failure Check if the seat switch circuit is conducted Carry out ON OFF test to seat switch with a multimete...

Page 131: ...CAL SYSTEM 9 119 For CPD30 35L1 S Fig3131 50028SM Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 23 18 circuit circuit between seat switch and traction controller is conducted ...

Page 132: ...stop switch the display of handheld unit will be flashing if the connection is successful the handheld unit display will be flashing if failed the display will have no display check if the circuit connection is normal 9 8 1 Handheld Unit Connection 启动 CONS AFG ZP100 RS232 CONSOLE CAN CONSOLE AUTOSCAN CAN CONSOLE UTILITIES MENU CONSOLE 09 10 CANCONSOLE SELECT NODE 2 SELECT SUB NODE 0 SELECT BAUDRA...

Page 133: ...er plug from the CNC connector of the controller and plug in the Zapi Handset connector as shown in Fig1221 50005SM 9 9 1 Fault Detection 9 9 1 1General The controller provides diagnostics information to assist technicians in troubleshooting problems When a fault is detected an alarm is recorded in the log book It has a FIFO First Input First Output structure that means the oldest alarm is lost wh...

Page 134: ...T down but ton 6 until the desired value setting is reached The option is now set at the desired value 7 Press the OUT button 4 to exit the options Press the Enter button to confirm the exit Fig0000 90005SM 9 9 2 Testing Truck Operation The Zapi Handset can be used to test certain truck operations as follows 1 Connect the Zapi Handset refer to paragraph 9 9 1 1 2 Press the ROLL up button 1 Fig0000...

Page 135: ...r button to confirm the exit RCHANGE display Fig0000 90005SM 9 9 4 Adjustments To change an adjustment proceed as follows and refer to Table 4 3 1 Connect the Zapi Handset refer to paragraph 9 9 1 1 2 Press the ROLL up button 1 Fig0000 90005SM and the SET up button 5 at the same time to enter the CONFIG MENU 3 Press the ROLL down button 1 or the ROLL up button 2 to find the ADJUSTMENTS display 4 P...

Page 136: ...BRK P10 STEER BRAKING P11 MAX SPEED FORW P12 MAX SPEED BACK P13 MAX SPEED LIFT P14 1ST PUMP SPEED P15 2ND PUMP SPEED P16 3RD PUMP SPEED P17 4TH PUMP SPEED P18 5TH PUMP SPEED P19 HYD PUMP SPEED P20 CUTBACK SPEED 1 P21 CUTBACK SPEED 2 P22 H S CUTBACK P23 CTB STEER ALARM P24 CURVE SPEED 1 P25 CURVE CUTBACK P26 FREQUENCY CREEP P27 TORQUE CREEP P28 MAX CURRENT TRA P29 MAX CURRENT BRK P30 ACC SMOOTH P31...

Page 137: ...XIMUM CURRENT P18 ACC SMOOTH P19 INV SMOOTH P20 STOP SMOOTH P21 BRK SMOOTH P22 STOP BRK SMOOTH P23 AUXILIARY TIME P24 ROLLING DW SPEED P25 MIN EVP P26 MAX EVP P27 EVP OPEN DELAY P28 EVP CLOSED DELAY NO Parameter Setting P1 ACC TORQUE DEL P2 DEC TORQUE DEL P3 ACCELER DELAY P4 RELEASE BRAKING P5 MAX SPEED LIFT P6 HYD SPEED COARSE P7 CUTBACK SPEED 1 P8 FREQUENCY CREEP P9 TORQUE CREEP P10 MAXIMUM CURR...

Page 138: ...an square value of the line current supplied to the motor Ampere 1 A IMAX LIM TRA Instantaneous value of the maximum current the inverter can apply to the motor to satisfy a traction request The value is evaluated basing on actual conditions inverter temperature motor temperature etc Ampere 1 A IMAX LIM BRK Instantaneous value of the maximum current the inverter can apply to the motor to satisfy a...

Page 139: ... motor torque Newton Meter 0 1 Nm DC BUS CURRENT Estimation of the DC current the inverter is drawing from the battery Ampere 1 A STEER ANGLE Current steering wheel angle When the steering is straight ahead STEER ANGLE is zero Degrees 1 TEMPERATURE Temperature measured on the inverter base plate Celsius degrees 1 C MOTOR TEMPERAT Motor windings temperature Celsius degrees 1 C A19 TILLER SW Status ...

Page 140: ...LUE Hz value This is the slip between the frequency and the speed of the motor SLIP VALUE FREQUENCY ENCODER CURRENT RMS Ampere value Root Mean Square value of the line current in the motor ID FILTERED RMS Ampere value Root Mean Square value of the current in d axle IQ FILTERED RMS Ampere value Root Mean Square value of the current in q axle IQ IMAX LIMIT Ampere value Root Mean Square maximum value...

Page 141: ... voltage the Backward Travel demand is Active OFF GND When it is not connected to a battery key voltage or it is connected to GND the Backward Travel demand is not active ON OFF A11 H S SW ON VB When it is closed to a battery key voltage the H S request is Active OFF GND When it is not connected to a battery key voltage or it is connected to GND the H S request is not active ON OFF A13 CUTBACK SWI...

Page 142: ...VALUE Hz value This is the slip between the frequency and the speed of the motor SLIP VALUE FREQUENCY ENCODER CURRENT RMS Ampere value Root Mean Square value of the line current in the motor ID FILTERED RMS Ampere value Root Mean Square value of the current in d axle IQ FILTERED RMS Ampere value Root Mean Square value of the current in q axle IQ IMAX LIMIT Ampere value Root Mean Square maximum val...

Page 143: ...G request is active OFF GND When it is not closed to a battery key voltage or connected to GND the LIFTING request is not active ON OFF A5 DESCENT SWITCH ON VB When it is closed to a battery key voltage the DESCENT request is active OFF GND When it is not closed to a battery key voltage or connected to GND the DESCENT request is not active ON OFF HYDRO SPEED REQ ON an hydro speed request is receiv...

Page 144: ...two digital inputs dedicated to the bumper functionality are high at the same time Turn off one or both inputs dedicated to the bumper functionality If the alarm occurs even if the inputs are in the rest position check if the micro switches are stuck In case the problem is not solved replace the logic board 176 HOME SENS ERR XX The controller detected a difference between the estimated absolute or...

Page 145: ...The software is not compatible with the hardware Each controller produced is signed at the end of line test with a specific code mark saved in EEPROM according to the customized Part Number According with this sign only the customized firmware can be uploaded Upload the correct firmware Ask for assistance to your dealer technician in order to verify that the firmware is correct 222 SEAT MISMATCH T...

Page 146: ...re Replace the logic board Fault displayed during motor driving If the alarm occurs during motor acceleration or when there is a hydraulic related request check the battery charge the battery health and power cable connections 18 LOGIC FAILURE 2 Fault in the hardware section of the logic board which deals with voltage feedbacks of motor phases The failure lies in the controller hardware Replace th...

Page 147: ...re checks the power bridge voltage without driving it The software expects the voltage to be in a steady state value If it is too low this alarm occurs Check the motor power cables Check the impedance between U V and W terminals and Batt terminal of the controller Check the motor leakage to truck frame If the motor connections are OK and there are no external low impedance paths the problem is ins...

Page 148: ...r bridge it turns on alternatively the high side power MOSFETs and expects the phase voltages increase toward the positive rail value If one phase voltage is below 66 of the rail voltage this alarm occurs Cause2 Motor running test When the motor is running the power bridge is on and the motor voltage feedback tested if it is lower than expected value a range of values is considered the controller ...

Page 149: ...he motor parameters 37 CONTACTOR CLOSED Before driving the LC coil the controller checks if the contactor is stuck The controller drives the power bridge for several dozens of milliseconds trying to discharge the capacitors bank If the capacitor voltage does not decrease by more than 20 of the key voltage the alarm is raised It is suggested to verify the power contacts of LC if they are stuck is n...

Page 150: ...not match then modify the ADJUST BATTERY parameter according to the value read by the voltmeter Replace the battery 196 MOT PHASE SH 36 MOT PHASE SH 37 MOT PHASE SH 38 Short circuit between two motor phases The number that follows the alarm identifies where the short circuit is located 36 U V short circuit 37 U W short circuit 38 V W short circuit Verify the motor phases connection on the motor si...

Page 151: ...s a problem in the power section Replace the controller 185 TILLER ERROR Input mismatch between Hard Soft input A11 and tiller seat input A6 the two inputs are activated at the same time Check if there are wrong connections in the external wiring Using the TESTER function verify that inputs are in accordance with the actual state of the external switches Check if there is a short circuit between A...

Page 152: ...stance to your dealer technician in order to verify that the maximum current that can be supplied by the hardware is not exceeded In case no failures problems have been found the problem is in the controller which has to be replaced 202 VDC LINK OVERV This fault is displayed when the controller detects an overvoltage condition Overvoltage threshold depends on the nominal voltage of the controller ...

Page 153: ...dback from the encoder has a jump higher than 40 Hz in few tens of milliseconds This condition is related to an encoder failure Check the electrical and the mechanical functionality of the encoder and the wires crimping Check the mechanical installation of the encoder if the encoder slips inside its housing it will raise this alarm Also the electromagnetic noise on the sensor can be the cause for ...

Page 154: ...stitute logic board 237 ANALOG INPUT This alarm occurs when the A D conversion of the analog inputs returns frozen values on all the converted signals for more than 400 ms The goal of this diagnosis is to detect a failure in the A D converter or a problem in the code flow that skips the refresh of the analog signal conversion If the problem occurs permanently it is necessary to replace the logic b...

Page 155: ...on supervisor uC Connect the Console to the supervisor uC and check which alarm is present 171 ACQUIRING A S Controller is acquiring data from the absolute feedback sensor The alarm ends when the acquisition is done 173 ACQUIRE END Absolute feedback sensor acquired 172 ACQUIRE ABORT The acquiring procedure relative to the absolute feedback sensor aborted 168 SIN COS D ERR This alarm occurs only wh...

Page 156: ...ition Check the wiring Through the TESTER function check if the sign of FREQUENCY and ENCODER are the same and if they are different from zero during a traction request If the problem is not solved replace the logic board 208 EEPROM KO A HW or SW defect of the non volatile embedded memory storing the controller parameters This alarm does not inhibit the machine operations but it makes the truck to...

Page 157: ...20 EV4 If more than one output is affected by this fault condition the code shown will correspond to the sum of the faulty EVs codes The device or its driving circuit is damaged Replace the controller 234 DRV SHOR EV XX One or more on off valve drivers are shorted 02 EV1 04 EV2 08 EV3 20 EV4 If more than one output is affected by this fault condition the code shown will correspond to the sum of th...

Page 158: ...The device itself or its driving circuit is damaged This type of fault is not related to external components Replace the logic board 216 EB COIL OPEN This fault appears when no load is connected between the NEB output A18 and the EB positive terminal PCOM A17 Check the EB coil Check the wiring If the problem is not solved replace the logic board 221 HANDBRAKE Handbrake input is active Check that h...

Page 159: ...r below 2 V This type of fault is not related to external components Replace the logic board 250 THERMIC SENS KO The output of the controller thermal sensor is out of range This kind of fault is not related to external components Replace the controller 62 TH PROTECTION The temperature of the controller base plate is above 85 C The maximum current is proportionally decreased with the temperature ex...

Page 160: ...TESTER function Check the sensor ohmic value and the sensor wiring If the sensor is OK improve the cooling of the motor If the warning is present when the motor is cool replace the controller 178 MOTOR TEMP STOP The temperature sensor has overtaken the STOP MOTOR TEMP threshold Check the temperature read by the thermal sensor inside the motor through the MOTOR TEMPERATURE reading in the TESTER fun...

Page 161: ...switches states If the problem is not solved replace the logic board 80 FORW BACK This alarm occurs when both the travel requests FW and BW are active at the same time Check that travel requests are not active at the same time Check the FW and BW input states through the TESTER function Check the wirings relative to the FW and BW inputs Check if there are failures in the microswitches If the probl...

Page 162: ...he hour meter of the controller is transferred and recorded on the hour meter of the standard MDI 179 STEER SENSOR KO The voltage read by the microcontroller at the steering sensor input is not within the STEER RIGHT VOLT STEER LEFT VOLT range programmed through the STEER ACQUIRING function Acquire the maximum and minimum values coming from the steering potentiometer through the STEER ACQUIRING fu...

Page 163: ... According with this sign only the customized firmware can be uploaded Upload the correct firmware Ask for assistance to your dealer technician in order to verify that the firmware is correct 242 SP MISMATCH xx This is a safety related test The master μC has detected a supervisor μC wrong set point Check the matching of the parameters between master and supervisor Ask for assistance to your dealer...

Page 164: ...ower cable connections 17 LOGIC FAILURE 3 A hardware problem in the logic board due to high currents overload An overcurrent condition is triggered even if the power bridge is not driven The failure lies in the controller hardware Replace the controller 213 INPUT MISMATCH The supervisor microcontroller records different input values with respect to the master microcontroller Compare the values rea...

Page 165: ... for undervoltage detection uC discerns between the two evaluating the voltage present across DC link capacitors High voltage Overvoltage condition Low normal voltage Undervoltage condition If the alarm happens during the brake release check the line contactor contact and the battery power cable connection 201 WRONG ENC SET Mismatch between ENCODER PULSES 1 parameter and ENCODER PULSES 2 parameter...

Page 166: ...ed the default settings If a CLEAR EEPROM has been made before the last key re cycle this warning informs you that EEPROM was correctly cleared A travel demand or a pump request cancels the alarm If the alarm appears at key on without any CLEAR EEPROM performed replace the controller 208 EEPROM KO A HW or SW defect of the non volatile embedded memory storing the controller parameters This alarm do...

Page 167: ...uit thus preventing the caps from charging Check if a lamp or a dc dc converter or an auxiliary load is placed in parallel to capacitor bank The charging resistance or PTC is opened insert a power resistance across line contactor power terminals if the alarm disappears it means the controller internal charging resistance is damaged The charging circuit has a failure inside the controller There is ...

Page 168: ...les have leakages towards truck frame If no problem are found on the motors the problem is inside the controller replace it Vmn low Cause1 Start up test Before switching the LC on the software checks the power bridge it turns on alternatingly the High side Power Mosfets and expects the phases voltage to increase toward the rail capacitor value If the phases voltage is less than 66 of the rail capa...

Page 169: ...erload protection This type of fault is not related to external components so when it is present it is necessary to replace the ACE logic board VDC off shorted This fault is displayed when the controller detects a low logic level of VDC Off signal during Start Up diagnosis It is very likely the fault is due to an over voltage so it is suggested to check Check the connection of power cables to the ...

Page 170: ...displayed during motor driving If the alarm happens during traction acceleration or driving hydraulic functions check battery charge condition power cable connection VDC link overv This fault is displayed when the controller detects an over voltage condition Over voltage threshold is 65V in the 48V controller In 116V controller the under voltage threshold is 30V Fault displayed at startup or in st...

Page 171: ... The driver circuit is damaged in the logic board which has to be replaced Contactor driver The MC coil driver is not able to drive the load The device itself or its driving circuit is damaged This type of fault is not related to external components replace the ACE3 logic board MC Coil shor This alarm occurs when there is a short circuit of the MC coils connected to CNA 16 output After the overloa...

Page 172: ...to verify if LC coil is connected to the right connector pin and if it is not interrupted If even connecting the coil to the right pin or replacing it the alarm is still present than the problem is inside the controller logic board replace it Stby I high The current transducer or the current feedback circuit is damaged in the controller This type of fault is not related to external components so w...

Page 173: ...en the A D conversion of the analog inputs gives frozen value on all of the converted signals for more than 400msec The goal of this diagnosis is to detect a failure of the A D converter or a problem in the code flow that omits the refreshing of the analog signal conversion If the problem occurs permanently it is necessary to substitute ACE logic board Wrong Ram Mem 05 The algorithm implemented to...

Page 174: ...ed in the logic board which has to be replaced EB driv open The EB driver is not able to drive the load The driver circuit is damaged in the logic board which has to be replaced EB coil open 04 EB Coil Open This fault appears when the no load is connected between the output NEB NAUX CNA 18 and PEB PEVP CNA 17 It is suggested to check the harness in order to verify if EB coil is connected to the ri...

Page 175: ... EV output Check if there is a short or a low impedance between the negative of the coil and BATT Otherwise the driver circuit is damaged and the controller must be replaced Coil shor EVAUX This alarm occurs when there is a short circuit of the EV coils After the overload condition has been removed the alarm exits automatically by releasing and then enabling a travel demand The typical root cause ...

Page 176: ...eceived by the controller Please check if the sign of FREQUENCY and ENCODER on the tester menu are the same and different than zero during a traction request Torque profile There is an error on the choice of the parameters of the torque profile Check in the hardware setting menu the value of those parameter Vacc not OK The test is made at key on and immediately after that both the travel demands h...

Page 177: ...demand active at key on Presence man sensor active at key on Check the wirings Check the micro switches It could be also an error sequence made by the operator A failure in the logic is possible too so when all of the above conditions were checked and nothing was found replace the ACE logic board Forward Backward This alarm occurs when both the travel demands Fwd and Bwd are active at the same tim...

Page 178: ...igher than 85 Then the maximum current decreases proportionally with the temperature increases from 85 up to 105 At 105 the Current is limited to 0 Amps It is necessary to improve the controller cooling For realise an adequately cooling in case of finned heat sink are important factor the flux m3 h and temperature C of cooling air In case of thermal dissipation realised with the controller base pl...

Page 179: ... range Check the sensor ohmic value and the sensor wiring If the sensor is OK then the problem is inside the ACE logic board replace it Iq mismatched The error between Iq set point and Iq estimated is out of range Ask the assistance of your dealer technician to do the correct adjustment of the motor parameters Power mismatched The error between Power set point and Power estimated is out of range A...

Page 180: ... they are different adjust the value of the ADJUST BATTERY function Brake run out The CPOTBRAKE input red by the microcontroller is at the maximum value without the hand brake request Check the mechanical calibration and the functionality of the brake potentiometer If the alarm is not disappeared the failure is in the ACE logic board replace it Current Gain MDI code alarm 92 The Maximum current ga...

Page 181: ...er it is necessary to replace it Out mismatch 01 This is a safety related test Slave μC has detected that the Master μC is driving traction motor in a wrong way not correspondant to the status of operator commands This is a internal fault of the controller it is necessary to replace it Logic Failure 1 This fault is displayed when the controller detects an under voltage condition Under voltage thre...

Page 182: ...failure is probably in the controller hardware so it is necessary to replace the logic board Fault displayed during motor driving If the alarm happens during release braking check line contactor contact battery power cable connection CTRAP threshold This fault is displayed when the controller detects a wrong value in the feedback for overcurrent protection circuit If the problem occurs permanently...

Page 183: ...REV 05 2020 ELECTRICAL SYSTEM 9 171 9 13 Electrical Schematic Diagrams CPD30 35L1 B ...

Page 184: ...er to controller 5 Controller to controller 6 Controller 7 Traction Power Cable U 8 Traction Power Cable V 9 Traction Power Cable W No Name 10 Pump Motor cable U 11 Pump Motor cable V 12 Pump Motor cable W 13 Power Discharging cable 14 Power Charging cable Assembly 15 Plug head 16 Plug head 17 Male head of plug and extractor ...

Page 185: ...REV 05 2020 ELECTRICAL SYSTEM 9 173 9 15 Wiring Harness and Connectors CPD30 35L1 B ...

Page 186: ...REV 05 2020 ELECTRICAL SYSTEM 9 174 9 16 Wiring Harness and Connectors CPD30 35L1 S ...

Page 187: ...175 10 10 TROUBLESHOOTING ...

Page 188: ...176 NOTE ...

Page 189: ...eter Identify if the battery voltage is normal according to the measured voltage As shown in the following table Battery Voltage Judgment 80V Greater than 80V Normal Less than 80V Needs to be charged Enter TESTER Menu to check the battery voltage If the battery voltage is still abnormal after being charged open the battery compartment check the voltage of each battery and its connection circuit re...

Page 190: ...ection failure e Controller failure Controller failure error carry out troubleshooting according to the fault code information on the instrument 1 Check if parking brake switch and seat switch or the connec tion of its circuit is normal 2 Check the gearbox 3 Check the travel switch and its connection circuit 4 Check the drive motor and its connection circuit 5 Replace the controller 2 The vehicle ...

Page 191: ...on and its connection circuit 4 Replace the controller 2 Pump motor works 1 Refer to the rated capacity marked on the nameplate 2 Lower the mast to the bottom check if the amount of oil in the oil tank can meet the requireme nts 3 Check the pipe and hydraulic components for oil leaks 4 Check the pump motor wiring 5 Check the cylinder for damage or deformation remove the cylinder to check for wear ...

Page 192: ...ugh roller screw or replace the roller Under the circumstances of normal lifting and lowering if failure occurs to any of other hydraulic actions forward backward shifting forward backward tilting and left right shifting perform troubleshooting to the corresponding control switch and its control circuit Steering Fault 1 The vehicle cannot be steered the vehicle can travel a Steering potentiometer ...

Page 193: ...hting combination switch and its connection circuit 3 Check fuse and its connection circuit 4 Check DC DC converter and its connection circuit 2 Horn does not sound a Horn switch or its circuit connection failure b Horn failure c Fuse failure d DC DC converter failure 1 Check the horn button and its connection circuit 2 Check the horn and its connection circuit 3 Check fuse and its connection circ...

Page 194: ...REV 05 2020 TROUBLESHOOTING 10 182 ...

Page 195: ...183 APPENDIX ...

Page 196: ...184 NOTE ...

Page 197: ...185 A A SERVICE MANUAL MAST ...

Page 198: ...186 NOTE ...

Page 199: ...r beam of inner and outer masts slightly lift the mast with crane Remove the shafts 2 between the outer mast and tilt cylinders A and B Installation Install according to the reverse order of rem oval Unscrew the shafts 3 and remove the fixed plate 4 between the outer mast and chassis C and D Remove the mast from the truck Make sure the lifting equipment is solid and secure and the load capacity sh...

Page 200: ...M Through screwing upward the jam nut 8 in the upper the chain will slowly tension When the chain is adjusted to be tensioned with no obvious loosening fasten the lower jam nut When the adjustment is completed there sh ould be an adjustable distance of at least three pitches over the chain bolts Pull out emergency stop switch and turn on the key switch Through repeatedly lifting lowering the mast ...

Page 201: ...hen unscrew the jam nuts 2 8 and from the chain joint 1 and chain joint 6 Remove the cotter pin 3 pull out the pin shaft 4 separate the chains 5 from the chain joint 1 on outer mast Remove the chain assembly from the chain sprocket Replace with new chains and hang the new chain assembly onto the chain sprocket Put the chain connector 6 through the fork carriage chain hanging plate screw the jam nu...

Page 202: ...190 REV 05 2020 SERVICE MANUAL MAST A A1 3 Mast Tubing Code Description A1 Lifting Lowering Mast Tubing A3 Right Shift Mast Tubing B1 Left Shift Mast Tubing ...

Page 203: ...ersonal injury Unscrew the mounting bolt 7 from the bott om of the cylinder Unscrew the bolt 6 lift the cylinder 5 up and remove it from the truck supporting Remove the tubing 5 Fig3131 60005SM to make it separate from the three pass component 2 Right Cylinder Removal Lower the mast to the bottom press the em ergency stop switch and disconnect the key switch Block the truck wheels with wooden wedg...

Page 204: ...on Clean with hydraulic oil of the same specific ations Replace the problem parts and assembly in reverse steps Use suitable hose clamps to avoid cylinder deformation caused by severely tight hose clamp Carry out the maintenance work in a clean environment to prevent impurities from entering into cylinder causing cylinder damage During the installation hydraulic oil of the same specifications must...

Page 205: ...eft shifting tubing 7 from the built in side shifter Before going on with the next step please fix the side shifter properly first Be sure to avoid the falling of side shifter during removal resulting in personal injury Remove the chain assembly and remove the side shifter from inner mast A1 5 2 Side Shifter Installation Install the side shifter according to the rever se order of removal according...

Page 206: ...ft shifting tubing 7 from the built in side shifter Before going on with the next step please fix the side shifter properly first Be sure to avoid the falling of side shifter during removal resulting in personal injury Remove the external side shifter 2 Fig3131 60009SM from fork carriage 4 A1 6 2 Side Shifter Installation Install the side shifter according to the rever se order of removal accordin...

Page 207: ...r beam of inner and outer masts slightly lift the mast with crane Remove the shafts 2 between the outer mast and tilt cylinders A and B Installation Install according to the reverse order of rem oval Make sure the lifting equipment is solid and secure and the load capacity should be greater than the total weight of the vehicle WARNING Unscrew the bolts 3 and remove the fixed plate 4 between the ou...

Page 208: ...olt Through screwing upward the adjusting nut 2 in the middle the chain will slowly tension When the chain is adjusted to be tensioned with no obvious loosening fasten the upper and lower lock nuts When the adjustment is completed there sh ould be an adjustable distance of at least three pitches over the chain bolts Pull out emergency stop switch and turn on the key switch Through repeatedly lifti...

Page 209: ...pin shaft 7 separate the chains 5 from the chain joint 4 on free middle cylinder Remove the cotter pins 8 pull out the pin shaft 9 separate the chains 5 from the chain joint 10 on fork carriage Remove the chain assembly from the chain sprocket Replace with new chains and hang the new chain assembly onto the chain sprocket Put the chain connector 10 through chain hole of fork frame insert the pin s...

Page 210: ...198 REV 05 2020 SERVICE MANUAL MAST A A2 3 Mast Tubing Code Description A1 Lifting Lowering Mast Tubing ...

Page 211: ...199 REV 05 2020 SERVICE MANUAL MAST A Code Description A3 Right Shift Mast Tubing B1 Left Shift Mast Tubing ...

Page 212: ...rting Remove the tubing 1 Fig3131 60012SM to make it separate from the three pass component 2 Remove the regulator 4 from the three pass component 2 Unscrew the bolt 6 Fig3131 60014SM and remove the cylinder clamp 7 Unscrew the mounting bolt 8 from the bott om of the cylinder Unscrew the bolt 3 lift the cylinder 4 up and remove it from the truck Remove the three pass component 2 Fig3131 60012SM fr...

Page 213: ...201 REV 05 2020 SERVICE MANUAL MAST A ...

Page 214: ...over plate 7 and O rings 8 from the cylinder cap Remove the bearing 5 and guide bush 6 from the cylinder tube 17 Pull out the piston rod 9 from the cylinder tube 17 and remove the bushing 11 Remove the support ring 12 from the piston and unscrew the fixing screw on the piston then separate the piston rod from the piston 13 Remove the support ring 10 from the piston rod then remove the retaining ri...

Page 215: ...d from the piston 13 Remove the support ring 10 from the piston rod then remove the retaining ring 14 spring 16 and buffer plunger 15 from the piston Clean with hydraulic oil of the same specifica tions Replace the problem parts and assembly in reverse steps If the piston rode or cylinder tube is damaged please replace the entire cylinder If the seals are aged or damaged please replace the complet...

Page 216: ... is damaged please replace the entire cylinder If the seals are aged or damaged please replace the complete set of seals Remove the support ring 10 and seal 9 retaining ring 12 and seal 13 from the piston A2 4 3 Cylinder Installation Install the cylinder according to the reverse order of removal according to A2 4 1 Add hydraulic oil of the same specifications into the tank see Section 2 2 3 Pull o...

Page 217: ...er beam of inner and outer masts slightly lift the mast with crane Remove the shafts 2 between the outer mast and tilt cylinders A and B Installation Install according to the reverse order of rem oval Unscrew the bolts 3 and remove the fixed plate 4 between the outer mast and chassis C and D Remove the mast from the truck Make sure the lifting equipment is solid and secure and the load capacity sh...

Page 218: ...least three pitches over the chain bolts CAUTION CAUTION Pull out emergency stop switch and turn on the key switch Through repeatedly lifting lowering the mast to test if the chain is tensioned If the chain is still loose repeat the steps above Loosen the upper lock nut 1 Fig3131 60011SM and the lower lock nut 3 on chain bolt Through screwing upward the adjusting nut 2 in the middle the chain will...

Page 219: ...17 Fig3131 60019SM Replace with new chains and hang the new chain assembly onto the chain sprocket Put the chain connector 10 through chain hole of fork carriage insert the pin shaft 9 and pins 8 Put the chain connector 4 through the middle cylinder chain hanging plate screw the adjusting nut 2 and lock nut 1 insert the pin shaft 7 and pins 6 Adjust the chains according to Section A3 2 1 A3 2 2 2 ...

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Page 221: ...209 REV 05 2020 SERVICE MANUAL MAST A A3 3 Mast Tubing Code Description A1 Lifting Lowering Mast Tubing ...

Page 222: ...210 REV 05 2020 SERVICE MANUAL MAST A Code Description A3 Right Shift Mast Tubing B1 Left Shift Mast Tubing ...

Page 223: ...s or tubings place a clean container under it for discharge of hydraulic oil Unscrew the bolt 6 Fig3131 60019SM and remove the cylinder clamp 7 Before going on with the next step please fix the cylinder properly first Be sure to avoid the falling of cylinder during removal resulting in personal injury Full Free Middle Cylinder with mast on the vehicle Hydraulic oil may damage truck parts and conta...

Page 224: ...y tight hose clamp Carry out the maintenance work in a clean environment to prevent impurities from entering into cylinder causing cylinder damage During the installation hydraulic oil of the same specifications must be used for cleaning or lubrication Lifting Side Cylinder CAUTION CAUTION Secure the cylinder to hose clamp and gently clamp the cylinder bottom Unscrew the cylinder cap 3 Fig3131 600...

Page 225: ...on Install the cylinder according to the reverse order of removal according to A3 4 1 Add hydraulic oil of the same specifications into the tank see Section 2 2 3 Pull out emergency stop switch and turn on the key switch Repeat Lift Lower cylinder to discharge the air within the tubings and cylinder Check the hydraulic oil level and make sure that the liquid is at standard level A3 5 Built in Side...

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Page 227: ...215 B B SERVICE MANUAL BATTERY ...

Page 228: ...216 NOTE ...

Page 229: ... for use maintenance without using original parts user corruption or viola tion of provisions when adding electrolyte and other circumstances the quality assurance will automatically void B1 2 1 Pre use Checks Check if the plug is tight Unplugged may cause the output to be disconnected or the plug to overheat Check the meter information whether the data is abnormal or report the fault information ...

Page 230: ...thium batteries are strictly prohibited from overcharging and overdischarging CAUTION Supplementary Charging Battery storage If the battery is not used for more than two months supplementary charging must be carried out to the battery to prevent permanent battery damage The charging capacity should be controlled at about 80 Charging method is in accordance with the requirements of normal charging ...

Page 231: ...is less than 26V or greater than 65V Flashing Yellow Charger failure a Output current or output voltage is too large b The temperature of charger is too high Flashing Red Charger failure No output current from the charger NO Lamping Charger failure The input of charger is not connected or charger failure For more information about Lithium Battery Maintenance Repairing please consult Lithium Batter...

Page 232: ...220 C C SCHEDULE ...

Page 233: ...221 ...

Page 234: ...ator No Daily Check Items O K Remark Drive Wheel Steering Wheel Horn Lights Lifting Lowering Control Functions Optional Features Forward Reverse Control Functions Steering control functions Braking Functions Check hydraulic system for leaks cylinders fittings tubings oil tank etc ...

Page 235: ......

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