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HELI CPD10, Operation & Service Manual

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HELI CPD10 Operation & Service Manual Download Page 103

 

100 

capacitor voltage is lower than 
20% of the rated voltage within 
the specified time, this fault will 
occur 

2. It may be that PTC or 
charging resistance is 
disconnected, or there is a 
problem in the controller, and 
the controller needs to be 
replaced 

62 

TH. 

PROTECTION 

The temperature of the controller 
is higher than 85 °c (the 
temperature of the controller is 
between 85 °c and 105 °c, and 
the maximum current is reduced 
proportionally; when 105 °c, the 
current is 0). 

Stop working and let the 
controller cool down. Check if 
the controller fan is working 
properly. 

65 

MOTOR 

TEMPERAT.   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NOTE:   

1.  The  truck  will  travel  with  default  mode  (E)  when  three  kinds  of  travelling 

mode (P/E/S) are or are not input at the same time. 

2. When turn signal device is invalid, the truck will travel with limited speed. 

 

5 Hydraulic System 

5.1 General Description 

The hydraulic system consists of oil pump, control valve, priority valve, lift cylinder, 

tilt cylinder, high & low pressure oil pipe an joint etc. The pump is driven directly by the 

electromotor. The hydraulic oil flow to control valve through the pump and are distribute 

to cylinders by the control valve. 

5.1.1 Oil pump 

The main parts of the gear oil pump for forklift are a pair of external gears mutually 

meshed and their working principle is as shown in Fig. 5-1. 

Summary of Contents for CPD10

Page 1: ......

Page 2: ...h quality motor battery MOSFET controller and LED display with large screen so they have a lot of advantages such as good performance easy operation wide visibility of operator flexible steering reliable braking powerful and smooth power low noise no contamination to environment and beautiful contour This manual states the trucks specifications operation maintenance service main assemblies constru...

Page 3: ...f Forklift Truck 1 Ⅱ Main Specifications of Forklift Truck 6 Ⅲ Construction Principle Adjustment and Maintenance of Forklift Trucks 14 1 Transmission System 14 2 Brake System 19 3 Steering System 34 4 Electric System 41 5 Hydraulic System 100 6 Lifting System 121 ...

Page 4: ...d be always at the positions specified in sling index plate when hoisting up the forklift truck 4 Charge the battery to make the electricity quantity to stay between 40 and 60 and press the emergency button 2 Storage of Forklift Truck 1 Apply antirust to the surface of the parts not painted Apply lubrication oil to the lift chain 2 Lower the mast to the lowest position 3 Apply the parking brake 4 ...

Page 5: ...he truck If any damages or defects are found operate it after repairing 4 At the rated loading center either overload or overload operation is strictly prohibited The center of cargo should be in line with the frame center not out of the line The fork should insert completely under the cargo and make the cargo placed on it evenly Do not raise an object with one fork end 5 The starting turning driv...

Page 6: ...ul and slowly driving over a dockboard or bridge plate 15 Shut down the truck and don t stay on the truck when checking fuel level 16 The unloaded forklift truck with attachments should be operated as a loaded truck 17 Don t handle unfixed stacked goods Be careful to bulky goods to be handled 18 If leaving the truck lower the forks on the ground and let the shift lever to neutral shut down the eng...

Page 7: ... or not 2 Oil used for forklift trucks Name Recommended brand Brand and temperature of using Level per unit L 1 1 8t 2 2 5t 3 3 5t Hydraulic oil Long pan Sticky grade L HM32 wearable hydraulic oil L HV32 low temp wearable hydraulic oil 25 34 40 Temp of using 5 20 cold region Brake fluid Chong qing yi ping 4604 compound brake fluid GB 12981 HZY4 0 2 Lubricating grease Long pan 2 L XDCBB2 low temper...

Page 8: ...5 ...

Page 9: ...6 Ⅱ Main Specifications of Forklift Truck Enternal view of forklift trucks ...

Page 10: ...earance H5 H6 mm 90 80 in the middle of the truck body 80 75 in the middle of the truck body Min turning radius r mm 1750 fork adjustment range outside Max min W5 mm 960 200 Travelling speed loaded unloaded km h 15 16 Lifting speed loaded unloaded mm s DC 290 450 270 450 280 530 AC 410 600 400 600 380 600 Descending speed loaded unloaded mm s 400 500 Gradeability loaded unloaded 20 25 19 24 17 22 ...

Page 11: ... H4 mm 1995 2150 Seat height Q mm 1100 Under clearance H5 H6 mm 110 at mast 115 in the middle of the truck body Min turning radius r mm 2000 2060 fork adjustment range outside Max min W5 mm 1030 244 Travelling speed loaded unloaded km h 14 5 15 Lifting speed loaded unloaded mm s DC 280 490 260 490 AC 350 510 330 510 Descending speed loaded unloaded mm s 410 490 Gradeability loaded unloaded 22 24 2...

Page 12: ...guard H5 H6 mm 2075 2215 2180 2215 Seat height mm 1165 Under clearance H1 H2 mm 135 at mast 145 in the middle Min turning radius r mm 2240 2260 fork adjustment range outside Max min W5 mm 1060 250 Travelling speed loaded unloaded km h 15 15 5 14 5 15 Lifting speed loaded unloaded mm s DC 280 460 270 440 AC 340 460 325 450 Descending speed loaded unloaded mm s 500 Gradeability loaded unloaded 17 20...

Page 13: ...rhead guard H1 H4 mm 2075 2215 2180 2215 Seat height mm 1165 Under clearance H5 H6 mm 135 at mast 145 in the middle Min turning radius r mm 2240 2260 Fork adjustment range outside Max min W5 mm 1060 250 Travelling speed loaded unloaded km h 17 18 16 5 17 5 Lifting speed loaded unloaded mm s 340 460 325 450 Descending speed loaded unloaded mm s 500 Gradeability loaded 18 15 Tyre front 28 9 15 14PR ...

Page 14: ...rhead guard H1 H4 mm 2075 2215 2180 2215 Seat height mm 1165 Under clearance H5 H6 mm 135 at mast 145 in the middle Min turning radius r mm 2240 2260 Fork adjustment range outside Max min W5 mm 1060 250 Travelling speed loaded unloaded km h 17 18 16 5 17 5 Lifting speed loaded unloaded mm s 340 460 325 450 Descending speed loaded unloaded mm s 500 Gradeability loaded 18 15 Tyre front 28 9 15 14PR ...

Page 15: ...erhead guard H1 H4 mm 2075 2215 2180 2215 Seat height mm 1165 Under clearance H5 H6 mm 135 at mast 145 in the middle Min turning radius r mm 2240 2260 Fork adjustment range outside Max min W5 mm 1060 250 Travelling speed loaded unloaded km h 17 18 16 5 17 5 Lifting speed loaded unloaded mm s 340 460 325 450 Descending speed loaded unloaded mm s 500 Gradeability loaded 18 15 Tyre front 28 9 15 14PR...

Page 16: ...0 CPD15 GC1Li GD1Li 300 825 10 70 720 1050 1414 1 551 72 1010 480 19 25 450 CPD18 GC1Li GD1Li 300 825 10 70 770 1050 1414 1 551 72 1010 480 19 25 450 CPD20 GC1Li GD1Li 370 890 11 50 790 1100 1457 15 15 86 1102 506 19 30 745 CPD25 GC1Li GD1Li 420 920 11 50 1160 1100 1457 15 15 86 1102 506 19 30 745 CPD30 GC1Li GD1Li GB3Li GB7Li G B2Li 405 895 12 25 1330 1140 1578 15 73 77 1164 459 19 57 785 CPD35 G...

Page 17: ...peed of the motor and the travel direction can be changed with the rotation direction of the motor 1 2 Differential assembly The differential is respectively installed on the main housing of the reducer casing and spindle head assembly of the axle housing through bearings on both ends The differential housing of 1 2 5t truck is of integral type The differential of 3 3 5t truck is of right and left...

Page 18: ... housing of 1 2 5t truck is a fission cast The housing of 3 3 5t truck is of wholly casted structure The tyre with the rim is fixed to the hub with bolts and nuts The power is transmitted to the half shafts through the differential and drives the front wheels through the hubs Each hub is fixed on the housing with two tapered roll bearings so that the half shafts bear only the torque transmitted to...

Page 19: ...b assembly 7 Half shaft Ⅰ 8 Oil seal AE2483E0 9 Bolt 10 Washer 20 11 O ring seal 90 5 3 12 Nut M30 1 5 13 Washer 30 14 Bearing 32208 15 Dual gear Ⅱ 16 Bearing 6010 C3 17 Washer 12 18 Bolt M12 40 19 Oil seal AE2791A0 20 Pinion 21 Bearing 6208 22 Dual gearⅠ 23 Bearing 6206 24 BoltM20 1 5 55 25 Bearing 32915 26 Half shaft Ⅱ 27 Spindle head assembly of the axle housing Ⅱ 28 Washer 75 29 Nut M75 2 30 C...

Page 20: ...17 Fig 1 4 Gearbox axle assembly 1 1 8t 2t 2 5t Figure 1 5 reducer and differential 3 3 5t ...

Page 21: ...e that the wheel hub starts rotating When the torque value measured reaches to regulated value screw down the hub nut Initial torque 5 15kg m Fig 1 7 Measure the torque value 4 Screw down the locking nut and lock the locking pin 5 Assembly of tyre Fix the drain tap and the cover on the tyre and screw down wheel rim bolts NOTE a the exhaust valve rod points outside and lies on the gap of the rim b ...

Page 22: ...ged to brake fluid pressure through the push rod of the master brake cylinder Fig 2 1 1 Service braking principle diagram Fig 2 1 2 Brake pedal 2 1 2 Master cylinder The cylinder contains valve seat return spring primary cup piston and secondary cup which are all kept in place with a stop washer and a stop wire The exterior of the cylinder is protected from the dust by means of a rubber dust cover...

Page 23: ...ased the piston is forced back by the return spring At the same time the brake fluid in each sub cylinder is pressured by the return spring returning into the mast cylinder through the check valve With the piston in its original position the fluid in the master cylinder flows into the reserve tank through the return port The brake fluid in the brake pipelines and sub cylinders has a residual press...

Page 24: ...er until the upper end of the secondary shoe is against the anchor pin and the brake shoe moves towards the rotation direction of the brake drum The friction force between the friction piece and brake drum increases when the anchor pin is laid against A large braking force is produced because the secondary brake shoe bears a larger force from the primary shoe than from the sub cylinder See Fig 2 3...

Page 25: ...f adjusting mechanism A proper clearance between the friction piece and the brake drum is maintained by the clearance self adjusting mechanism See Fig 2 6 Fig 2 6 Clearance self adjuster The clearance self adjusting mechanism actuates only when the truck in reverse travel Operation of the clearance self adjuster When brake during travelling backward the secondary brake shoe contact with main ...

Page 26: ...ing action and thus B point lowers When the clearance between friction disc and brake drum increases b rotating vertical dimension increases The clearance decreases with the elongating of adjusting rod when the adjuster is stirred one gear See figure 2 7 See the follow table for clearance adjusting range 1 1 8t 2 2 5t 3 3 5t Clearance 0 35 0 55 0 5 0 55 0 25 0 4 Fig 2 7 Clearance self adjuster ...

Page 27: ...Spring pull rod 11 Return spring for brake shoe 12 Guide pad 13 Guide plate 14 Brake cylinder ass y 15 Front brake shoe with friction plate 16 Bassplate ass y 17 Washer 10 18 Spring washer 19 Pin roll for pull rod 20 Snap ring 21 Parking pull rod 22 Spring pull rod 23 Spring seat 24 Spring 25 Plug 26 Pullback spring 27 Clearance self adjuster 2 1 4 Operating device of the parking brake ...

Page 28: ...9 Pull force 20 to 30kg Note Adjuster is inside the cover Cover need to be disassembled before adjusting Fig 2 9 parking brake shank 2 2 Assembling and disassembling adjustment of brake This paragraph covers the disassembly reassembly and adjustment of the brake in the state of the wheels and hubs are disassembled It also covers the adjustment method of the brake pedal The description here is main...

Page 29: ...g device and spring of secondary shoe See Fig 2 10 Fig 2 10 2 Remove two shoes return springs See Fig 2 11 Fig 2 11 3 Remove the hold down springs See Fig 2 12 Fig 2 12 4 Remove the primary and secondary shoes At the same time remove adjuster and adjusting spring See Fig 2 13 Fig 2 13 ...

Page 30: ...uring the parking brake cable to the backing plate Remove the backing plate mounting bolts and detach the backing plate from the axle See Fig 2 15 Fig 2 15 7 Remove the boot and push the piston assembly out of the operating cylinder See Fig 2 16 Fig 2 16 2 2 2 Inspection of brake Inspect all parts to make sure if there s any worn or damaged part If unsatisfactory repair or replace with new one ...

Page 31: ...one 3 Check the free length of the operating cylinder spring If unsatisfactory replace it 4 Check the friction piece for thickness to see if it is excessive worn If necessary replace it See Fig 2 18 Unit mm 1 0 1 8t 2 0 2 5t 3 3 5t Standard 4 8 5 7 8 0 Limiting 2 5 3 5 6 0 Fig 2 18 5 Check the condition of the brake drum inner surface If any damage or excessive wear is found repair by machining or...

Page 32: ...e 3 Install the backing plate on the front axle 4 Apply heat resisting grease on the points indicated in Fig 2 20 with care not to contaminate the friction piece with grease Fig 2 20 5 Install the brake cable assembly on the backing plate with an E retainer 6 Install shoes on the backing plate with hold down springs 7 Put the spring on the parking push rod then install the rod on the shoe See Fig ...

Page 33: ... spring direction of the push rod Spring hook at anchor pin side should be located at the opposite side to push rod d Make sure that the adjusting lever end is in contact with the adjuster gear teeth See Fig 2 23 Fig 2 23 10 Install the brake line on the operating cylinder 11 Measure the inner diameter of drum and the outer diameter of brake shoe Adjust the adjuster to obtain the 1mm difference ne...

Page 34: ...operate normally after it is built in the machine 2 If the adjuster fail to do the above operation when the adjusting lever is pulled proceed with the following inspection a Make sure that the adjusting lever push rod and the return spring for push rod are securely installed b Check the push rod return spring and adjuster spring for deterioration and also check the adjuster gear for rotating condi...

Page 35: ...3 Press the brake pedal Pull the push rod out until its front end comes into contact with the master cylinder piston 4 Tighten the push rod locking nut Fig 2 26 Brake switch adjustment a After you adjust the height of the brake pedal loose the lock nut of the brake switch ...

Page 36: ...ck for dragging Readjust Repair or replace Check brake fluid Adjust Noisy brake 1 Hardened friction piece surface or foreign matter adhered thereto 2 Deformed backing plate or loose bolts 3 Deformed shoe or incorrect installation 4 Worn friction piece 5 Loose wheel bearing Repair or replace Repair or replace Repair or replace Replace Repair Uneven braking 1 Oil contaminated friction piece 2 Poor a...

Page 37: ...the turning direction with very small force As requested by the working characteristic of the forklifts the operation site and driving pass are relatively narrow changing over is frequent and the minimum radius turnings are often needed therefore the steering system is required to be reliable and light in operation Since the load of steering axle occupies about 60 of the vehicle weight in case of ...

Page 38: ... through steering gear when it is at neutral position to save the energy 3 3 Composition of Steering System 1 Control mechanism of steering Fig 3 1 Steering control device The control mechanism of G series forklift of 1 0 3 5t mainly consists of steering wheel tubular column coupling steering gear and mounting support etc as shown in Fig 3 1 They are fixed on the instrument panel by mounting suppo...

Page 39: ...pezium is made of cranks and blocks When pressure oil moves the cylinder piston rod the tie rod revolves the knuckles then the truck may be steered The steering axle is fixed with bolts through support on the tail bracket at rear of the frame after bumper block is mounted on the front and end plate so that the axle can sway around the pin roll on the end plate and obtains certain shock absorbing e...

Page 40: ...teering cylinder 18 steering axle body 19 link rod 20 pin axle 1 Steering knuckle Both steering knuckles are fitted between the upper and the lower steering axle body through two king pins thrust bearings needle bearings dust covers and seal rings The king pin is locked on the steering knuckle with a lock pin The upper end of the knuckle is supported on the steering axle body by thrust bearing Bot...

Page 41: ...onnected with steering knuckles through connection rod Left or right of the truck turning is achieved with the help of the left or right travel of the piston rod driven by the pressure oil from the powered steering unit The seal unit is consist of the supporting ring and O ring seal U ring seal is adopted between the cylinder head and the piston rod The cylinder is fitted to the steering axle thro...

Page 42: ...2 Press the hub bearing into the hub and fit the hub on the knuckle shaft 3 Fit a flat washer and tighten a castle nut to a torque of 206 235Nm 21 24kgm and loosen it and then tighten it again to a torque of 9 8Nm 1kgm 4 To ensure firm installation of the hub slightly knock at it with a wooden hammer and in the meantime rotate the hub for 3 4turns 5 Tighten the castle nut and align one of its notc...

Page 43: ...nuckle arm need to be checked every 40 hours and lubrication grease replenished every 300 hours 2 Change the grease of the bearing of steering hub every 1200 hours 3 Pay attention to the working condition of steering system during routine maintenance The manual operation force on the steering wheel should be 10 25N during steering and the difference of right and left acting force is not more than ...

Page 44: ...oo low Adjust the pressure 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 cylinder Inspect the seal of the piston Truck s snacking or moving with oscillation Spring damaged or elasticity insufficient Replace Large steering flow Adjust Splite flow valve flow Excessive noise...

Page 45: ...traction motor pump motor battery pack control switch lighting and wiring harness etc Notice Our Company has the right to improve on the production Please contact with our company if there is any difference between the product and the manual The circuit diagram of electric system are shown in Fig 4 1 Fig 4 12 ...

Page 46: ...43 Fig 4 1 Circuit diagrams of electric system CPD10 18 GC1Li ...

Page 47: ...44 Fig 4 2 Circuit diagrams of electric system CPD10 18 GD1Li ...

Page 48: ...45 Figure 4 3 Circuit diagrams of electric system CPD10 18 GD3Li ...

Page 49: ...46 Fig 4 4 Circuit diagrams of electric system CPD20 25 GC1Li ...

Page 50: ...47 Fig 4 5 Circuit diagrams of electric system CPD20 25 GD1Li ...

Page 51: ...48 Figure 4 6 Circuit diagrams of electric system CPD20 25 GD3Li ...

Page 52: ...49 Fig 4 7 Circuit diagrams of electric system CPD30 35 GC1Li ...

Page 53: ...50 Fig 4 8 Circuit diagrams of electric system CPD30 35 GD1Li ...

Page 54: ...51 Figure 4 9 Circuit diagrams of electric system CPD30 35 GD3Li ...

Page 55: ...52 Figure 4 10 Circuit diagrams of electric system CPD30 35 GB7Li ...

Page 56: ...53 Figure 4 11 Circuit diagrams of electric system CPD30 35 GB3Li ...

Page 57: ...PSH 3A19 3A20 K1 OUT 2 BUZZER 12VDC 12VDC 12VDC 3A17 BATT IN 0 Y Anti lower electromagnetic valve 12V 11W MODEL E 1A16 NLC NENC 1A10 CPOT2 MC COIL 3A6 P B ENABLE Traction Motor 选 项 OPTION ACE3 80V 450A Traction controller Lift ing enable 蜂鸣提示Caution buzzer 后大灯Rear head lamp 刮水器Wiper 驾驶室顶灯Cab lamp 电风扇Cab fan 风扇开关Fan Sw 顶灯开关Cab lamp SW 雨刷开关Wiper SW 后大灯开关Rear head lamp Sw 警示灯开关Caution lamp Sw SMART D...

Page 58: ...r display 16 Backward indication light 17 Seat switch status indicator 2 Function and application CURTIS ENGAGE Ⅳ instrument receives the fault signal in serial mode from the fault outlet end of walking controller and pump controller and is displayed on the instrument in digital form TRAVEL indicates walking controller and HYD the pump controller Power display and insufficient power warning The li...

Page 59: ...ndication information Indication Information LED lamp does not work Power supply of controller has not been connected or the battery of vehicle uses up or other serious faults Yellow LED lamp flickers Controller works normally Yellow and red LED lamps are often on Controller is at program loading status Red LED is often on Watchdog no longer works or software Not installed Restart with the key swi...

Page 60: ...a kind of truck instrument based on CAN and wireless communication The instrument can not only show truck speed working time battery dump energy dual language display password protection fault code and so on it also can realize long distance voice alarm arrangement vehicle positioning long distance truck locking long distance assist and other industrial engineering functions It also can reset truc...

Page 61: ...e battery When the 10 squares are off fault remind figure and lifing lock figure will be on and at that time the travelling speed will be reduced and the lifting operation is null Charge the battery in time c Display of travelling mode the operator can choose travelling mode through mode switch The current mode is shown on instrument interface see figure 4 12 The system has three modes P refers to...

Page 62: ...59 Fig 4 17 Panel layout of Songzheng instrument 4 2 3 2 Parameter specification of instrument 1 The instrument interface displays a tree diagram ...

Page 63: ... 20 driver 1 status 2 1 21 driver 2 status 2 1 22 driver 3 status 2 1 23 driver 4 status 2 1 24 driver 5 status 2 1 26 driver 7 status 2 1 25 driver 6 status 2 1 27 inside 15V output 2 1 28 5V output 2 1 29 12V output 2 1 33 Proportional drive output 2 1 37 Lock line voltage 2 1 41 Controller temperature 2 1 45 Controller overtemperature limit 2 1 49 Regeneration limit 2 1 30 External supply curre...

Page 64: ...igure this parameter enter the correct password first Percentage of pump power forbidden when the meter shows the power through this parameter the pump lift and tilt are forbidden to work to configure this parameter enter the correct password first Password input enter the password here It is necessary to enter the password again before parameter setting to modify the parameters default password 0...

Page 65: ...rument panel connected to the vehicle system through CAN bus The intelligent instrument panel provides diagnosis and Settings for the entire vehicle system Connect the smart display to a ZAPI handheld device or single chip Windows device which can read or modify the Settings of all modules in the CAN bus network The display forms an interactive interface with the operator through the main page and...

Page 66: ...same time the walking speed will slow down and the lifting action will be cut off The battery should be charged in time c Driving mode display in traction operation the driver can select driving mode through the mode switch and the current mode is displayed on the instrument interface see figure 4 19 The system has three modes E for economy mode default P for powerful mode and S for slow mode d Fa...

Page 67: ...ed from Sweden ZAPI motor controller imported from Italy and SONGZHENG motor controller an independent domestic brand The control system has advanced high frequency MOS tube technology excellent speed control performance good security flexibility and first class protection and other advantages At the same time it has the advantages of advanced AC flux vector control technology to ensure efficient ...

Page 68: ...65 4 3 2 CURTIS control device Fig 4 21 The controller of CPD10 18 GC1Li ...

Page 69: ...66 Fig 4 22 The controller of CPD10 18 GD1Li ...

Page 70: ...67 Fig 4 23 The controller of CPD10 18 G31Li ...

Page 71: ...68 Fig 4 24 The controller of CPD20 25 GC1Li ...

Page 72: ...69 Fig 4 25 The controller of CPD20 25 GD1Li ...

Page 73: ...70 Fig 4 26 The controller of CPD20 25 GD3Li ...

Page 74: ...71 Fig 4 27 The controller of CPD30 35 GC1Li ...

Page 75: ...72 Fig 4 28 The controller of CPD30 35 GD1Li ...

Page 76: ...73 Fig 4 29 The controller of CPD30 35 GD3Li ...

Page 77: ...74 Fig 4 30 The controller of CPD30 35 GB7Li ...

Page 78: ...75 Fig 4 31 The controller of CPD30 35 GB3Li ...

Page 79: ...anty for motor controller and the manufacturer will be informed in time for after sales service in case of fault Please do not open it for maintenance without authorization of manufacturing The users will be responsible for the personal and property losses caused by maintenance at their own will ...

Page 80: ...e 32 3V 32 3V 32 3V 33V 33V 52V 52V Rated current 214A 214A 214A 260A 260A 250A 250A Rated speed 1140r mi n 1140r min 1140r mi n 1800r min 1800r min 3100r mi n 3100r min Lifting motor model XQD 7 5 3 S XQD 8 6 3S XQD 10 4 S XQD 13 4S Excitation way Series excitation Series excitation Series excitation Series excitation Rated power 7 5kW 8 6kW 10 5kW 13kW Rated voltage 48V 48V 48V 75V Rated current...

Page 81: ...e brush is integrity and glides agilely the pressure of the balance spring in gear h The area of interface between brush and commutator should not less than 80 and require polished with 00 type of thin emery cloth before instead 2 Daily maintenance Notice the surface of motor for example the mud or other adherent matter on the housing to avoid affect motor dispel heat Check every half a year in ge...

Page 82: ... piece change black in group without regulation The center of commutator moved and the surface of commutator is not circle or flat 4 The brush is frayed change color and disintegrated The motor vibrate the space between brush holder and brush is too big the space between brush holder and the surface of commutator is too big The talc between the commutating piece extruded the material or type of br...

Page 83: ...ery have a great influence on the performance and service life of battery therefore the users must make maintenance and service referring to the actual condition and according to the maintenance instruction on lithium battery provided by manufacturer Please read the manual carefully before using the electric truck and operate and use according to the procedures and methods regulated in the manual ...

Page 84: ...ity conductive objects except bolt and conductive band The operation may lead on injuries or property loss 6 It is prohibited to expose or store battery in an environment higher than 55 Do not heat or put battery in fire The operation may lead on injuries or property loss 7 It is prohibited to charge the battery without proper charging protection devices such as lithium battery protective circuit ...

Page 85: ...r a long time will speed up the aging of battery internal material and shorten battery service life So it is not recommended to use the truck under this temperature for a long time 3 Storage and longtime operation below 25 or above 55 are prohibited 4 When the truck has to be stored for a long time keep the battery electricity to be 40 60 and store it in dry and shady environment and charge the ba...

Page 86: ... Disconnect the connection between the battery and the truck and charging equipment during transporting Make sure there is no any charging and discharging 3 Lithium battery maintenance notes 1 When the battery is lower than 20 Charge it in time and it is prohibited to over discharge 2 Charge the battery full after using It is prohibited to over charge 3 When the truck has to be stored for a long t...

Page 87: ...ot modify or disassemble charging port and charging equipment or fault or fire may be caused 5 Keep the following precautions during charging in order to avoid serious harm a Do not contact charging terminal or terminal inside of the charging spearhead b When there is lighting do not charge the battery or touch the truck if it is hit by the lighting charging equipment may be damaged and human inju...

Page 88: ...1 It acts as safety switch Press the button in emergency to ensure truck safety it is prohibited to press the button frequently if it is not emergency or parts service lift will be badly affected 2 Press the emergency button in the following cases to prevent battery feed a When the truck will not be used for more than 72h press the button when the battery quantity meeting storing requirements refe...

Page 89: ... mechanical moving of the contactor every three months if there is any damage or condition affecting the safety contact with controller dealer Notice After chopper is installed raise the wheel of vehicle off the ground for test In this way there will be no danger even connection is wrong After electric lock switch is off there is a certain voltage left in filter capacitor within a period of time C...

Page 90: ...of controller 17 Sever Undervoltage The selection of controller s voltage parameter is wrong Capacitor voltage too low inside the controller Overcurrent when start Battery resistance too high Battery disconnected while driving Battery fuse burn or main contact not actuation 18 Sever Overvoltage The selection of controller s voltage parameter is wrong Controller s capacitor voltage too high Battery...

Page 91: ...act Wiring error 33 Coil3 Driver Open Short Open or short on driver load Check COIL3 for open or short Bad contact Wiring error 34 Coil4 Driver Open Short Open or short on driver load Check COIL3 for open or short Bad contact Wiring error 35 PD Open Short Open or short on driver load Check PD for open or short Bad contact Wiring error 36 Encoder Fault Motor encoder failure Check encoder for fault ...

Page 92: ...wer than set value Check accelerator 55 Turn sensor open Turn sensor open Check turn sensor 56 Turn enable setting fault It is valid when the turn sensor and turn switch is set at the same time Check turn sensor and turn switch 57 BMS hot The temperature inside of battery is high Check battery 58 BMS severe overvoltage Battery severe overvoltage Check battery 59 GPS lock the truck CAN bus disconne...

Page 93: ...hrough LED flickering times and serial port Table 4 6 Fault code and troubleshooting of 1235 series controllers Code Status LED Description Possible cause LED OFF off No power or defective controller Solid ON On all the time Controller or microprocessor fault 0 1 Controller operational no known faults 1 1 EEPROM fault 1 EEPROM data lose or damaged 2 EEPROM checksum error Can be cleared via modify ...

Page 94: ...acceleration pedal 21 ERROR Direction switch is activated when starts Shift direction switch to neutral gear 22 ERROR front and rear direction switches are activated at the same time direction switch failure 23 ERROR acceleration pedal analog quality exceeds range Acceleration pedal fault or recalibrate analog quality 24 ERROR acceleration pedal analog failure 31 ERROR CAN communication of driver ...

Page 95: ...eck power harness 90 WARNIN traction driver default value is loaded Safe protection after refreshing procedures it will be ok after restart the key switch 91 WARNING traction driver performance limiting mode Low battery quantity and truck performance is limited 97 ERROR traction driver output port failure Check if the output port harness is short circuit or open circuit such as main contactor back...

Page 96: ...ess 141 ERROR pump drive short circuit 142 ERROR pump driver temperature is high Cool driver 143 ERROR high pump motor temperature Cool motor 144 ERROR pump driver current calibrating failure Restart 145 ERROR pump driver precharging overtime Change precharging resistance 150 ERROR pump driver DC bus voltage low Driver input voltage is overlow and check battery voltage or check if contactor is con...

Page 97: ...t is required 1 Replace the main contactor 2 Restart the key 1 The main contactor is not suction 2 Within 2 seconds the fault indicator will report the 3 8 fault code 4 Precharge fault Precharge failure 1 Ensure the correct connection of B and B lines 2 Restart the key 1 The main contactor is not suction 2 Within 2 seconds the fault indicator will report the 1 4 fault code 5 High pedal Close the k...

Page 98: ...mperature detection of enabling motor is required Properly connect motor temperature sensor 1 Limit the output of the controller to 50 of the maximum current 2 The failure indicator light report 2 9 fault code 12 Controller temperature is seriously too low Controller temperature 40 1 Controller temperature 40 2 Restart the key 1 The controller does not output 2 The failure indicator light report 1...

Page 99: ...to write correct data to EEPROM 2 The written data is not in the specified range 1 Ensure hardware connect properly 2 Write the correct data 3 Restart the key 1 The controller does not output 2 The failure indicator light report 4 6 fault code 20 Read EEPROM failure 1 Unable to read correct data from EEPROM 2 The data read out is not within the set range 1 Ensure correct hardware connection 2 Writ...

Page 100: ... Lithium batteries have a higher temperature The lithium battery returned to normal The controller reduces power output 32 The charging connection The lithium battery charging connection is established The lithium battery returned to normal The controller does not output 33 current limiting protection Abnormal failure of lithium battery The lithium battery returned to normal The controller reduces...

Page 101: ...ine voltage If the voltage of one phase is lower than 66 of the mainline voltage this fault will occur Case 2 This fault occurs during operation when the motor is running the power bridge is closed and the motor phase voltage feedback is completed If the phase voltage is lower than expected this fault will occur Case 1 solution the coil of the main contactor is not closed in this case please check...

Page 102: ...r tens of milliseconds to try to discharge the capacitor group If the voltage of the capacitor group does not reduce the voltage of the key port by 20 this fault will occur Check the contact of the main contactor It is recommended to replace the main contactor 38 CONTACTOR OPEN The controller drives the main contactor coil but the contactor contacts do not appear to be engaged To detect this the c...

Page 103: ...king properly 65 MOTOR TEMPERAT NOTE 1 The truck will travel with default mode E when three kinds of travelling mode P E S are or are not input at the same time 2 When turn signal device is invalid the truck will travel with limited speed 5 Hydraulic System 5 1 General Description The hydraulic system consists of oil pump control valve priority valve lift cylinder tilt cylinder high low pressure o...

Page 104: ...e through the oil suction pipe of pump While 2 indicates that the volume of space engaging part for gear entering changes from big to small and press the oil into pressure oil circuit i e 1 is oil suction cavity 2 is oil pressing cavity and they are separated by meshing point of two gears With constant rotation of gear the suction and discharge outlets of the pump continuously absorb and drain oil...

Page 105: ...2 Main pump 1 Pump body 2 Driving gear 3 Driven gear 4 Front cover 5 Rear cover 6 Lining plate 7 Seal ring 8 Ring 9 Oil seal 10 Snap ring 5 1 2 Control Valve The external of the control valve as shown in Fig 5 3 ...

Page 106: ...ing valves inside the control valve The safety relief valve is at the top of oil inlet of control valve to control the pressure of the system The tilt locking valve is on the tilt valve block and is mainly used to prevent the serious consequence due to wrong operation of control rod when the tilt cylinder has no pressure source The check valve is mounted between oil inlet and inlet port of lifting...

Page 107: ...heck valve and to flow into the port B The return oil from the port A flows through the low pressure passage to the tank and the spool is restored to its neutral position by the return spring Fig 5 5 Push in spool c Drawing out of spool See Fig 5 6 With the mid passage closed the oil from the main oil inlet pushes up the check valve and flows into the port A The return oil from the port B flows th...

Page 108: ...valve E will open The oil flows into LP side through holes around the valve as shown in Fig 5 8 Fig 5 7 Fig 5 8 Once the pilot valve E opens the pressure inside valve C will drop valve E and valve C are on the valve seat The liquid flowing to the rear of the valve D will be closed so the pressure inside will be decreased See Fig 5 9 The HP passage pressure and inside pressure of oil pump are not e...

Page 109: ...l flows through the port B to tilt cylinder and moves the tilt lock valve to let the port A connect with the low pressure tank The tilt cylinder and the mast is tilted forward Fig 5 11 b The spool is pushed in when the lift motor stops When the lift motor stops no pressure oil flows to the tilt lock valve The port A can t connect with the low pressure tank and the mast doesn t be tilted forward Fi...

Page 110: ...h the lift lever forward the mast fall down when you pull the lift lever backward The mast tilt forward when you push the tilt lever forward the mast tilt backward when you pull the tilt lever backward Fig 5 14 The symbol on the operation lever 5 Setting pressure of the control valve See Fig 5 15 ...

Page 111: ...inder The lift cylinder is of single acting piston type It consists of cylinder body piston piston rod cylinder cap cut off valve and oil seals The cylinder head is equipped with bushing and oil seal and the bushing supports the piston rod and the oil seal keeps dust off See Fig 5 16 When the hoist valve of control valve is placed at lifting position hydraulic oil enters into the lower part of pis...

Page 112: ... support block 16 Nut M12 1 25 17 Piston rod 18 dust proof ring 40 52 7 10 19 guide sleeve 20 Seal ring 40 50 6 21 Steel backed bearing 4030 22 Shim 23 Screw M5 6 24 O ring d49 7 2 4 25 Cylinder body 26 Steel cable baffle ring 27 support ring 50 10 2 5 28 Valve assembly 29 Piston 30 Adjusting sleeveφ48 40 5 31 retaining plate 50 40 3 32 seal ring for hole 50 40 6 33 shim 34 sleeve 35 steel cable b...

Page 113: ...e and slide valve does not work If the flow rate through the spool hole exceeds the setting value due to high pressure pipe cracking or other reasons the pressure difference before and after spool will be larger than the spring force and move the spool to the left In this way hole A is closed only small amount of oil flows out from the small clearance of spool and valve bush and the goods descends...

Page 114: ...le 2 Spring 3 Ring seal 4 Snap ring 5 Spool 6 Sleeve 7 Steel ball 8 Spring of the check valve 9 Valve body 5 1 6 Tilt cylinder The tilt cylinder is of double action and piston type hydraulic cylinder and is mounted at both sides of mast with its piston rod end connecting with mast The bottom of tilt cylinder is connected through dowel with connecting end of frame and mast and the forward and backw...

Page 115: ...assembly to tilt forward until 6 degrees When the tilt lever is pulled backward high pressure oil enters into the cylinder body from the guide sleeve and moves the piston backward tilting the mast assembly backward Fig 5 19 Tilt cylinder 1 Ear ring 2 Dust ring 3 Snap ring 4 Yx ring 5 O ring 6 Guide sleeve 7 Bushing 8 O ring 9 Piston rod 10 Cylinder body 11 Yx ring 12 Wearing 13 Piston 14 Yx ring 5...

Page 116: ...ystem principle diagram 1 Oil tank 2 Oil suction filter 3 Pump motor 4 Gear pump 5 Steering unit 6 Steering cylinder 7 Control valve 8 Flow regulator valve 9 Cut off valve 10 Lift cylinder 11 Tilt cylinder 12 Return oil filter ...

Page 117: ...nside work oil tank is sufficient and check and clean the strainer mesh of oil filter mounted in the work oil tank once every week Normally change the oil in the work oil tank once every 1200 1500 hours of work and mixed use of oils of different brand number is not allowed 5 2 2 Maintenance of lift pump 1 Disassembly Before disassembling the pump put the removed parts on the paper or cloth Don t d...

Page 118: ...m front cover or rear cover Notice Don t remove the seal ring and ring from the front cover and rear cover if the seal ring and ring needn t be replaced Fig 5 22 Gear pump 1 Pump body 2 Drive gear 3 Driven gear 4 Front cover 5 Rear cover 6 Lining plate 7 Seal ring 8 Ring 9 Oil seal 10 Snap ring ...

Page 119: ... of the lining plate If the surface is worn or its thickness is smaller than the specified value replace the lining plate The specified thickness of the lining plate 4 94mm Fig 5 24 c Front and rear pump cover If the color changed range of the inner surface of the bushing exceed 150 replace the bushing Fig 5 25 d Inspect the drive gear and the driven gear from front and rear If they are worn exces...

Page 120: ...the pump Notice Don t twist Fig 5 29 c Install a new ring on the front cover of the pump The direction of the installation see Fig 5 30 Fig 5 30 d Install the pump body on the front cover Pay attention to the direction of the pump body Fig 5 31 e Install the lining plate on the groove of the front cover don t confuse the inlet oil port and the outlet oil port Pay attention to the direction of the ...

Page 121: ... gear don t confuse the inlet oil port and the outlet oil port Fig 5 35 i Install a new seal ring and a new ring on the groove of the rear cover Apply lubricating grease on the seal ring Fig 5 36 j Install the rear cover on the pump body with it s seal ring downward don t confuse the inlet oil port and the outlet oil port Fig 5 37 k Tighten up the connecting bolts with a specified torque of 9 to 1...

Page 122: ...ge the hydraulic oil or filter before carrying out the test run on the forklift truck a Install the pump onto the truck and the pressure gauge onto the pressure test end of the control valve b Loose the adjusting screw of the relief valve and make the pump running at a speed of 500 1000rpm for 10 minutes Make sure the oil pressure be lower than 10kg cm2 c Increase the pump speed to 1500 2000rpm fo...

Page 123: ...plating the valve rod to couple with the hole with the gap at 0 01 0 02 5 Change the sealing ring screw tight the screw in sequence 6 Check to see whether there is damage to the sealing ring or connecting nut and screw tight the pipe joint 7 Replace the unqualified hydraulic oil stop operation to lower oil temperature and try to find the cause of over high oil temperature 8 Lift load according to ...

Page 124: ...eel ball exists and if there is dirty stuff blocking the steel balls 4 Adjust pressure of the overflow valve or clean it 5 Use oil liquid with recommend ded viscosity 6 Lifting System 6 1 General Description The lifting system is of the two stage roller type with veritical up and down It consists of the inner mast the outer mast and the lift bracket 6 2 Inner and Outer Masts The inner and outer ma...

Page 125: ... sustain the longitudinal loads And side rollers sustain the transverse loads When forks reach its maximum height the upper pair of main rollers will come out from the inner mast top 6 4 Layout of Rollers Ten main rollers are separately installed on the upper end of the outer mast two lower end of the inner mast two and both side of the lift bracket upright six Eight side rollers are separately in...

Page 126: ...123 Fig 6 1 Layout of the rollers Fig 6 2 Adjusting method and request of the main and side rollers ...

Page 127: ...r of the lift bracket Fig 6 4 Additional remarks for the roller adjusting of the lift bracket 6 5 Maintenance 6 5 1 Adjust lift cylinder It must readjust stroke of the lift cylinder when the lift cylinder the inner mast or the outer mast is replaced As following ...

Page 128: ... 0 5mm 4 Adjust the tightness of lift chains The adjustment of lift cylinder also belongs to exalted maintenance Please be careful Fig 6 5 Adjust lift cylinder 6 5 2 Adjust lift bracket s height 1 The truck should be stopped on horizontal ground And ensure the masts erect 2 Lower the forks on the ground adjust the set nut of tie in on the upper of chains to assure the distance A 19mm 20mm between ...

Page 129: ... tie in on top of the chains And take out chains from sheave See Fig 6 7 4 Make the inner mast rise 5 The forklift can be reversed when the lift bracket disengaged from the outer mast 6 Replacing main rollers a Take apart all of snap ring from the lift bracket and take out main rollers b Fit the new main roller the same type as the old one on the lift bracket and fastened with snap ring Fig 6 7 6 ...

Page 130: ...5 Take apart bolts which jointed lift cylinders and the bottom of outer mast and take apart the oil pipe between two lift cylinders without loosing the nipple 6 Main rollers on the upper outer mast will be showed on the top of the inner mast as soon as main rollers were taken apart from bottom of the inner mast after laying down the inner mast 7 Replacing main rollers a Take apart the upper main r...

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