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184

REV. 07/2019

SERVICE MANUAL - BATTERY

Battery Fault Analysis

Fault

Negative Phenomena

Cause

Handling Methods

Battery Short
Circuit

1. Low static voltage below 2V

2. Electrolyte density is too low

3. High temperature during

charging

4. Truck is with short working

time

1. Electrode plate deformed and

short circuit

2. Spacer missing or broken

during assembly

3. Positive electrode active

substances shedding, short

circuit at bottom

Battery needs to be replaced

Broken

circuits

1. Abnormal and unstable

voltage upon external

connection with load

2. Current fails to input when

charging

1. Poor welding during assembly

of electrode pole or electrode

plate

2. External short circuit

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

and negative electrodes during

charging

1. Reverse charging is

allowable

2. Battery needs to be

replaced in severe situations

Battery Leaks 1. Filling hole leaks

2. Leaks at sealing seams of

tank and filling cap

3. Drainage

4. Marks of bumps on external

surface of tank

1. Tank, filling cap with poor

heat sealing

2. Electrode lug rubber ring

problems

3. Sealing compound cracked

4 External impact due to

negligence during use

1. Repair

2. Battery needs to be

replaced if necessary

Содержание LIST JX0

Страница 1: ...Service Manual JX0 Task Support Vehicle...

Страница 2: ...Service Manual Task Support Vehicle JX0...

Страница 3: ...r 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...

Страница 4: ...mplete 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 beca...

Страница 5: ...5 Storage Table Lowering Switch 24 3 1 6 Storage Table Lifting Switch 24 3 1 7 Charge Gauge 24 3 1 8 Horn 24 3 1 9 Tilt Buzzer optional 25 3 1 10 Tilt Buzzer optional 25 3 1 11 Door Safety Switch 25 3...

Страница 6: ...Installation 40 5 1 2 Faults and Causes 40 5 2 Electromagnetic Brakes 41 5 2 1 Removal and Installation 41 5 2 2 Faults and Causes 42 5 2 3 Checking and Testing 42 5 2 4 Control Circuit Troubleshootin...

Страница 7: ...s and Causes 58 6 3 3 Checking and Testing 58 6 3 4 Control Circuit Troubleshooting 59 6 4 Travel Switch 62 6 4 1 Removal and Installation 62 6 4 2 Faults and Causes 62 6 4 3 Checking and Testing 62 6...

Страница 8: ...llation 74 7 2 2 Component 74 7 3 Pump Motor 75 7 3 1 Removal and Installation 75 7 3 2 Faults and Causes 75 7 3 3 Checking and Testing 76 7 3 4 Control Circuit Troubleshooting 76 7 4 AUX Pump Motor 7...

Страница 9: ...4 2 Faults and Causes 103 8 4 3 Checking and Testing 104 8 4 4 Control Circuit Troubleshooting 104 8 5 Deadman Switch 106 8 5 1 Removal and Installation 107 8 5 2 Faults and Causes 107 8 5 3 Checking...

Страница 10: ...ng 116 8 12 TESTER Menu 118 8 13 A Handheld Unit Optional 125 8 13 1 Handheld Unit Connection 125 8 13 2 Handheld Unit Menu Options 125 8 13 B Handheld Unit Optional 127 8 13 1 Fault Detection 127 8 1...

Страница 11: ...Cylinder Installation 178 B SERVICE MANUAL BATTERY 179 B1 Lead acid Battery 181 B1 1 Safety and Warnings 181 B1 2 Use of Battery 181 B1 2 1 Pre use Checks 181 B1 2 2 Discharging 181 B1 2 3 Charging 1...

Страница 12: ...2019 TABLE OF CONTENTS B3 2 1 Pre use Checks 190 B2 2 2 Discharging 190 B2 2 3 Charging 190 B3 3 Maintenance Care 191 B3 4 Common problems and solutions 192 C SCHEDULE 192 7 6 TABLE OF CONTENTS SECTIO...

Страница 13: ...ntenance 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...

Страница 14: ...1 1 1 INFORMATION SPECIFICATIONS...

Страница 15: ...2 NOTE...

Страница 16: ...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...

Страница 17: ...hassis 2 Storage table 12 Load wheels 3 Lift mast 13 Lift platform 4 Additional storage table 14 Hydraulic pump 5 Drive wheel 15 Flash light 6 Controller 16 Safety Gates 7 Caster 17 Emergency operatio...

Страница 18: ...isconnects the supply current deactivates all electrical functions causing the truck to brake automatically 27 Travel switch Select the required driving direction and speed 28 Right dead man switch Ap...

Страница 19: ...y charging status 34 Emergency stop switch Disconnects the circuit all electrical functions are deactivated 35 Lowering button Lower the lift platform under cover only for service 36 Low control Coope...

Страница 20: ...ex Wrench 2 14 One Set 2 Hex Head Socket Wrench 8 24 One Set 3 Phillips Screwdriver 2 One Piece 4 Slotted Screwdriver 2 One Piece 5 Sockets and Knobs One Set 6 Circlip Pliers One for holes and one for...

Страница 21: ...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 Ta...

Страница 22: ...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...

Страница 23: ...10 2 2 MAINTENANCE...

Страница 24: ...11 NOTE...

Страница 25: ...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 ap...

Страница 26: ...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 150 At least once pe...

Страница 27: ...en the controllers and contactors A Check fault information records and operating hours A Power Supply Drive System Check the battery cables for damage and replace if necessary A Check the battery cha...

Страница 28: ...if there is damage A Check the cylinders for leaks A Check the cylinders for damages and check the fixation A Check the oil tank fixation and check for leaks A Check the aux pump motor and check for...

Страница 29: ...h grease A L Check and lubricate the rollers on mast and storage table A L Check the fixation of lift mast A Check the tubing on mast for connections and leaks A Check and lubricate the chains A L Che...

Страница 30: ...k the chassis for cracks or damages A Check the connections of bolts and nuts A Checking covering parts for damages A Check the casters for wear and cracks A Check if the optional features are functio...

Страница 31: ...n containers It is strictly forbidden to mix different types and specifications of lubricants with each other except for those can be mixed under clear statement The use and disposal of lubricants mus...

Страница 32: ...L HM46 See the table below Hydraulic System Low temperature anti wear hydraulic oil cold storage L HV32 B Multi purpose grease Polylub GA352P Appropriate amount Sliding surface See Table 2 4 C Grease...

Страница 33: ...MAINTENANCE 2 Table 2 4 Sliding Surface Lubrication Table Code Position L1 Steel channel and rollers L2 Steering gear L3 Large chain gear L4 Chains L5 Storage table rollers L6 Caster L7 Load wheels S...

Страница 34: ...21 3 3 STRUCTURE FUNCTIONS...

Страница 35: ...22 NOTE...

Страница 36: ...n under normal circumstances switch cover is at high position and the circuit is connected when pressing this switch the circuit is disconnected Note Unserviceable 3 1 3 Key Switch Location left contr...

Страница 37: ...d alarm through the operation to horn switch operation Description 24V operating voltage Note Unserviceable Location right control lever Function to lower the storage table Description the lowering sw...

Страница 38: ...oller and the drive controller will then control the buzzer to make sound alarm Description N A Note Unserviceable 3 1 11 Door Safety Switch Location on both left and right door column Function if the...

Страница 39: ...er be lifted Note Unserviceable 3 1 15 Speed Reduction Switch Location Right in front of the mast Function to limit the travel speed of forklift when the mast is lifted Description speed reduction swi...

Страница 40: ...ical mounting plate Function overcurrent protection Description fusing current is 200A Note Unserviceable DUALPMX HP Traction Controller EPS AC0 Controller Fuse 1 Location electrical mounting plate Fu...

Страница 41: ...re vehicle Description N A Note Unserviceable 3 1 23 AUX Pump Motor AUX pump Motor Location Under the storage table Function to provide pressure for hydraulic sys tem of the storage table Description...

Страница 42: ...ng pressure is 3 5 MPa Note Unserviceable 3 1 26 Deadman Switch Stepper Motor 3 1 27 Stepper Motor Location on the pedal cover Function when the foot switch is not pressed you cannot operate the truck...

Страница 43: ...erating voltage Note Unserviceable Location Rear frame Function When the truck is started the Blue lights will show Description 24V operating voltage Note Unserviceable Location Right in front of the...

Страница 44: ...ote Unserviceable Enable switch 3 1 32 Enable swtich Location left control lever Function Keep your hands on the operating position to operate normally Description 24V operating voltage Note Unservice...

Страница 45: ...32 4 4 CHASSIS SYSTEM...

Страница 46: ...33 NOTE...

Страница 47: ...under the chassis near load wheel make the load wheel off the ground When replacing wheels be sure that the truck won t tilt see Figure 50102 Unscrew the four screws 3 in baffle 10 and remove the baff...

Страница 48: ...h be in contact with the ground When the truck is running check if the three wheels are functioning properly After long time of use the drive wheel will wear and tear to certain level at this time adj...

Страница 49: ...utton 3 Figure50107 to lift mast to proper height Engage the emergency stop switch and turn off key switch Unscrew four screws 3 then remove the addtional storage table 2 Unscrew two screws 10 remove...

Страница 50: ...37 5 5 DRIVE SYSTEM...

Страница 51: ...38 NOTE...

Страница 52: ...19 DRIVE SYSTEM 5 No Name 1 Drive Wheel 2 Large Chain gear 3 Chain 4 Horn 5 Proximity Switch 6 Chain gear No Name 6 Chain Gear 7 Steering Motor 8 Speed Encoder 9 Encoder 10 Electromagnetic brakes 11 D...

Страница 53: ...inor wear on a regular basis or replace the caster with heavy wear Quality of tyres directly affects the stability and driving performance of the device If you need to replace the factory fitted tyres...

Страница 54: ...ake gear 4 Dust cover 5 Friction plate 6 Electromagnetic coil 7 Spring 8 Pressure plate 5 2 1 Removal and Installation Removal The brake is installed on the drive motor See Figure 30204 Switch off the...

Страница 55: ...ck 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...

Страница 56: ...in the air gap that may affect the absorption or bouncing off of the pressure plates Spring Checks Deformation or foreign bodies stuck in the spring may affect the normal absorption of pressure plates...

Страница 57: ...ipment 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 Im...

Страница 58: ...sh 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 Nega...

Страница 59: ...sitive 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 Te...

Страница 60: ...ove the speed encoder and check if its sensing surface is parallel to the round section of magnet Check if the connection between 30 and 31 is reversed If the two circuits are connected reversely the...

Страница 61: ...e proximity switch into the mounting hole on the plate Make sure that Lock Washer 2 Figure 50219 has been mounted 5 6 Gearbox 5 6 1 Removal and Installation See Section 5 3 1 Please add gear oil to th...

Страница 62: ...ring gear to be between 1 2 mm Turn the key switch on and pull the emergen cy stop switch the system will carry out self test positioning to the position of drive wheel The truck starts properly instr...

Страница 63: ...n induction state LED is lit the switch has been damaged please replace if there is no voltage move on to the next step Touch the inductive surface with an iron sheet to make it trigger signals If the...

Страница 64: ...23 and remove plate 8 Unscrew one screws 5 Figure 50223 to pull out gear 2 and steering motor 1 Steering motor 7 Figure 50201 is mounted on the drive mounting base Removal 5 8 2 Faults and Causes 1 Fa...

Страница 65: ...Cause Stator winding short circuit motor burnt 6 Fault Excessive temperature rise Cause a Stator winding short circuit b Motor positive and negative electrodes with surface oxidation resistance incre...

Страница 66: ...turning slow Cause Speed encoder or its circuit failure 5 9 3 Checking and Testing Checking Check if the speed encoder and the appear ance of cables are in good condition and if the plug connection is...

Страница 67: ...4 Control Circuit Troubleshooting Control Circuit Figure 50226 Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 90 93 94 95 circuit circuit between speed en...

Страница 68: ...55 6 6 OPERATING SYSTEM...

Страница 69: ...56 NOTE...

Страница 70: ...al When removing or installing please pay attent ion to protect the cables from being damaged 6 2 Right Control Assembly Removal Installation Install according to the reverse order of rem oval When re...

Страница 71: ...ircuit press the button key switch to ON emerg ency stop switch to Pulled out status the circuit is conducted There are two ways to test it Press the lowering button if the sixteenth grid is not brigh...

Страница 72: ...eter to ON OFF Check if 21 circuit circuit between lifting button and controller is conducted Check if 61 circuit circuit between lifting button and controller is conducted Platform Lowering Button Co...

Страница 73: ...ter Set the multimeter to ON OFF Check if 21 65 circuit circuit between lower ing button and controller is conducted Storage Table Lowering Button Control Circuit Figure 50307 Check if the circuit is...

Страница 74: ...nds the horn is working properly Horn does not sound horn failure needs to be replaced Set the multimeter to ON OFF Check if 21 14 circuit circuit between lower ing button and controller is conducted...

Страница 75: ...ult Travel switch not operated the vehicle goes forward or backward automatically Cause Travel switch failure Enter TESTER Menu to check the status of the switches BACKWARD SWITCH toggle the switch ba...

Страница 76: ...cuit Troubleshooting Enable Switch Left hand of steering wheel Control Circuit Figure 50310 Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 3 106 18 circuit...

Страница 77: ...uit Troubleshooting Proximity Switch Control Circuit Right hand Figure 50309 Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 3 107 18 circuit circuit betwee...

Страница 78: ...motor and steering wheel is secure and if there is loosening 6 6 3 Checking and Testing STEPPER MOTOR turn the steering wheel if the voltage display is always 0 it indicates that the stepper motor ha...

Страница 79: ...arance of key switch its wiring harness are in good condition and if the connectors are connected securely 6 7 3 Checking and Testing Testing Check if the key switch circuit is conducted Carry out ON...

Страница 80: ...short circuit Checking Check if the appearance of emergency switch its wiring harness are in good condition and if the connectors are connected securely 6 8 3 Checking and Testing Testing Check if the...

Страница 81: ...nting plate Removal Installation Install according to the reverse order of rem oval 6 9 2 Faults and Causes 1 Fault No display on the charge gauge Cause a Charge gauge failure b Charge gauge circuit n...

Страница 82: ...lectrical Schematic Diagrams Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 3 18 50 51circuit is conducted 11 right hand enable switch 12 aux lift switch 1...

Страница 83: ...70 7 7 HYDRAULIC SYSTEM...

Страница 84: ...71 NOTE...

Страница 85: ...ic oil is becoming less please tho roughly check the hydraulic system for leaks Disassembly of cylinder needs to be perfor med in a clean environment Before removing the cylinder the stains on the cyl...

Страница 86: ...73 REV 07 2019 HYDRAULIC SYSTEM 7 7 1 1 Hydraulic Schematic Diagram...

Страница 87: ...e 1 see Figure 50403 Unscrew the direct joint between tubing and hydraulic station with a wrench and remove the tubing 2 Unscrew the two bolts 3 and remove the hydraulic assembly Removal Installation...

Страница 88: ...ck 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 WARNI...

Страница 89: ...pump 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...

Страница 90: ...n 4 3 1 Remove the bottom circle 1 with circlip pliers knock out shaft 6 remove the aux pump motor Install according to the reverse order of rem oval Installation 1 Fault Motor does not rotate Cause a...

Страница 91: ...otor Control Circuit Figure 50406 Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if circuit circuit between motor and controller is conducted Check if aux mot...

Страница 92: ...olenoid 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...

Страница 93: ...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...

Страница 94: ...not hammer forcefully it such case cannot be avoided please lay a copper rod to avoid damage to the parts special tools must be used for the parts having such requirements do not hammer forcefully or...

Страница 95: ...tention 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 Installa...

Страница 96: ...l Press the lift button 2 Figure50107 and low control button 3 Figure50107 to lift mast to proper height Engage the emergency stop switch and turn off key switch Remove the rear cover see section 4 3...

Страница 97: ...lace 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...

Страница 98: ...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 com...

Страница 99: ...86 8 8 ELECTRICAL SYSTEM...

Страница 100: ...87 NOTE...

Страница 101: ...switch Gate interlock switch Inclination sensor switch Deadman interlock switch deadman switch Slack chain switch bule light Flash light button switch etc Fuse 1 Control Function Module Diagram The co...

Страница 102: ...ack of controller Place the controller onto the electrical moun ting plate tighten the four screws with a wrench Plug the wiring harness and cables into cor responding ports 8 1 1 Removal and Installa...

Страница 103: ...controller TILLER input A 2 PEB Positive of the electromechanical brake coil For 24V version only it passes through an High Side Driver A 3 PEV Positive supply for electrovalves EV1 EV2 EV3 EV4 EV5 E...

Страница 104: ...ch quick inversion function is activated Active high A 8 PPOT Positive supply for external device 12 5V 150mA maximum A 9 EV 1 Positive supply for external device 12 5V 150mA maximum A 10 KEY Input of...

Страница 105: ...put is activated A 20 DI6 Input of the switch DI1 The input is activated when it is connected to Batt The default function is the controller DESCENT enable input A 21 DI12 CPOT4 Input of the switch DI...

Страница 106: ...used as potentiometer negative reference Using this input as NPOT the diagnosis PEDAL WIRE KO is implemented A 31 DI4 Input of the switch DI4 The input is activated when it is connected to Batt The de...

Страница 107: ...Right Limit Switch RLS A 4 NK1 Safety Switch Lower Voltage Point A 5 K1 Safety Switch Higher Voltage Point A 6 CANL Can Bus Low A 7 KEY Key in 24 36 Vbatt A 8 CPOC2 QL 2nd SP POT Wiper or Stepper Mot...

Страница 108: ...VDC Encoder Positive Supply B 5 PPOC Twin SP POT Positive Supply 5 Vdc B 6 CPOT FB POT Wiper B 7 CHB Encoder Channel B B 8 CHA Encoder Channel A C Interface handheld unit communication interface Pin N...

Страница 109: ...5 DI5 Fifth digital input A 6 DI6 Sixth digital input A 7 DI7 Seventh digital input A 8 DI8 Eighth digital input A 9 PPOT Positive of AI1 AI2 AI3 AI4 AI5 AI6 A 10 AI2 Second analog input A 11 AI3 Thir...

Страница 110: ...t circuit to CNA 14 B 6 SAS Internal connected to DI1 with a 100 resistance C Interface Pin No Signal Name Description C 1 DI9 Ninth digital input C 2 AI1 First analog input C 3 NPOT Negative of analo...

Страница 111: ...Gauge 6 Horn 7 Flash Light 8 Blue Light 9 Lowering flash light Failure Normal 8 2 Fuse The entire vehicle is installed with three fuses altogether When there is fuse failure the truck may not be able...

Страница 112: ...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 anoth...

Страница 113: ...ve the cables and wiring harness on the main contactor and remove the main contactor from the electrical mounting plate Unscrew the two fastening screws 4 with a Phillips screwdriver and remove the to...

Страница 114: ...e multimeter As shown in the following table Resistance Measurement Judgment Approx 52 Normal 0 Coil shorting replace the contactor Coil breaking replace the contactor Contact Checks Check if the surf...

Страница 115: ...he back cover 1 and side cover 4 Limit switch is variable roller lever type By function Slack Chain Switch Lifting Limit Switch Speed Reduction Switch 1 Stage Speed Reduction Switch 2 Stage Speed Redu...

Страница 116: ...tch is not reset and always in a closed state 2 Fault When 2 stage speed reduction switch is activated the speed is not reduced Cause 2 stage speed reduction switch is not reset and always in a closed...

Страница 117: ...h see Section 8 13 Check if the switches circuits are conducted Carry out ON OFF test to switches with a multimeter Reset the switches original position the circuit is disconnected Press the switches...

Страница 118: ...F Check if 3 84 85 circuit circuit between Slack chain switch and controller is conducted Lifting Limit Switch and speed reduction Switch Control Circuit Figure 50518 Check if the circuit is broken by...

Страница 119: ...Safety Switch Control Circuit Figure 50519 Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 3 126 108 circuit circuit between switches and controller is con...

Страница 120: ...lift button 2 Figure50107 and low control button 3 Figure50107 to lift mast to proper height Engage the emergency stop switch and turn off key switch Disconnect the foot switch connector 1 8 5 2 Fault...

Страница 121: ...e then it indicates the foot switch or its circuit failure see Section 8 13 Check if the foot switch circuit is conducted Carry out ON OFF test to foot switch with a multimeter Reset the foot switch o...

Страница 122: ...t switch is mounted on the chassis bottom plate underneath the rear cover See Section 3 1 11 Installation Install according to the reverse order of rem oval 8 6 2 Faults and Causes 1 Fault Under lifti...

Страница 123: ...icle starts the warn ing light won t light up Cause a Warning light failure b Warning light circuit not condu cted Checking Check if the appearance of warning light and its wiring harness are in good...

Страница 124: ...circuit not condu cted Checking Check if the appearance of Flash light and its wiring harness are in good condition and if the connectors are connected securely 8 8 3 Checking and Testing Check if wa...

Страница 125: ...ting 8 9 4 Control Circuit Troubleshooting Pressure sensitive switch Control Circuit Figure 50527 Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 125 202 23...

Страница 126: ...rated but the vehicle the vehicle can lift and lower Cause Push button switch failure Button enable switch control Button Switch lift and lower 1 Fault Operate the push button switch but the vehicle r...

Страница 127: ...button switch at original position broken circuit press the button key switch to ON emerg ency stop switch to Pulled out status the circuit is conducted Enter TESTER Menu to check the status of the s...

Страница 128: ...and controller is conducted Check if 124 18 circuit circuit between lifting button and GND is conducted Platform lowering Button Control Circuit Figure 50531 Check if the circuit is broken by using a...

Страница 129: ...ghting Charger failure Installation Install according to the reverse order of rem oval 8 11 2 Faults and Causes 1 Fault No display from indicator Cause a Indicator failure b Indicator circuit not conn...

Страница 130: ...REV 07 2019 ELECTRICAL SYSTEM 8 117 operational...

Страница 131: ...brake coil OUTP GATE ALARM It is the status of the EV output for gate alarm OFF GND OUTPUT LED1 NONE OFF GND OUTPUT LED2 NONE OFF GND OUTP EV3 HORN It is the status of the EV output for horn OFF GND S...

Страница 132: ...f horn switch on tiller controller OFF GND TDI13 SW NONE OFF GND TDI12 SW NONE OFF GND TDI11 SW NONE OFF GND TDI10 SW NONE OFF GND TDI9 AUX LOW SW It is the status of aux lower switch on tiller contro...

Страница 133: ...DI6 LIFT STOP SW It is the status of lift stop switch OFF GND DI5 TR CTB 2 SW It is the status of cutback 2 switch OFF GND DI4 BACKWARD SW It is the status of backward switch OFF GND DI3 FORWARD SW It...

Страница 134: ...ENT DC current in the traction motor Display the current value A BATTERY CHARGE It shows the residual charge of the battery as a percentage of the full charge level Display the current capacity BATTER...

Страница 135: ...eed of steering motor Display the current frequency Hz MOTOR CURRENT Check the current of steering motor Display the current value A MOTOR VOLTAGE Check the voltage of steering motor Display the curre...

Страница 136: ...e display of handheld unit will be flashing if the connection is successful the handheld unit display will be flashing if failed the display will have no display check if the circuit connection is nor...

Страница 137: ...ing OK select ENTER the menu PARAMETER CHANGE parameter change TESTER vehicle running test ALARMS error alrms PROGRAM VACC accelerator match SAVE PARAMETERS read parameter RESTORE PARAMETERS write par...

Страница 138: ...button 1 to find the TESTER display 4 Press the ENTER button 3 to view the tests 5 To verify various switch functions locate the switch on the display and then operate that funct ion to verify operat...

Страница 139: ...he desired value 7 Press the OUT button 4 to exit the options Press the Enter button to confirm the exit 8 13 4 Adjustments To change an adjustment proceed as follows and refer to Table 4 3 1 Connect...

Страница 140: ...Press the ENTER button 3 again to view the pa rameters 4 Press the ROLL down 2 or the ROLL up button 1 to find the parameter to be changed 5 Press the SET up button 5 or the SET down but ton 6 until...

Страница 141: ...oad An overcurrent condition is triggered even if the power bridge is not driven The failure lies in the controller hardware Replace the controller 18 LOGIC FAILURE 2 Fault in the hardware section of...

Страница 142: ...PWM applied The pump motor output is higher than expected considering the PWM applied Motor internal connections If motor windings cables have leakages towards truck frame If no problem are found on...

Страница 143: ...check motor internal connections ohmic continuity motor power cables connections if the motor connections are OK the problem is inside the controller Replace it B If the alarm occurs while the motor...

Страница 144: ...ce across line contactor power terminals if the alarm disappears it means that the charging resistance is damaged 3 The charging circuit has a failure or there is a problem in the power section Replac...

Страница 145: ...the thickness of the frame and the planarity and roughness of its surface If the alarm occurs when the controller is cold the possible reasons are a thermal sensor failure or a failure in the logic b...

Страница 146: ...he load The device itself or its driver circuit is damaged This type of fault is not related to external components replace the logic board 78 VACC NOT OK At key on and immediately after that the trav...

Страница 147: ...m occrus do activation with EP TOOLS 143 WRONG PASSWORD if the EP PASSWORD function is active but haven t enter the correct password the alarm occurs 1 enter the correct password 2 disable the passwor...

Страница 148: ...the battery charge level 2 check if the battery is ok 3 replace the BMS 151 EP BMS TRAC STOP if the battery charge level is to low the BMS require the controller to stop the traction function this al...

Страница 149: ...coder the failure is in the controller 178 MOTOR TEMP STOP The temperature sensor has overtaken the threshold defined by STOP MOTOR TEMP 1 Check the temperature read by the thermal sensor inside the m...

Страница 150: ...e value before switching the LC on If the voltage is different it could be due to the fact that the motor connected to P is not still For this reason the software waits 30 seconds for the voltage to b...

Страница 151: ...WAIT MOTOR STILL warning 2 Motor internal connections 3 Motor power cables connections 4 Motor leakage to truck frame 5 If the motor connections are ok the problem is inside the controller it is nece...

Страница 152: ...set as 1 TILLER SEAT 1 Verify that the parameter POSITIVE E B is set in accordance with the actual coil positive supply see paragraph 8 2 5 2 In case no failures problems have been found the problem...

Страница 153: ...tore and save again the parameters list 199 PARAM TRANSFER Master uC is transferring parameters to the supervisor Wait until the end of the procedure If the alarm remains longer re cycle the key 200 V...

Страница 154: ...fore closing the LC the software checks the power bridge voltage without driving it The software expects the voltage to be in a steady state value If it is too high this alarm occurs The hexadecimal v...

Страница 155: ...h the key off and then on again if the alarm is still present replace the logic board 211 STALL ROTOR The traction rotor is stuck or the encoder signal is not correctly received by the controller 1 Ch...

Страница 156: ...sk for assistance to EP in order to verify that the software diagnoses are in accordance with the type of coil employed If the problem is not solved it could be necessary to replace the controller 216...

Страница 157: ...ve by mistake 2 Check the SR HB input state through the TESTER function 3 Check the wirings 4 Check if there are failures in the microswitches 5 If the problem is not solved replace the logic board 22...

Страница 158: ...ed to enable and disable the power bridge or the LC driver output A12 is found to be faulty The hexadecimal value XX facilitates EP technicians debugging the problem This type of fault is related to i...

Страница 159: ...s necessary to replace the controller 17 LOGIC FAILURE 3 This alarm occurs in the rest state if the output of the voltage amplifier of the phase Vu Vw have a drift larger than 0 25 V It is necessary t...

Страница 160: ...motor higher than 150 degree still with DIAG MOTOR TEMP to ON Check the thermal sensor in the motor is right working If it is improve the cooling of the motor 70 HIGH CURRENT This alarm occurs if the...

Страница 161: ...pot 85 STEER HAZARD This is just a warning to inform that the steering controller is limiting the angle in the steering direction No speed reduction occurs on the traction 218 CLOCK PAL NOT OK The ma...

Страница 162: ...sign of the stepper motor speed this alarm occurs Closed loop application only If the slave uC detects the stator voltage phasor rotates in the opposite direction respect to the commanded position th...

Страница 163: ...an input for the slave uC SYNC When the slave uC detects no edge for more than 100 msec on this input this alarm occurs This is just a watch dog function when the main uC does not execute the code cyc...

Страница 164: ...It occurs at the initial alignment if the straight ahead condition is not matched within 6sec Throughout this 6 secs delay the steer is not activated yet the safety relays are open and the traction is...

Страница 165: ...e acquiring the motor resistance or when adjusting the parameters to compensate for the gain of the current amplifiers maximum current factory adjusted Recycle the key 244 GAIN EEPROM KO The parameter...

Страница 166: ...Vdc to 5 5 Vdc Check the connections of the potentiometer This alarm occurs when one connection of the command potentiometer is broken 249 F B OUT OF RANGE This alarm occurs for a fault on the feedba...

Страница 167: ...ler 254 KS CLOSED This alarm occurs if the main uC detects the safety contact of the slave uC closed prior to be commanded This alarm occurs if the connection CNA 4 NK1 is around a voltage of 12 Vdc w...

Страница 168: ...Cable Wiring Diagrams No Name 1 Lithium battery 2 B Cable 3 B Cable 4 Pump Power Cable 5 Pump Power Cable 6 E F Cable No Name 7 EPS Cable 8 EPS Cable 9 Steering Motor Cable V 10 Steering Motor Cable...

Страница 169: ...REV 07 2019 ELECTRICAL SYSTEM 8 156 8 16 Electrical Schematic Diagrams...

Страница 170: ...REV 07 2019 ELECTRICAL SYSTEM 8 157...

Страница 171: ...REV 07 2019 ELECTRICAL SYSTEM 8 158 8 17 Wiring Harness and Connectors TO Handheld unit communication cable...

Страница 172: ...REV 07 2019 ELECTRICAL SYSTEM 8 159...

Страница 173: ...160 9 9 TROUBLESHOOTING...

Страница 174: ...161 NOTE...

Страница 175: ...rror carry out troubleshooting according to the fault code information see Section 8 13 1 Check if the foot switch and door safety switch or the con nection of its circuit is normal See Section 8 5 an...

Страница 176: ...s normal See Section 8 5 and Section 8 4 2 Check the pump motor and its connection circuit see Section 7 3 3 Check the lifting switch and its connection circuit see Section 6 3 4 Check the lifting lim...

Страница 177: ...relief valve pressure or blocked 1 Refer to the rated capacity marked on the nameplate 2 Check the pipe and hydraulic components for oil leaks 3 Wash or replace the valve body see Section 7 2 2 6 Slow...

Страница 178: ...tor or its connection circuit see Section 5 7 4 Check the proximity switch or its connection circuit see Section 5 6 5 Replace the controller Other Failures 1 Blue lights do not light a Light failure...

Страница 179: ...166 APPENDIX...

Страница 180: ...167 NOTE...

Страница 181: ...168 A A SERVICE MANUAL MAST...

Страница 182: ...169 NOTE...

Страница 183: ...r mast Unscrew two bolts 12 remove the plate 11 chain wheel 10 and roller 2 Remove left drag chain see A1 2 1 1 Remove left chain1 from the mast Remove right chain1 from the mast in the same way Press...

Страница 184: ...f key switch Unscrew the twenty fastening screws 3 Figure 50602 and remove the back cover 1 Figure 50602 and side cover 4 Figure 50602 Remove the rear cover see section 4 3 1 Remove cotter pin 5 Figur...

Страница 185: ...172 REV 07 2019 SERVICE MANUAL MAST A...

Страница 186: ...two blot 13 Figure 50603 remove the plate 14 and chain wheel 15 Unscrew two screws 9 remove the plate 12 Disconnect the upper connector 10 of left drag chain 11 Disconnect the bottom connector of lef...

Страница 187: ...174 REV 07 2019 SERVICE MANUAL MAST A...

Страница 188: ...mast 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 Please fix the cylind...

Страница 189: ...e 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 pr...

Страница 190: ...177 B B SERVICE MANUAL BATTERY...

Страница 191: ...178 NOTE...

Страница 192: ...verflow 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...

Страница 193: ...mpleted 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 tempe...

Страница 194: ...han 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 inst...

Страница 195: ...fficient 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 Charge...

Страница 196: ...er 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 ye...

Страница 197: ...uit 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...

Страница 198: ...ns 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...

Страница 199: ...ng 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 speci...

Страница 200: ...re source heat source where the temperature exceeds the safety range When the battery is low please charge the battery in time to avoid over discharge the replaced battery should also be charged in ti...

Страница 201: ...otal voltage the maximum and minimum cell voltages power temperature charging current and other information pay particular attention to the charging current and the maximum and minimum cell voltages a...

Страница 202: ...f discharging such as the voltage difference of the battery The normal charging temperature range of the battery is 0 C 45 C The voltage difference between the maximum and minimum cell voltages during...

Страница 203: ...seness cracks cracks in the insulation layer burn marks etc of the battery s pole pressing bolts conductive strips main circuit wires and connectors are found before and during the installation stop u...

Страница 204: ...191 C C SCHEDULE...

Страница 205: ...192 NOTE...

Страница 206: ...ht lowering flash light etc Forward Reverse control functions Steering control functions Lift limit switch Slack chain switch door safety switch deadman switch tilt switch pressure sensitive switch fu...

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