Sovan's CBD25T Operation Manual Download

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CBD25T/CBD30

Electric Pallet Truck



Operation Manual



Parts Catalogue

2012-01

Summary of Contents for CBD25T

Page 1: ...CBD25T CBD30 Electric Pallet Truck Operation Manual Parts Catalogue 2012 01 ...

Page 2: ...ual We reserve the right to modify technology of the electric pallet truck If there is anything in the manual that is not consistent with the actual truck the actual truck should be considered correct and the manual is only for reference Warning Operators must strictly conform to ISO3691 Safety Specifications of Motor Industrial Vehicles Untrained personnel are not allowed to operate the truck ...

Page 3: ...tery and charge 13 Ⅵ Inspection before operation 16 Ⅶ Inspection after operation 16 Ⅷ Periodic maintenance and repair 17 Ⅸ The store and transportation of forklift 22 Ⅹ The tow of the pallet truck 23 Ⅺ The disassembly and assembly of some parts 24 Ⅻ Common fault and trouble shooting 27 Appendix Motor industrial vehicle Safety norms 32 ...

Page 4: ...sive or corrosive environment with acid and alkali Description The instruction manual shall be kept by the operator and shall be read by the operator until he gets a full understanding The instruction manual is composed of correct operation convenient and simple maintenance and routine inspection The instruction manual shall be carefully read before operation for purpose of correct drive and suita...

Page 5: ...1 Ⅰ Technical parameters 1 CBD25T CBD30 Outline drawing ...

Page 6: ...t h3 mm 135 135 4 9 Min Max height of operation handle in driving position h14 mm 1041 1374 1041 1374 4 15 Height lowered h13 mm 82 82 4 19 Overall length l1 mm 2143 2143 4 20 Length to fork face l2 mm 923 923 4 21 Overall width of truck body b1 mm 936 936 4 22 Fork dimension S e l mm 55x230x1220 55x230x1220 4 25 Overall width of fork b5 mm 685 685 4 32 Wheelbase ground distance m2 mm 27 27 4 33 A...

Page 7: ...button 4 accelerator knob 5 operation handle 6 emergency reverse button 7 multi functional instrument 8 electric lock 9 electric control unit 10 driving unit 11 platform 12 steering power unit 13 hydraulic power unit 14 storage battery 15 handrail 16 handrail control box 17 tool pallet 18 backrest ...

Page 8: ...electromagnetic brake When the accelerator is released during the traveling of the truck the controller will carry out regenerative braking at first This kind of brake can turn the dynamic energy to electric energy which can be recharged to battery When the truck is stopped the electromagnetic arrester will be out of power and braked again This type of regenerative brake with electromagnetic brake...

Page 9: ...you press the button 4 Emergency reverse button when the operation handle is placed in area B and the emergency reverse button is pressed the truck will travel in an opposite direction away from the operator immediately This is a safety switch which can avoid the operator from being squeezed under unexpected condition 5 Slow down button When this button is pressed the truck will travel at an extre...

Page 10: ...truck for a long time It is strictly forbidden to make sharp turn on narrow aisle When it is turning slow down the truck so as to ensure the safety of personnel and goods Descend the forks to the lowest position when the truck is not used It is strictly forbidden to put any part of the body under heavy goods and forks This truck is suitable to be used on flat ground or flat platform Don t put the ...

Page 11: ...ance of the truck B No modification or addition shall be made to the truck without written permission by our company A modification of the truck may have a negative effect on its safe operation Prepare safety operation procedure Safety operation procedure shall be formulated with consideration of practical situations before operation of the truck Safety shall be taken into full consideration in pr...

Page 12: ...e At crossroad or other places impeditive for view the driver shall not drive until there is no person at both sides Notice Keep concentration when operating truck Caution The driving mechanism of truck is installed on the backside Due to this difference from common vehicles the backside of truck swings comparatively fast when turning around For this reason to prevent collision with other objects ...

Page 13: ...pull the handle abruptly 5 Never use the truck as towing vehicle 6 When transporting over wide goods the driver shall be extremely careful to turn slowly to keep balance of the goods Decelerate when ascent and descent meanwhile watch around for sake of safety The faulty truck for future repair must not be parked at places impeditive for traffic Lower down the fork arms to the lowest position and p...

Page 14: ... released slowly the truck will slow down so as to decelerate Then the truck will be in a state of sliding When the operation handle is turned to area B regenerative braking take effect And the truck will slow down until it stops Turning Caution The driving mechanism of truck is installed on the backside Due to this difference from common vehicles the backside of truck swings comparatively fast wh...

Page 15: ...rger and it starts to charge after several seconds 1 Initial charge 1 11 Initial charge shall be made for new battery i e the first time charge Clean up the surface of the battery before the initial charge and then check for damage to ensure reliable connection 1 2 Open gas cap 1 3When the charging equipment is able to operate normally pour the sulfuric acid electrolyte with a density of 1 260 0 0...

Page 16: ... life of the batteries the batteries in use should be fully charged Insufficiently charged batteries must not be used During the process of use close attention should be paid to the discharge extent Over discharge is prohibited the voltage reduces to 1 7V per battery when the total voltage reduces to 1 7V 12 20 4V When the density of the electrolytic solution reduces to 1 17 discharging should be ...

Page 17: ...mount of water The electrolyte spills into eyes wash with large amount of water and then seek help from specialized doctor The electrolyte spills on clothes take off clothes right away wash with water and then flush with week basic soap solution The electrolyte leakage in case of electrolyte leakage outside neutralize it with lime strong carbonic acid soda or carbonic acid soda and then flush with...

Page 18: ... grease if necessary Replace faulty components Ⅷ Periodic maintenance and repair Comprehensive check for truck can avoid malfunction and ensure the service life The hours listed in maintenance procedures is based on the cases that the truck works for 8 hours per day and 200 hours per month For the sake of safety maintenance shall be carried out according to maintenance procedure Notice All the rep...

Page 19: ... top plastic lids of storage battery The plastic pot with storage battery electrolyte inside is raised using plastic funnel and the electrolyte is poured into the storage battery in a slow way until the liquid level can be seen After all the storage battery is filled conduct initial charge to the storage battery timely according to the operation requirements of initial charge 5 1 3 Daily inspectio...

Page 20: ...tion condition 8 Oil pipe Whether oil pipes leak or not 9 Hydraulic oil Proper quantity of oil 10 Lifting oil cylinder Whether there is any oil leakage or not Storage battery charger and electric system 11 Electrolyte Liquid level specific gravity and cleanness 12 Plug Function whether it is damaged or not 13 Key switch Function 14 Contactor Contact performance and function 15 Inching switch Funct...

Page 21: ...e advise Hydraulic oil LHPISOVG46 in accordance with standard DIN51524T 2 the average sustained temperature should between 40 degrees to 60 degrees B When it is over loaded we advise Hydraulic oil LHPISOVG68 in accordance with standard DIN51524T 2 the average sustained temperature is above 60 degrees C When it is lightly loaded with low temperature we advise Hydraulic oil HLPISOVG32 in accordance ...

Page 22: ...ment 1200 hours Fork wheel Replacement 1200 hours Seals Replacement 1200 hours Replace when finding out damage Gearbox Replacing lubricant grease 1000 hours Hydraulic oil Replacement 1000 hours High pressure oil pipe Replacement 2000 hours Replace when finding out damage Strainer of hydraulic reservoir Cleaning 1000 hours Oil pump motor Check for carbon brushes and bearings 1000 hours Contactor Bu...

Page 23: ...noid wood block Fasten the truck to transport vehicle with ropes 3 Loading and unloading of truck Before loading the truck check out the nameplate for the total weight of truck to choose appropriate hoisting handling equipment The hoisting of truck shall be kept level and landing shall be kept slow and stable The personnel around shall watch for safety One of the personnel is responsible for condu...

Page 24: ...hods for abnormal noise The lifting cylinder or seal ring is worn Replace the cylinder sleeve or seal ring The quantity of oil is not enough Add oil The truck cannot start Storage battery is used up Inspect charge or replace the storage battery The wire terminal is loosened Screw down the terminal screw The fuse is burn out Replace the fuse The accelerator is damaged Replace accelerator The direct...

Page 25: ...and install pressure meter with capacity over 20Mpa at the high pressure oil outlet 2 Press lifting operation button to measure the system pressure The stipulated system pressure is 14Mpa for truck with rated load of 2500KG 3 If oil pressure is not in accordance with the specified value please loosen locknuts of the overflow valves Turn pressure screw left and right until the pressure reaches the ...

Page 26: ...22 ...

Page 27: ...23 schematic wiring diagram CBD25T COMBIACI Electrical diagrams ...

Page 28: ...upgraded to the state of trunk configuration failure warming will be happen Handle Should change the controller 4 MICRO SLAVE 8 CAN Bus code 212 Cause The Lord microprocessor which is calculated by encoder does not match with microprocessor fault alarm Handle Should change the controller 5 INPUT ERROR 1 CAN Bus code 99 Cause Before the security contacts closing voltage of CNA 4 is higher than12V N...

Page 29: ...he connection CNA 5 K1 is in 12 V voltage range when close the electric lock fault alarm In fact When security contact disconnect K1 should be attached to a negative terminal battery voltage is end not 12 V Check the hardware or replace the controller 12 KS OPEN CAN Bus code 252 Cause When the Lord microprocessor testing safety contact is in closed state but in broken state from a microprocessor d...

Page 30: ...PRESENT causes fault Contactor close is controlled by traction controller eps ac0 outstanding messege through CAN If this information lacks more than about 1 5 secs this alarm occurs If there is no information transmission more than 1 5 seconds may cuase fault Handle The cause of the problem is the traction control of the main contactor in the open 8 CAN BUS KO CAN Bus code 247 Cause when CAN BUS ...

Page 31: ... ERROR CAN Bus code 228 Cause the fault occurred when tests potentiometer feedback 1 When the feedback potentiometer is used together with the feedback encoder When feedback potentiometer and feedback encoder used together and controls steering Angle of steering wheel The same setting in the test menu of FEEDBACK ENC and FEEDBACK POT When both numerical different more than 20 degrees will be alarm...

Page 32: ...NCODER potentiometer is not calculated value change at this time will failure Treatment In the application of trigger switch check if the encoder is mechanical loose or not and steering wheel has choking phenomenon or not Make sure that the wiper is not beyond the maximum machinery limitation of steering wheel In addition fault may occur in the installation when the motor rotation direction is not...

Page 33: ...in compensation parameters ADJUSTMENT 03 and ADJUSTMENT 04 of current amplifier For example not to adjust the biggest current value Treatment Need to adjust the maximum current value of Zapi controller 14 1 5 Trouble lightflickers5times 1 HIGH TEMPERATURE CAN Bus code 61 Cause Fault occurred in electronic control base temperature higher than 75 Treatment Improve the refrigeration condition of cont...

Page 34: ...ttention of a particular state of truck 1 STEER HAZARD CAN Bus code 85 Cause This is only a notice warned turning controller to limit the turn direction angle and will not slow down in traction 2 WAITING DATA CAN Bus code 237 Cause The warming occurs in setting CAN BUS to PRESENT close the electric lock eps ac0 through CAN Bus to receive parameter inventory from traction controller Request cannot ...

Page 35: ... 83 BAD ENCODER SIGN 84 STEER SENSOR KO 85 STEER HAZARD 99 INPUT ERROR 1 212 MICRO SLAVE 8 218 CLOCK PAL NOT OK 219 STEPPER MOTOR MISM 220 MOTOR LOCKED 221 MICRO SLAVE 4 222 FB POT LOCKED 223 JERKING FB POT 225 CURRENT GAIN 226 NO SYNC 227 SLAVE COM ERROR 228 POSITION ERROR 237 WAITING DATA 238 EPS NOT ALIGNED 239 WAITING FOR TRAC 241 ENCODER ERROR 242 Q LINE SENSOR KO 243 D LINE SENSOR KO 244 GAI...

Page 36: ... up to now Several times alarm from the first time to this day 14 1 Fault diagnosis system COMBIAC1 Controller fault diagnosis system can be divided into two groups ALARMS The fault is will shut off the power unit and is shut off the power bridge main contactor disconnect activate electric braking Cause for fault Motor or controller fault the power unit can t drive the vehicle Security reasons WAR...

Page 37: ...ection of main contactor and EMBR coil Valve pump motor Traction electric machine is stopped Master contactor is disconnection electromagnetic braking start Request ofvalve lift or traction COIL SHORTED AL76 Await for traction Main contactor or braking coil shorted Valve pump motor Traction electric machine stopped Master contactor is disconnection electromagnetic braking Static state traction Req...

Page 38: ...damaged cannot close Valve pump motor Traction electric machine stopped Master contactor is disconnection electromagnetic braking Static state traction Request ofvalve lift or traction POS AUX SHORT Auxiliary coil positive pole shorted Await for traction When the handlebreak up Smart Instrument drivingoutputs high level to EMBR coil Valve pump motor Traction electric machine stopped Master contact...

Page 39: ... INPUT Await for traction Fault digital to analogconverter of main microcontroller Valve pump motor Traction electric machine stopped Master contactor is disconnection electromagnetic braking Start static state traction Request ofvalve lift or traction ENCODER ERROR AL58 Await for traction Encoder error Valve pump motor Traction electric machine stopped Master contactor is disconnection electromag...

Page 40: ...tor Traction electric machine stopped Master contactor is disconnection electromagnetic braking Start static state traction Restart the switch lock WRONG SETPOINT Await for traction micro controller control hydraulic function set is wrong which is detected from mian mircocontroller Valve pump motor Traction electric machine is stopped Master contactor is disconnection electromagnetic braking conti...

Page 41: ...he controller charging resistance damage C Controller internal charging circuit fault D Power unit of controller fault 1 VMN LOW Low voltage of motor Cause 1 Detection when start before closed main contactor switch with the software testing power bridge alternate closed above power MOS tube hope to increase phase voltage to power capacitor voltage value if phase voltage not increase will fault ala...

Page 42: ...ontactor detected the power bridge use soft close the top and bottom MOS tube alternately in the hope of reducing phase voltage to battery negative extreme value increase phase voltage reachs to battery positive value If phase voltage is not in conformity with the requirements will failure Solution ways The fault type has no relationship with external constitute change the controller 5 COIL SHORTE...

Page 43: ... shows failure Solution Check the connection between the mian contactor and power unit replace the main contactor 11 AUX DRIVER SHORTED Cause Drive circuit of electric braking coil shorted Solution A Detection of negative electromagnetic brake coil AMP saab type on the end of CNA 31 AMP seal type on the end of CNA 4 check if it has shorted with battery cathode or not B Controller driving circuit i...

Page 44: ...ts will have fault Solution ways It doesn t matter with the external constitute so need to change the logic card when ha s fault 15 LOGIC FAILTURE 3 Logic card fault 3 Reson circuital current of logic card is overtop overload resulted in hardware failure Solution ways It doesn t matter with the external constitute so need to change the logic card when has fault 16 STBY I HIGH quiescent current is ...

Page 45: ... of AMP saab type of CNA 7end and imput voltage of CNA 6 end AMP seal type connection check CNA 29 end and CNA 1 end If the input of the state is correct that may is the internal controller fault need to replace the controller 22 WATCHDOG watchdog fault Cause This is a safety detection implement the diagnosis between nternal main micrcontroller in logic card and micrcontroller Solution Alarm maybe...

Page 46: ... Traction stopped Start await orders traction Tracrion request INCORRECT START AL79 Startup sequence is wrong Traction stopped Start await orders traction Tracrion request VACC NOT OK Accelerator fault AL78 he accelerator values is higher than the set direction and permission switch disconnect Traction stopped Start await orders traction Tracrion request HIGH TEMPERATU RE AL62 controller temperatu...

Page 47: ...e procedure Stop pulling Await orders Request of traction PEDAL WIRE KO Footstep connection is wrong AL86 The accelerator potentiometer negative NPOT voltage range beyond less than 0 3 V or greater than 2 V Stop pulling Start Await orders traction Request of traction TILLER OPEN AL97 The handle switch broke and the truck in static maintenance time is more than 30 S Main contactor switch disconnect...

Page 48: ...s wrong also may be the logical card fault So when examined above may reasons then if any mistake replace the controller 5 VACC NOT OK Accelerator fault Cause Test after the request of electric lock closed or broke 20S When release the accelerator If accelerator value read from the TESTER menu higher than that read from the minimum voltage accelerator set 1 V fault alarm 6 HIGH TEMPERATURE Reason ...

Page 49: ...p with external constitute change the controller 11 CHECK UP NEED Sevice warming Reason It is time to examine and repair 12 DATA ACQUISITION Reason Current gain Solution ways Obtained 13 PEDAL WIRE KO REASON The connection of two input terminals of continuation detection potentiometer two input terminals connection of software which is testing accelerator potentiometer continuation Testing includi...

Page 50: ...aking Start static state Request of valve lift or traction PUMP VMN HIGH AL31 Awaiting for node Output voltage is on the high side of pump motor controllef by PWM Valve pump motor Traction electric machine stopped Master contactor is disconnection electromagnetic braking Lifting status Request of valve lift or traction ANALOG INPUT Awaiting for node Converter fault of microcontroller A D Valve pum...

Page 51: ...mp motor Tractionelectricmachine stopped Master contactor disconnection electromagneti sm brake continuation Restart the switch lock INPUT MISMATCH Awaiting for node Input tested from microcontroller figure imitate and encoder doesnot match with imput that corresponding with Main microcontroller Valve pump motor Tractionelectricmachine stopped Master contactor disconnection electromagneti sm brake...

Page 52: ...eti sm brake continuation Restart the switch lock HW FAULT Awaiting for node main microcontroller Tested from microcontroller can t stop the hydraulic functions Valve pump motor Tractionelectricmachine stopped Master contactor disconnection electromagneti sm brake Start test involved in solenoid valve static state test involved inhoist controller Restart the switch lock ...

Page 53: ...m can be used D The overall weight of the platform the load and the people should not over the half of the weight marked on the vehicle nameplate E The platform on the truck should not be used to transport people But if for the hand work the truck can be adjusted for operation in a small range 14 1 4 The use of the forklift 14 1 4 1 The change of the capacity and nameplate of the truck The truck i...

Page 54: ...and changing of the battery The battery charging station should set in the appointed area The charging station should prepare the equipment using for flushing and neutralizing the overflow electrolyte the fire control device the measure avoiding the truck damage the charging device and the adequacy ventilation facility blow away the fume off from the battery In the area of charging it is forbidden...

Page 55: ... fix firmly to prevent the accidental move vibration or slide On the gangplank or transition board should equipped handing or other available equipment to the effect of safety transport On the conditions of possible should set the fork hole or suspending ear for moving goods The gangplank or transition board should have non slip finishing On the both sides of the gangplank or transition board shou...

Page 56: ...ponents without the permission to influence the performance of the truck It is not allowed to install accessorial frame or handle on the steering wheel except the factory has installed it The driver should use the truck in the using range When operating high stacking job convey high and multi piece piled goods using driving type high lift truck it is necessary to use the truck with blind goods she...

Page 57: ...ile exactly If the mast can tilt backward the fork should tilt back properly to stabilize the load If it is reach truck it is necessary to draw back the fork After make sure the road is smooth descend the load from the pile The fork should be descended to the operation height and the mast tilt backward mostly After make sure the road is smooth drive the truck away placidly 14 2 3 Running driving r...

Page 58: ...ce between the vehicle and the platform or platform edge must keep at least a truck tyre width E When the gradient is more than 10 during the truck s running up and down the slope if possible when the lifted load truck and flat stacking truck except the side bearing load fork lift truck cross country fork lift truck stride truck and platform carrying vehicle moves the load surface must be in a upg...

Page 59: ...cessary to inspect the technical condition of the truck According to the different type of the truck should pay more attention to some special location for example fuel oil system alarm system power system brake steering equipment lighting wheel and air tire pressure namely gas filled type and lifting system including lifting chain wire rope limit switch and hydraulic cylinder If the truck is foun...

Page 60: ... measures to prevent open flame spark or electric arc Smoking is forbidden The tools and other metal substance should put far away from the top of the battery without cover The top of the battery should keep dry the connection terminal should keep clean wipe a little Vaseline and screw down correctly Without approval the battery of different voltage weight or size could not replace the former one ...

Page 61: ... containers or filling fuel into all the liquefied petroleum gas containers to see whether there is the following defective or damage A Dent scuffing flute B Damage of various valves or lever meters C Scraps in emergency valve D Damage or loss of emergency valve bonnet E Leakage at connection of valve and thread F Deterioration damage or loss of flexible seal at connections of gas filling or gas s...

Page 62: ... and repairing recording card Items Maintenance time Maintenance part Material used Maintenance personnel Remarks Customer advisement feedback Items Time occurred Trouble location Fault cause Trouble shooting Remarks ...

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Sovan's CBD25T, Operation Manual

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