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CPD10/15/18/20/25/30J 
CPD10/15/18/20/25/30J D1 
CPD10/15/18/20/25/30/35J C1 
CPD10/15/18/20/25/30/35J C2 
CPD40/45/50J D1 
CPD40/45/50J C2 

1

～

5t    J Series Counterbalanced Battery Forklift Truck 

 

SERVICE MANUAL 

 

 

 

 

Original Instruction

 

 

 

 

 

 

 

 

HANGCHA GROUP CO., LTD. 

Dec. 2010 3

rd

 edition

 

Summary of Contents for J Series

Page 1: ...20 25 30J D1 CPD10 15 18 20 25 30 35J C1 CPD10 15 18 20 25 30 35J C2 CPD40 45 50J D1 CPD40 45 50J C2 1 5t J Series Counterbalanced Battery Forklift Truck SERVICE MANUAL Original Instruction HANGCHA G...

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Page 3: ...you haven t been trained Our product design will update and perform better so the content in this manual may be not the same as the forklift you owned If you have any questions please keep touches wit...

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Page 5: ...MASTER CYLINDER 19 3 2 FOOT BRAKE 20 3 3 HAND BRAKE DEVICE 22 4 HYDRAULIC SYSTEM 23 5 LIFTING SYSTEM 27 5 1 DATA 27 5 2 FAULT 28 5 3 MAST 30 5 4 LIFTING CYLINDER 32 5 5 TILTING CYLINDER 32 6 ELECTRIC...

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Page 7: ...rk XQ 5 3A 5 3 45 139 1700 3200 separate excitation F IC01 IP20 60 95 tow XQD 8 2 3D 8 2 45 172 8 1600 3200 series excitation F IC01 IP20 5 65 work CPD20 25J Model Rated Power kw Rated Voltage V Rated...

Page 8: ...ted Voltage V Rated Current A Rated speed r m Max Speed r m Excitations Mode Insulation Grade Cooling Mode Protecting Grade Ration m Weight Kg Remark YDQ11 75 4HC 10 6 51 180 1200 AC F IC01 IP20 60 11...

Page 9: ...peed r m Max Speed r m Excitations Mode Insulation Grade Cooling Mode Protecting Grade Ration m Weight Kg Remark TSP180 4 180 48V 10 5 31 280 1200 2000 AC F IC01 IP20 60 135 tow TSW112 4 195 T 48V 11...

Page 10: ...emperature Until on the surface of motor dew 100 Cooling air Must not contain volatile gas most work current of the motor Tractor motor Three times of rated current admit time is one minute Lifting mo...

Page 11: ...een brush and box is bigger working surface distance between the box and commutator is bigger mice between parts of commutator extrude material of the brush is bad trademark of the brush is wrong Spar...

Page 12: ...armature s head A2 motor armature s end F1 Separated Excitation excitation s head F2 Separated Excitation excitation s end Connection mode Series excitation motor Separate excitation motor series exc...

Page 13: ...must make out marker can become flexible bolt When the brush s shelf reposition aim at marker line screw down bolt in order to keep brush in the former neutral location winding isolating resistance s...

Page 14: ...ne grade planet gear So the gear box is very small Trouble Probably cause Method of troubleshooting When traveling or change direction Gear clearance is too big Too much worn of gear Adjust Replace To...

Page 15: ...ght Kg 125 130 195 198 202 208 350 380 1 3 2 Trouble diagnoses and corrections condition Probable cause Corrective action Abnormal noises loose driving axle and body connecting blots loose wheel nut w...

Page 16: ...aring 15 Adjusting nut 16 Lock nut 17 Pin 18 Paper shim 19 Oil seal 20 Axle case 21 Supporter Tighten torque N m 1 1 8t 2 3t 4 5t Axle shaft bolt A 44 58 73 5 88 3 105 156 Trig soleplate bolt B 76 107...

Page 17: ...evice 10 Remove bolts securing axle mounting bracket to frame see fig 5 2 11 Remove nuts securing axle case to differential gear carrier see fig 5 3 12 Remove driving axle assemble Fig 1 1 Fig 1 2 Fig...

Page 18: ...contract brake shoe lining refer to Fig 5 5 b evenly tapping on brake drum with brass bar or wooden mallet Fig 1 4 Fig 1 5 5 Remove wheel hub be careful not to drop bearing inner race 6 Remove oil sea...

Page 19: ...ock nut until it can no longer be rotated with one hand then turn back approx 600 6 Install snap ring and settles down felt ring install lock washer so as to set its hole in the pin of snap ring Screw...

Page 20: ...s steering gear priority valve clamp bolt and hydraulic switch etc You can adjust the steering angle forward and backward by yourself Refer to fig 2 1 1 Steering wheel 3 Upside steering column 8 Gimba...

Page 21: ...se 1 8 1 6 rotations Kingpin adjusting washer thickness mm Part No Or wheel hub rotation starting torque at hub blot 10 29 8N 0 10 0 30 0 70 N163 220012 000 Axial play mm Less than 0 10 Truck type 1 1...

Page 22: ...16...

Page 23: ...2 4 Kingpin and steering spindle 1 Remove rod 2 Loose lock bolts See fig 2 2 3 Remove grease nipples on kingpin 4 Remove kingpin Caution Hold kingpin to prevent it from dropping See fig 2 3 5 Take of...

Page 24: ...r of roller bearing also apply grease between lip and groove of seal tape 5 pack all grease nipple with a sufficient 2 2 5 Wheel bearing adjustment 1 Slowly rotate hub Tighten steering spindle nut unt...

Page 25: ...ed outwards This brings the brake shoes into contact with the wheel drum and slows or stops the lift truck Meanwhile the cavity caused behind the piston is filled with brake fluid led through the retu...

Page 26: ...Cylinder return spring 4 Rubber cap 5 Piston 6 Cylinder dust cover 7 Push rod 8 Air bleeder cap 9 Air bleeder screw 10 Brake shoe assemble front 11 Brake shoe assemble rear 12 Guider 13 Adjuster cable...

Page 27: ...d frame 8 Stop engine 9 Remove wheel tire nuts and brake drum 10 Replace brake shoes with new ones 11 Install brake drum 12 Adjust shoe to drum clearance Remove adjusting hole plug on the bottom of th...

Page 28: ...use hand brake to stop the truck condition Probable cause Corrective action Insufficient brake force Oil leakage in brake lines Air in brake lines Improper functioning of master cylinder or wheel cyl...

Page 29: ...ssure line so as to make mast tilt forward or backward Main pump Trouble Probable cause Corrective action No oil from oil pump Low oil level in tank Add oil to specified level Clogged suction pipe or...

Page 30: ...tilt relief valve assembly Lowering distance of mast is big when spool valve is in the centre Valve body and spool valve is worn and clearance between them is too great Replace spool valve with specif...

Page 31: ...main relieve valve is all right Otherwise adjust it as step 3 3 If the forklift can t work enhance the pressure main relieve valve remove the front soleplate loosen the tightening nut of the main rel...

Page 32: ...nnage Items 1 3t 1 5t 1 8 3 5t 4 5t The max input pressure of redirector 16MPa 16MPa 16MPa 16MPa Main safety valve pressure of multi spool control valve 12 MPa 15 MPa 17 5 MPa 18 5 MPa Rated pressure...

Page 33: ...or Lifting capacity N m Lift chain lock nut 1 1 5t 127 157 M16 245 314 M20 single chain 2 3t 176 216 M18 245 314 M20 Mast support cap blot 1 1 5t 89 118 M14 2 3t 176 216 M18 Tilt cylinder lock nut 1...

Page 34: ...d mast Adjust clearance with rollers 3 Biting foreign materials between moving part Remove foreign materials 4 Insufficient lubrication Apply grease on contact surfaces of sliding parts butter 5 Bent...

Page 35: ...hydraulic control valve resulting in excessive oil leaks Replace 5 Oil leaks occur between the hydraulic control valve sections Dismantle for regrinding the joint surfaces and reassemble the valve 6...

Page 36: ...iew 1 Outer mast 2 Inner mast 3 Back rest 4 Fork arm carrier 5 Fork 6 Chain 7 Left lifting cylinder 8 Right lifting cylinder 9 Tilting cylinder 10 Idler wheel Fig5 2 Double full free lift mast 1 Outer...

Page 37: ...6 Fork 7 Sideway cylinder 8 Left rise cylinder 9 Right rise cylinder 10 Fork arms 11 Tilt cylinder Fig 5 4 Triple full free lift mast 1 Outer mast 2 Inner mast 3 Chain 4 Free lifting cylinder 5 Fork a...

Page 38: ...ort ring 14 Back up rings 15 OSI ring 16 Valve guide 17 Snap ring 18 Steel axletree 19 Blowout patch 20 Adjusting washer 5 5 Tilting cylinder Fig 5 6 Tilting cylinder 1 Retaining ring 2 Knuckle bearin...

Page 39: ...ntrollers the 1244 offers superior operator control of the vehicle s motor drive speed Features include _ Full bridge field and half bridge armature power MOSFET design providing Infinitely variable f...

Page 40: ...each mode _ Continuous diagnostics during operation with microprocessor power on self test _ Internal and external watchdog circuits ensure proper software operation _ Programmable coil drivers provi...

Page 41: ...puts 2 Wrong START LOCKOUT type selected 3 Misadjusted throttle pot 4 Sequencing delay too short 3 1 CONT DRVR OC cont driver output over current 1 Contactor coil shorted 3 2 MAIN CONT WELDED welded m...

Page 42: ...lifting lock of the controller is touch off 2 3 Order fault Startup lockout Any switch of SS1 SS4 closes earlier than KSI or INTERLOCK 3 2 Contact err 1 Main contact bonded 2 The set of parameter CONT...

Page 43: ...TECTION FEATURES Reverse Polarity of the battery Connection errors All inputs are protected against connections errors Current overload protection it have detecting element control peak current Therma...

Page 44: ...ty drive reclaim part of electric energy prolong work time of every time control speed during downgrade speed lie on accelerator if speed exceed set point controller may automatic braking this give op...

Page 45: ...nnection stud that prevents the capacitor bank from charging 2 See 1311 menu Monitor Battery Capacitor Voltage 1 5 Controller Severe Undertemp 1 Controller is operating in an extreme environment 2 See...

Page 46: ...ce too high for given regen current 4 Battery disconnected while regen braking 5 See 1311 menu Monitor Battery Capacitor Voltage 2 5 5V Supply Failure 1 External load impedance on the 5V supply pin 26...

Page 47: ...short on driver load 2 Dirty connector pins 3 Bad crimps or faulty wiring 3 5 PD Open Short 1 Open or short on driver load 2 Dirty connector pins 3 Bad crimps or faulty wiring 3 6 Encoder Fault 1 Moto...

Page 48: ...equence 2 Faulty wiring crimps or switches at KSI interlock direction or throttle inputs 3 See 1311 menu Monitor Inputs 4 7 Emer Rev HPD 1 Emergency Reverse operation has concluded but the throttle fo...

Page 49: ...ype parameter value is out of range 9 2 EM Brake Failed to Set 1 Vehicle movement sensed after the EM Brake has been commanded to set 2 EM Brake will not hold the motor from rotating 9 3 Limited Opera...

Page 50: ...nt overload protection It have detecting element control peak current Thermal protection If the controller temperature exceeds 85 C the maximum current reduces in proportion to the thermal increase Th...

Page 51: ...speed during downgrade speed lie on accelerator if speed exceed set point controller may automatic braking this give optimal ramp Notice 1 Maintain electric control must first cut off electrical sourc...

Page 52: ...ess than 24 8V 8s KEY ON OFF OFF KEY OFF Detected by VMC20 not by ACS 108 ACS under voltage Voltage limit Parameter for more than 0 8sec KEY ON OFF OFF KEY OFF Detected by VMC20 not by ACS 109 Battery...

Page 53: ...e ACS does not respond at startup KEY ON OFF ON ON KEY OFF Check CAN bus wiring 257 ACS PDO timeout ACS CAN open timeout detected by VMC20 KEY ON OFF ON ON KEY OFF Check CAN bus wiring 258 ACS SDO err...

Page 54: ...r Speed feedback sensor not connected short circuit KEY ON ON ON ON KEY OFF or sensor connected ACS can not control speed correctly No driving allowed 208 ACS high voltage warning ACS voltage 68V KEY...

Page 55: ...ut detected by VMC20 KEY ON OFF ON ON KEY OFF Check CAN bus wiring 358 ACS SDO error ACS SDO error wrong SW version KEY ON OFF ON ON KEY OFF Check SW version 359 CANopen timeout ACS CAN open timeout d...

Page 56: ...wed 308 ACS high voltage warning ACS voltage 68V KEY ON ON ON ON KEY OFF or voltage back to normal Lowest Accel will be used 309 ACS low voltage warning ACS voltage 22 5V KEY ON ON ON ON KEY OFF or vo...

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Page 58: ...52 WIRING DIAGRAM OF CPD10 15 18 20 25 30J...

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Page 60: ...54 ELECTRICAL SYSTEM PRINCIPLE DIAGRAM OF CPD10 15 18 20 25 30 40 45 50J C2...

Page 61: ...55 ELECTRICAL SYSTEM PRINCIPLE DIAGRAM OF CPD10 15 18 20 25 30 40 45 50J D1...

Page 62: ...56 WIRING DIAGRAM OF CPD10 15 18 20 25 30J D1 E 1 S P h 8 m k 2 3 T B A D E 1 2 5 4 0 P WIRING DIAGRAM OF CPD10 15 18 20 25 30 40 45 50 J D1...

Page 63: ...57 7 Maintenance record Date Maintain content Maintainer...

Page 64: ...cturing site 88 Donghuan Road LinAn Econimic Development zone Zhejiang P R China ZIP 311305 Registered Address 398 Shi Qiao Road Hangzhou P R China ZIP 310004 Fax 0086 571 88926789 0086 571 88132890 W...

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