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111

REV. 09/2016

SERVICE MANUAL - BATTERY

B

Battery Fault Analysis

Fault

Negative Phenomena

Cause

Handling Methods

Electrode
plate sulfation

1. Battery capacity drops
during normal discharge
2. Density drops to be lower
than normal value
3. Voltage drops quickly when
discharging
4. Start charging under high
voltage
5. Bubbles generated during
charging
6. Coarse crystallization of
PbSO4

1. Insuf

fi

cient initial charge

2. Long time of storage under
the state of discharge
3. Long-term insuf

fi

cient

charged
4. Electrolyte density is too high
5. Electrolyte level is too low,
the upper part of electrode
plate is exposed outside of
the electrolyte
6. Impure electrolyte
7. Internal short circuit

1. Over-discharge method
2. Repeated charging method
3. Water treatment method

Excessive
shedding
of active
substances

1. There is gray-brown
substance rising from the
bottom when charging
2. Battery capacity reduced

1. Brown precipitation is due to
excessive large charging
current
2. White sediment is due to
over-discharge
3. Battery electrolyte is impure

1. Clean up the precipitation
2. Adjust the density
3. Battery needs to be
replaced if necessary

Battery
overcharged

1. Color of battery

fi

lling cap

becomes yellow, and then
red
2. Battery casing deformation
3. Battery spacers
carbonization, deformation
4. Positive electrode corrosion,
broken
5. Electrode pole rubber
bushing raised, aged and
cracked
6. Frequent water-adding,
electrolytic turbidity during
charging
7. Evenly shedding of active
substances from electrode
plate
8. Positive electrode plate
detonation

1. Charger voltage and current
are set too high
2. Charging time is too long
3. Frequent charging
4. Less discharging, but much
charging
5. Charger failure

1. Adjust and repair the
charger
2. Adjust the charging system
3. Battery needs to be
replaced in severe situations

Battery Over-
discharge

1. Low static voltage
2. Electrolyte density is still
low after charging
3. Positive and negative
electrode plates curved or
fractured

1. Go on using the battery
despite of insuf

fi

cient charge

2. Battery pack short circuit
3. Small current long time
discharge

1. Supplementary charging
2. Repair the vehicle
3. Battery needs to be
replaced in severe situations

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Содержание EPT20-15ET

Страница 1: ...Service Manual Electric Pallet Truck EPT20 15ETL EPT20 15ET ...

Страница 2: ...Service Manual Electric Pallet Truck EPT20 15ETL EPT20 15ET ...

Страница 3: ...ve 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 latest versions of the manual please cont...

Страница 4: ...omplete 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 and i...

Страница 5: ... 1 2 Lifting Lowering Switch 21 3 1 3 Emergency Reverse Switch 21 3 1 4 Horn Switch 21 3 1 5 Emergency Stop Switch 22 3 1 6 Key Switch 22 3 1 7 Charge Gauge 22 3 1 8 LED Charging Indicator 22 3 1 9 Buzzer 23 3 1 10 Fuse 23 3 1 11 Controller 23 3 1 12 Charger 23 3 1 13 Lifting Limit Switch 24 3 1 14 Interlock Switch 24 3 1 15 Pump Motor 24 3 1 16 Gear Pump 24 3 1 17 Pump Contactor 25 3 1 18 Solenoi...

Страница 6: ... Causes 40 5 4 Drive Motor 41 5 4 1 Removal and Installation 41 5 4 2 Faults and Causes 41 5 4 3 Checking and Testing 42 5 5 Gearbox 43 5 5 1 Removal and Installation 43 5 5 2 Faults and Causes 43 6 OPERATING SYSTEM 45 6 1 Control Lever 47 6 2 Button Switch 47 6 2 1 Removal and Installation 47 6 2 2 Faults and Causes 48 6 2 3 Checking and Testing 48 6 2 4 Control Circuit Troubleshooting 49 6 3 Tra...

Страница 7: ... 64 7 6 2 Cylinder Installation Precautions 65 7 6 3 Removal and Installation 66 7 7 Hydraulic Troubleshooting 68 7 8 Hydraulic Symbol 69 8 ELECTRICAL SYSTEM 71 8 1 Controller 73 8 1 1 Removal and Installation 73 8 1 2 Controller Interface Function 73 8 2 Fuse 75 8 2 1 Location of Fuses 75 8 2 2 Checking and Testing 76 8 3 Key Switch 77 8 3 1 Removal and Installation 77 8 3 2 Faults and Causes 77 ...

Страница 8: ... 2 Connection Mode 82 8 8 3 Faults and Causes 82 8 8 4 Checking and Testing 82 8 8 5 Control Circuit Troubleshooting 83 8 9 Handheld Unit Optional 84 8 9 1 Handheld Unit Connection 84 8 9 2 Handheld Unit Main Menu 84 8 9 3 Parameter Settings 85 8 9 4 TESTER Menu 87 8 10 Controller Error Message 88 8 10 1 Traction Controller 88 8 11 Electrical Schematic Diagrams 91 8 12 Cable Wiring Diagrams 94 8 1...

Страница 9: ... 3 1 Daily Maintenance 108 B1 3 2 Weekly Maintenance 108 B1 3 3 Monthly Maintenance 109 B1 3 4 Care 109 B1 4 Storage 110 B1 5 Troubleshooting 110 B2 Maintenance free Battery 113 B2 1 Safety and Warnings 113 B2 2 Use of Battery 113 B2 2 1 Pre use Checks 113 B2 2 2 Discharging 113 B2 2 3 Charging 114 B2 3 Maintenance Care 114 C SCHEDULE 115 5 5 TABLE OF CONTENTS SECTION PAGE ...

Страница 10: ...REV 09 2016 TABLE OF CONTENTS ...

Страница 11: ...intenance underneath the vehicle make sure that the lifting 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 cond...

Страница 12: ...1 1 1 INFORMATION SPECIFICATIONS ...

Страница 13: ...2 NOTE ...

Страница 14: ... nxsp ep zl com Customer Components Warehouse Customer service to input into After sales System After sale Engineer to call back to confirm the accuracy of the information about the components Shipped within 24 hours Claim Form Customer service to input into After sales System After sale Engineer to call back to confirm about the specific fault information Within two business days after the mainte...

Страница 15: ...ame 1 Control Lever 2 Emergency Stop Switch 3 Charge Gauge 4 LED Charging Indicator 5 Key Switch 6 Upper Cover 7 Charging Plug No Name 8 Battery 9 Chassis 10 Balance Stand Caster Wheel 11 Drive Wheel 12 Lower Cover 13 Lift Cylinder 1 2 Introduction ...

Страница 16: ...ly be operated by single operator other personnel is forbidden from riding 1 3 Common Tools No Name Remark 1 Hex Wrench 2 14 One Set 2 Hex Head Socket Wrench 10 27 One Set 3 Phillips Screwdriver 2 One Piece 4 Slotted Screwdriver 2 One Piece 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 9 D...

Страница 17: ... 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...

Страница 18: ... 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 ...

Страница 19: ...REV 09 2016 INFORMATION SPECIFICATIONS 1 8 ...

Страница 20: ...9 2 2 MAINTENANCE ...

Страница 21: ...10 NOTE ...

Страница 22: ...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...

Страница 23: ...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...

Страница 24: ...urs 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 the position of various bearings for noise A Clean or add the gear grease A L Check the gearbox for abnormal noise or leaks A Check and lubricate t...

Страница 25: ...leaks A Check the hydraulic oil level A Clean or replace the hydraulic oil Replace after 100 hours of early operation Then replace once every 2000 hours Check the function of emergency pressure relief valve A Check and clean oil tank air filter A Replace the oil tank air filter and filter A Check the relief pressure A Breking System Check the braking functions of electromagnetic brake A Check the ...

Страница 26: ...ving parts of connecting rod mechanism A L Check the lifting and lowering speed A Other Check if the signs are clear and complete A Check the chassis for cracks or damages A Check the connections of bolts and nuts 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 ma...

Страница 27: ...ners 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 Sliding surface Hydraulic oil injection nozzle Gear oil injectio...

Страница 28: ...ydraulic System Low temperature anti wear hydraulic oil cold storage L HV32 B Multi purpose grease Polylub GA352P Appropriate amount Sliding surface See Table 2 3 C Grease MoS2 100 grams Gearbox Table 2 3 Sliding Surface Lubrication Table Code Position L1 Mounting Shaft L2 Steering Bearing L3 Drive Wheel L4 Long Shaft L5 Load Wheel ...

Страница 29: ...18 REV 09 2016 MAINTENANCE 2 ...

Страница 30: ...19 3 3 STRUCTURE FUNCTIONS ...

Страница 31: ...20 NOTE ...

Страница 32: ...rse switch is normally open When pressing the reverse switch is on after release the switch will automatically reset Note Unserviceable 3 1 4 Horn Switch Location control lever Function to press the horn Description the horn switch is normally open When pressing the horn switch is on after re lease the switch will automatically reset Note Unserviceable Travel Switch Lifting Lowering Switch Emergen...

Страница 33: ...can display three colors red yellow and green Note Unserviceable LED Charging Indicator Location electrical mounting plate Function to disconnect the circuit and switch off all electrical functions achieving emergency 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 ...

Страница 34: ...cation electrical mounting plate Function to control the truck through the signal input Description 24V operating voltage to control the circuit Note Unserviceable 3 1 12 Charger Location electrical mounting plate Function charge the battery Description 100V 240V operating voltage Note Unserviceable Buzzer Fuse Controller Charger Location electrical mounting plate Function overcurrent protection D...

Страница 35: ...e operated if the interlock switch is not closed Description to prevent misuse of truck Note Unserviceable Lifting Limit Switch Interlock Switch 3 1 15 Pump Motor 3 1 16 Gear Pump Location electrical mounting plate Function to provide power for gear pump for lifting the loading rack Description upon receiving the signal input by control switch traction controller to control the power transmission ...

Страница 36: ...al obtained by drive controller from lifting switch controls the ON OFF of pump contactor Note Unserviceable Pump Contactor Solenoid Valve 3 1 18 Solenoid Valve Location on valve body at pump and motor as sembly Function to realize the lowering of fork con troller gets signal from the lowering switch to control the absorption of solenoid valve forming a hydraulic circuit Description 24V operating ...

Страница 37: ...26 REV 09 2016 STRUCTURE FUNCTIONS 3 ...

Страница 38: ...27 4 4 CHASSIS SYSTEM ...

Страница 39: ...28 NOTE ...

Страница 40: ...he wheel bridge 1 with an ejector pin Turn the wheel bridge to vertical direction knock out the wheel pin shaft 3 from side and remove the load wheel and bearing assembly Remove the bearing 5 of load wheel 4 with hammer and jacking equipment Installation and Commissioning Install according to the reverse order of rem oval Run the truck to see if the load wheel is fun ctioning properly If there is ...

Страница 41: ...auses 1 Fault Bearing noise or jammed Cause Bearing fatigue damage or foreign 2 Fault Abnormal tyre wear cracking or degumming Cause Improper use CAUTION 4 2 Cover 4 2 1 Removal and Installation Removal Unscrew the two large flat head screws 1 and pull out the upper cover 2 Unscrew the six screws 3 with a wrench and remove the upper drive cover 4 and the lower drive cover 5 The covers are all made...

Страница 42: ...117 mm 4 3 2 Connecting Rod Adjustment Lift the vehicle carefully with lifting equipment through the lifting holes at at front and back Make sure the lifting equipment is solid and secure and the load capacity should be greater than the total weight of the vehicle Lifting height of not more than 400mm to prevent the hazards to the maintenance personnel working under the vehicle for connecting rod ...

Страница 43: ...ix the wheel bracket first Be sure to avoid the falling of wheel bracket during removal resulting in personal injury CAUTION Tap the coiled elastic cylinder 11 into the short axis 12 and tap the short axis 12 out from the side to separate the lower connecting rod with the bearing bridge Remove the circlip 8 from the holes at both sides of front chassis tap out the support shaft 7 and remove the lo...

Страница 44: ...33 5 5 DRIVE SYSTEM ...

Страница 45: ...34 NOTE ...

Страница 46: ...35 REV 09 2016 DRIVE SYSTEM 5 No Name 1 Drive Assembly 2 Electromagnetic Brakes 3 Gear Cover 4 Gear Case 5 Drive Wheel 6 Drive Motor Drive System ...

Страница 47: ...c brake When the truck is powered off the electromagnetic coil 6 doesn t absorb the pressure plate 8 the friction force generated between brake pads 2 pressure plate and friction plates 5 will prevent the drive motor from rotating thus to brake the vehicle No Name 1 Mounting screws 2 Brake pads 3 Brake gear 4 Dust cover 5 Friction plate 6 Electromagnetic coil 7 Spring 8 Pressure plate Unscrew the ...

Страница 48: ...er of rem oval When installing the brake gear 7 make sure the flat key is installed on the shaft of drive motor 8 CAUTION Adjustment The electromagnetic brake used in this series of truck is an air gap adjustment free brake After the normal installation is completed the air gap between electromagnetic coils and pressure plate should be standard gap distance As shown in the following table Air gap ...

Страница 49: ... pressure plate with feeler gauge measurement method is as shown in Figure 50208 Determine if the air gap is normal according to the gauge measurements As shown in the following table Air gap distance Judgment 0 2 0 4mm Normal 0 4mm The air gap is too large replace brake pads After a period of use brake pads of the electr omagnetic brake will wear After being worn too much the air gap between elec...

Страница 50: ...ooting Brake Control Circuit Figure 30207 Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 6 circuit circuit between brake and controller is conducted Check if 7 circuit circuit between brake and controller is conducted ...

Страница 51: ...uipment manufacturer to reach the original design performance of the truck 5 3 2 Faults and Causes 1 Fault Drive wheel slipping or jumping Cause Wear 2 Fault Drive wheel cracking or degumm ing Cause Improper use 3 Fault Vehicle sways while running Cause Drive wheel lock nut loosening CAUTION Installation Install according to the reverse order of rem oval Dismantle the motor cable mounting base 1 a...

Страница 52: ...ush By running the motor with repeated lifting letting the carbon brush to be fully running making its surface smooth to fit the rotor 5 4 2 Faults and Causes 1 Fault Motor does not rotate Cause a Negative electrode cable broken b Motor positive and negative electrode with loose terminals c Armature winding with broken circuits d Motor bearing damaged and blocked e Serious wearing of carbon brush ...

Страница 53: ...ck if the drive motor and appearance of cables are in good condition and if the plug connection is secure Check if the circuit is connected Carry out ON OFF test to motor positive and negative electrodes with a multimeter If connected the motor is normal If not connected 1 Broken circuits in rotor coils replace the motor 2 Carbon brush wearing move on to the next step Testing Replace the carbon br...

Страница 54: ...for specifica tion and filling amount CAUTION 5 5 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 nuts loosening b Support bearing damage c Foreign objects in gear oil ...

Страница 55: ...44 REV 09 2016 DRIVE SYSTEM 5 ...

Страница 56: ...45 6 6 OPERATING SYSTEM ...

Страница 57: ...46 NOTE ...

Страница 58: ...at makes the dynamic and static contacts ON or OFF to achieve the switching of circuits through push button drive mechanism In the electrical control circuits of this truck the push button switch is used for manual emitting of control signals to control the vehicle lifting lowering horn and emergency reverse By function Lifting Button Switch Lowering Button Switch Horn Button Switch Emergency Reve...

Страница 59: ...ng to the reverse order of rem oval Emergency Reverse Switch See Figure 30303 Remove pin 5 securing button and remove the emergency reverse button 1 and springs 2 from bracket 4 Remove pin 3 and remove the emergency reverse switch 6 Install according to the reverse order of rem oval Emergency Reverse Button 6 2 2 Faults and Causes 1 Fault Operate the push button switch but the vehicle responds wit...

Страница 60: ...push button switch at original position broken circuit press the button the circuit is conducted Horn Switch See Figure 30304 Emergency Reverse Switch See Figure 30308 Carry out ON OFF test to the circuit with a multimeter push button switch at original position 1 12 conducted 1 13 broken 1 12 broken 6 2 4 Control Circuit Troubleshooting Lifting Switch Control Circuit Figure 30305 Check if the cir...

Страница 61: ...noid Valve Key Switch Horn Switch Control Circuit Figure 30307 Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 1 circuit circuit between horn swit ch and key switch is conducted Check if 4 circuit circuit between horn swit ch and buzzer is conducted Key Switch Buzzer Buzzer Checks Energize the buzzer with a voltage of 24V Buzzer sounds it is working prop...

Страница 62: ...cannot go forward or backward Cause a Travel switch failure b Travel switch circuit not conducted 2 Fault Travel switch not operated the vehicle goes forward or backward automatically Cause Travel switch failure Checking Check if the appearance of travel switch and its wiring harness are in good condition and if the connectors are connected securely 6 3 3 Checking and Testing Testing Enter Monitor...

Страница 63: ...el switch Pin 11 24V Normal Pin 12 0V Normal Pin 22 0V 5V the maximum value is 4V 5V Normal Toggle the travel switch backward measure the voltage of pin 11 pin 12 and pin 22 of the travel switch Pin 11 0V Normal Pin 12 24V Normal Pin 22 0V 5V the maximum value is 4V 5V Normal 6 3 4 Control Circuit Troubleshooting Travel Switch Control Circuit Figure 30311 Check if the circuit is broken by using a ...

Страница 64: ...53 7 7 HYDRAULIC SYSTEM ...

Страница 65: ...54 NOTE ...

Страница 66: ...tem 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 the cylinder seals Hydraulic Oil Hydraulic oil for truck Specificatio...

Страница 67: ...56 REV 09 2016 HYDRAULIC SYSTEM 7 7 1 1 Hydraulic Schematic Diagram ...

Страница 68: ...ur bolts 2 with wrench and remove the electrical board assembly from the chassis Removal Installation Install according to the reverse order of rem oval When removing the tubing and pump and motor assembly the system will lose some hydraulic oil please refer to Section 2 2 3 for supplementary adding of hydraulic oil CAUTION Unscrew the two screws 3 with a wrench and remove the hydraulic station fr...

Страница 69: ...motor rotor are mated in place Rotate the motor around to make the end surface of motor be in full contact with valve block CAUTION Due to magnetic force the rotor and the stator may pull each other therefore when disman tling motor rotor do not hold your hand between the rotor and the stator to avoid pinch hazard WARNING Install according to the reverse order of rem oval When replacing the carbon...

Страница 70: ...d negative electrode with loose terminals and poor connection b Carbon brush wear and tear c Armature winding has circuit broken unit 4 Fault Motor with abnormal noise or vibration Cause a Uneven clearance between stator and rotor b Bearing failures c Loosening fixing screws on motor housing 5 Fault Motor smoking or burning smell Cause Stator winding short circuit motor burnt 6 Fault Excessive tem...

Страница 71: ...he contactor coil is powered off the magnetic force disappears the pressure plate is released along with the release of spring and the contact recovers normally opened con tact C and D disconnected so the circuit is disconnected 7 4 1 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 shaf...

Страница 72: ...tance Measurement Judgment Approx 22 Ω Normal 0 Ω Coil shorting replace the contactor Ω Coil breaking replace the contactor Energize the contactor coil between end point A and B 24V If the contact is not absorbed without the sound of absorption the contactor is having mechanical failure with its contact replace the contactor If the coil is normal move on to the next step 7 4 3 Control Circuit Trou...

Страница 73: ...enoid valve blocked by impurities c Spring deformation d Balancing hole blocked by impurities e High frequency of use service life has expired already 3 Fault Internal leakage Cause Damaged seals or spring deformations 4 Fault External leakage Cause Loose connections or damaged seals 5 Fault Noisy when energized Cause a Unstable supply voltage b Impurities on absorption surface or uneven surface o...

Страница 74: ...g for correct re assembly and wiring also check the oil mist spray orifice for blockage and if the lubricant is sufficient If the solenoid valve is found with the above mechanical failures it is recommended to re place the solenoid valve directly 7 5 3 Control Circuit Troubleshooting CAUTION Solenoid Valve Control Circuit Figure 30306 Check if the circuit is broken by using a multi meter Set the m...

Страница 75: ... 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 shocks Upon removal the damage to cylinder threads oil port threads cylinder cap threads piston rod surface and inner cylinder wal...

Страница 76: ...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 6 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 ...

Страница 77: ...he pin shaft 3 from the side and remove the cylinder Hydraulic oil may damage truck parts and cont aminate the environment When removing joints or tubings place a clean container under it for discharge of hydraulic oil CAUTION 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 CAUTION Lower ...

Страница 78: ...ide bush 8 from the cylinder tube 5 Pull out the piston rod 1 from the cylinder tube Remove the support ring 6 and seal 7 from the piston rod Clean with hydraulic oil of the same specifica tions 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 p...

Страница 79: ...place with new hydraulic oil 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...

Страница 80: ... valve Tank Pipe end above liquid level Check valve Filter Cylinder Single acting direction Service line Supply line or return line Relief valve Control line Drain line Throttle valve With pressure compensation device Connecting pipe Solenoid Valve Two way two pass Port Test port Motor Hydraulic pump 7 8 Hydraulic Symbol ...

Страница 81: ...70 REV 09 2016 HYDRAULIC SYSTEM 7 ...

Страница 82: ...71 8 8 ELECTRICAL SYSTEM ...

Страница 83: ...72 NOTE ...

Страница 84: ...ponding ports 8 1 1 Removal and Installation Remove the upper cover See Section 4 2 1 Remove the wiring harness and cables on the controller Unscrew the two screws 1 with a wrench and remove the controller 2 and cooling fin 3 Removal 8 1 2 Controller Interface Function Traction Controller 1212 J1 Interface Pin No Description J1 1 Pot wiper J1 2 J1 3 J1 4 Mode switch open M1 closed M2 J1 5 Keyswitc...

Страница 85: ...nterface J2 Interface Pin No Description J2 1 Rx J2 2 B J2 3 Tx Charge inhibit J2 4 Mode switch open M1 closed M2 J3 Interface J3 Interface Pin No Description J3 1 Positive of electromechanical brake coil J3 2 Negative of electromechanical brake coil Terminal stud Terminal stud Pin No Description M1 Negative of the motor M2 Positive of the motor B Batt B Batt ...

Страница 86: ...rn Failure Ο Normal 8 2 Fuse The entire vehicle is installed with two fuses altogether When there is fuse failure the truck may not be able to run properly due to that 8 2 1 Location of Fuses Fuse 1 installed on electrical mounting plate Fuse 2 installed on main harness Fuse position in electrical schematic diagram FUSE 2 10A FUSE 1 100A MOTOR P C CHARGER KEY SW INTERLOCK SW ...

Страница 87: ...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...

Страница 88: ...rs are connected securely 8 3 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 8 3 4 Control Circuit Troubleshooting Key Switch Control Circuit Figure 30517 Check if the circuit is broken by using a multi meter Set...

Страница 89: ...r to ON OFF Check if 0 1 9 8 circuit is conducted Remove the upper cover See Sention 4 2 Disconnect the charge gauge connector from main wiring harness Unscrew the nut and remove the charge gau ge from the mounting plate Removal Installation Install according to the reverse order of rem oval Charge gauge without timer Charge gauge with timer 8 4 2 Faults and Causes 1 Fault No display on the charge...

Страница 90: ...unting panel Installation Install according to the reverse order of rem oval 8 5 2 Faults and Causes 1 Fault No display from indicator Cause a Indicator failure b Indicator circuit not connected c Charger failure Checking Check if the appearance of LED charging indicator its wiring harness are in good con dition and if the connectors are connected securely 8 5 3 Checking and Testing Testing Check ...

Страница 91: ...ring harness are in good condition and if the connectors are connected securely Repeatedly press the limit switch to check if it can reset properly 8 6 3 Checking and Testing Check if the limit switch circuit is conducted Carry out ON OFF test to limit switch with a multimeter Reset the limit switch original position the circuit is connected press the limit switch the circuit is discon ducted Test...

Страница 92: ...tedly press the interlock switch to che ck if it can reset properly 8 7 3 Checking and Testing Enter Monitor Menu to check the status of the switch Inhibit press the interlock switch if the display does not change then it indicates the interlock switch or its circuit failure see Section 8 9 Check if the interlock switch circuit is condu cted Carry out ON OFF test to interlock switch with a multime...

Страница 93: ...d Cause a Speed mode switch failure b Speed mode switch with broken circuit 2 Fault When speed mode switch is activ ated the speed is not reduced Cause a Speed mode switch failure b Speed mode switch shorted short circuit 8 8 2 Connection Mode Speed mode switch has 3 terminals The switch can be switched between open and close by toggling the roller lever to achieve the control of connection and di...

Страница 94: ...ted Check the ON OFF normally closed NC terminal with a multimeter with handwheel at natural position Terminal 1 and 3 con ducted toggle the handwheel Terminal 1 and 3 not conducted Testing Enter Monitor Menu to check the status of the switch Mode Input press the switch if the display does not change then it indicates the switch or its circuit failure Speed Mode Switch Control Circuit Figure 10513...

Страница 95: ... will be flashing if the connection is successful The program mer automatically powers up and displays this screen while it loads information from the controller Once the programmer has upload ed the information from the controller it displays the Main Menu If the controller is not turned on when the pro grammer is connected you can power up the programmer by pressing the Power key the message No ...

Страница 96: ...off Decel 10 E Stop Decel 11 E Stop Pause 12 Soft Start 13 Gear Soften 14 Creep Speed 15 Soft Stop Speed 16 Speed Mode 1 Full speed Max Speed Min Speed Rev Max Speed Rev Min Speed Mode 2 Slow Max Speed Min Speed Rev Max Speed Rev Min Speed THROTTLE MENU Paramete Setting 1 Type 2 Neutral Input 3 PotHigh 4 PotLow 5 Neutral Deadband 6 Throttle Max 7 HPD 8 Speed Limit Pot 9 Throttle Map 10 Tremor Supp...

Страница 97: ...e Voltage 4 Start Charge Voltage 5 Reset Voltage 6 Discharge Factor 7 Charge Factor 8 Low BDI Level 9 Low BDI Max Speed 10 External Lift Lockout 11 Lift Lockout Enable 12 Lift Lockout Threshold 13 Lift Lockout Output Type COMPENSATION MENU Paramete Setting 1 IR Comp 2 Anti Rollback Comp EMERGENCY REVERSE MENU Paramete Setting 1 Speed 2 Time Limit 3 Decel Rate 4 Accel Rate 5 Max Braking Current 6 S...

Страница 98: ...e current capacity Mode Input Check the status of speed mode switch If the function is triggered properly the value will change Reverse Input Check the backward status of travel switch If the function is triggered properly the value will change Inhibit Check the status of interlock switch If the function is triggered properly the value will change Push Input Check the status of push switch If the ...

Страница 99: ...r under temperature cutback 1 Temperature 80 C or 10 C 2 Excessive load on vehicle 3 Operation in extreme environments 4 Electromagnetic brake not releasing 1 2 THROTTLE FAULT PotLow and or PotWiper out of range 1 Throttle input wire open or shorted 2 Throttle pot defective 3 W r o n g t h r o t t l e t y p e selected 1 3 SPEED POT FAULT speed limit pot wiper out of range 1 Speed limit pot wire s ...

Страница 100: ... driver On fault 1 Main contactor driver failed closed 3 1 WIRING FAULT HPD fault present 10 sec 1 Misadjusted throttle 2 Broken throttle pot or throttle mechanism 3 2 BRAKE ON FAULT brake On fault 1 Electromagnetic brake driver shorted 2 Electromagnetic brake coil open 3 3 PRECHARGE FAULT precharge fault 1 Brake driver shorted 2 Precharge circuit damaged 3 MOSFET failure 3 4 BRAKE OFF FAULT brake...

Страница 101: ...HARDWARE FAILSAFE motor voltage out of range 1 Motor voltage does not correspond to throttle request 2 Short in motor or in motor wiring 3 Controller failure 4 3 EE CHECKSUM FAULT EEPROM fault 1 EEPROM failure or fault 4 5 BATTERY DISCONNECT FAULT battery disconnected 1 Battery not connected 2 Poor connection to battery terminals ...

Страница 102: ...r Emergency Reverse External Control CHARGER LED E BRAKE Speed Mode SW Interlock SW LED CMD REV BELLY ACCEL CMD FWD REV POTLOW HORN E VALVE PUMP CONTACTOR FAN Lifting Limit SW Lifting SW Lifting SW Lowering SW Lowering SW Horn SW Key SW Fuse 10A Fuse 150A Pump Motor Pump Contactor Emergency SW ...

Страница 103: ...rse External Control CHARGER LED E BRAKE Speed Mode SW Interlock SW LED CMD REV BELLY ACCEL CMD FWD REV POTLOW HORN E VALVE PUMP CONTACTOR FAN Lifting Limit SW Lifting SW Lifting SW Lowering SW Lowering SW Horn SW Key SW Fuse 10A Fuse 150A Pump Motor Pump Contactor Emergency SW ...

Страница 104: ...Reverse Internal Control CHARGER LED E BRAKE Speed Mode SW Interlock SW CMD FWD REV POTLOW HORN E VALVE PUMP CONTACTOR FAN Lifting SW Lifting SW Lowering SW Lowering SW Horn SW Key SW Fuse 10A Fuse 150A Pump Motor Pump Contactor Emergency SW BELLY SW CMD Lifting Limit SW ...

Страница 105: ...V 09 2016 ELECTRICAL SYSYTEM 8 94 8 12 Cable Wiring Diagrams No Name 1 Cable C2 2 Power Cable BATT 3 Cable M2 4 Cable M1 5 Cable B No Name 6 Cable B 7 Pump Motor Cable PA 8 Pump Motor Cable PA 9 Cable C3 ...

Страница 106: ...ectors HORN BATT BATT PUMP CONTACTOR SOLENOID VALVE COIL MAIN WIRE HARNESS Interlock SW E BRAKE CHARGER FAN CONTROLLER LED LED KEY SW CHGRGE GAUGE SPEED MODE SW REVERSE SW POTENTIONMETER TRAVEL SW LIFT LOWER SW ELBOW WIRE HARNESS LIFTING LIMIT SW DRIVE WIRE HARNESS ...

Страница 107: ...REV 09 2016 ELECTRICAL SYSYTEM 8 96 ...

Страница 108: ...97 9 9 TROUBLESHOOTING ...

Страница 109: ...98 NOTE ...

Страница 110: ... Greater than 24V Normal Less than 24V Needs to be charged Enter Monitor Menu to check the battery voltage see Section 8 9 If the battery voltage is still abnormal after being charged open the battery compartment check the voltage of each battery and its connection circuit respectively CAUTION CAUTION i NOTE Identify if the battery voltage is normal according to the measured voltage As shown in th...

Страница 111: ...n the instrument see Section 8 10 1 Check if the interlock switch or the connection of its circuit is normal See Section 8 7 2 Electromagnetic brake and its connecting circuit see Section 5 2 3 Check the travel switch and its connection circuit see Section 6 3 4 Check the drive motor and its connection circuit see Section 5 3 5 Replace the controller 2 The vehicle can travel at low speed but canno...

Страница 112: ...tion 6 2 4 Check the lifting limit switch and its connection circuit see Section 8 6 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 see Section 2 2 3 3 Check the pipe and hydraulic components for oil leaks 4 Check the pump motor wiring 5 Check the cylinder for damage or de...

Страница 113: ...olenoid valve blocking b Valve body failure throttle valve failure or blocked 1 Wash or replace the solenoid spool see Section 7 5 2 Wash or replace the valve body 5 Unstable Lifting Lowering of Vehicle a Lifting mechanism loosening or wear b Poor lubrication of lifting mechanism 1 Check if the lifting mechanism is normal see Section 4 3 Other Failures 1 Horn does not sound a Horn switch or its ci...

Страница 114: ...103 APPENDIX ...

Страница 115: ...104 NOTE ...

Страница 116: ...105 B B SERVICE MANUAL BATTERY ...

Страница 117: ...106 NOTE ...

Страница 118: ...overflow Only distilled water can be added the adding of tap water or mineral water is prohibited As for the decrease of battery capacity or even damage to the battery due to failure to comply with the above provisions the quality assurance will automatically void As for failure to comply with instructions for use maintenance without using original parts user corruption or viola tion of provisions...

Страница 119: ...g is completed B1 2 4 Temperature Rated temperature of electrolyte is 30 C If the temperature is too high it will reduce the service life of the battery too low may reduce the battery capacity When the temperature reaches the limit temperature of 55 C it is prohibited to run the battery B1 3 1 Daily Maintenance B1 3 Maintenance Care Charge the discharged battery Visual inspection for excessive dir...

Страница 120: ...than 1 05 then that battery cell has been damaged and needs to be replaced And you can identify if the battery is fully discharged according to the specific gravity of battery electrolyte when the instrument alarms and identify if the capacity indicated on the instrument is accurate If there is fault please notify service personnel for repairs B1 3 4 Care Battery surface should be clean and dry to...

Страница 121: ...ufficient Battery Charge 1 Low static voltage 2 Low density cannot meet the requirements after being charged 3 Short working time 4 When running the instrume nt displays quick drop of capacity 1 Charger voltage and current are set too low 2 Insufficient initial charge 3 Charger failure 1 Adjust and repair the charger 2 Battery supplemental charge 3 Battery needs to be replaced in severe situations...

Страница 122: ...ver discharge 3 Battery electrolyte is impure 1 Clean up the precipitation 2 Adjust the density 3 Battery needs to be replaced if necessary Battery overcharged 1 Color of battery filling cap becomes yellow and then red 2 Battery casing deformation 3 Battery spacers carbonization deformation 4 Positive electrode corrosion broken 5 Electrode pole rubber bushing raised aged and cracked 6 Frequent wat...

Страница 123: ...cuit 3 Large current discharge 4 Poor wiring connection or disconnected 5 Electrode plate corrosion 1 Battery needs to be repaired 2 Battery needs to be replaced if necessary Battery Reverse Electrodes 1 Negative voltage values 2 Electrolyte density is lower than 1 20g cm3 after charging 3 Positive and negative electrode lugs colors of electrode plates are reversed Wrong connections of positive an...

Страница 124: ...ons for use maintenance without using origi nal parts user corruption or violation of provisions when adding electrolyte and other circumstances the quality assurance will automatically void B2 2 1 Pre use Checks Check if the fixing bolts on the bracket for the battery are tightened insecure installation may cause damage to the case due to the shock during the travel of the vehicle Metal objects s...

Страница 125: ...ing measures the charging must be stopped when the temperature reaches 45 degrees When the battery voltage remains constant for more than 2 hours and the load voltage of the battery is within the specified range between 20 8V 24 4V it indicates that the charging is completed Daily Maintenance Compared to lead acid batteries mainten ance free battery eliminates the maintenance to electrolyte B2 3 M...

Страница 126: ...115 C C SCHEDULE ...

Страница 127: ...116 NOTE ...

Страница 128: ...rator No Daily Check Items O K Remark Drive Wheel Load Wheel Casters Horn 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 ...

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