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REV. 09/2020

BRAKE SYSTEM

6.2 Service Brake

6.2.1 Removal and Installation
Removal

Turn off the truck power and remove the key;

Remove the cushion and open the floorboard;

Loosen the nut (1) and remove the two tubings

on the brake master pump (5);

Remove the cotter pin (2) on the pin shaft (3),

then knock out the pin shaft (3) from side;

Unscrew the two bolts (4), then remove the

brake master pump (5) from the chassis.

Install according to the reverse order of rem-

oval.

Installation

Fig3132-10002SM

When removing the tubing and brake pump, the

system will lose some brake fluid, please refer

Section 2.2.3

for supplementary adding of

brake fluid.

CAUTION

After replacing the brake master cylinder or

tubings, the air within the entire brake pipeline

must be discharged.

6.2.2 Air Discharge / Adding Brake Fluid

-
-

Fill the oil cup with brake fluid;

Press the brake pedal repeatedly until the

stepping pressure becomes heavy;

CAUTION

Open the vent on brake cylinder of drum

brake, press the brake pedal pressure to the

bottom, discharge the residual air from the

vent through high level of brake fluid;

When there is flow of fluid running out of

the vent, it indicates that the air discharge is

completed, release the brake pedal and close

the vent.

During the entire process of operation, there

must always be brake fluid in the oil cup.

Add brake fluid into the oil cup until it fills 2/3

of the cup. Please apply as specified (see

Section 2.2.3

for specifications).

CAUTION

7. HYDRAULIC SYSTEM

Содержание ICE301B

Страница 1: ...Service Manual Electric Forklift Truck ICE301B ...

Страница 2: ...re 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 contact our service department or dealer to obtain Service Manual Electric Forklift Truck ICE301B ...

Страница 3: ...sing may be slightly different from what has been described in this Manual therefore we must reserve the right to modify the appearance configuration and technical specifications If you have any questions please contact our sales department or dealer i Copyright Copyright of Service Manual belongs to EP Equipment Co Ltd TABLE OF CONTENTS 1 INFORMATION SPECIFICATIONS 1 1 1 After sales Service Platf...

Страница 4: ...0 8 1 Wide View Two stage Mast 72 8 1 1 Removal and Installation 72 8 1 2 Lifting Chains 73 8 1 2 1 Chain Adjustment 73 8 1 2 2 Chain Replacement 74 8 1 3 Mast Tubing 75 8 1 4 Lift Cylinder 76 8 1 4 1 Cylinder Removal with mast on the vehicle 76 8 1 4 2 Cylinder Maintenance 77 8 1 4 3 Cylinder Installation 77 8 1 5 Built in Side Shifter 78 8 1 5 1 Side Shifter Removal 78 8 1 5 2 Side Shifter Insta...

Страница 5: ...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 condition All nameplates and safety signs on the truck should be cleaned r...

Страница 6: ...ement Parts Service Platform In order to provide you with a fast and efficient after sales service when you claim order spare parts or after sales service upon maintenance please provide accurate truck model vehicle body serial number and part number After sales Maintenance Service Platform i NOTE ...

Страница 7: ...e for rated load capacity of the vehicle The vehicle can only be used on the level gro und indoors never use it on mezzanine or balcony area WARNING Truck can only be operated by single operator other personnel is forbidden from riding 1 3 Common Tools No Name Remark 1 Hex Head Socket Wrench 8 27 One Set 2 Phillips Screwdriver 2 One Piece 3 Slotted Screwdriver 2 One Piece 4 Sockets and Knobs One S...

Страница 8: ...08 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 908 1087 1437 1717 1984 2375 2318 2775 M30 2 1005 1203 1587 1900 2196 2629 2566 3072 M36 1587 1900 2506 30...

Страница 9: ...9 2 REV 09 2020 INFORMATION SPECIFICATIONS 1 8 2 MAINTENANCE ...

Страница 10: ...ooden 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...

Страница 11: ...arting to clean all necessary security measures must be taken to prevent sparking short circuit during operation If the truck is powered by battery battery plug must be pulled out When cleaning electrical and electronic com ponents you should use low intensity suction gas or compressed dry air Meanwhile clean the dust on the surface of components with non conductive and antistatic brush Do not use...

Страница 12: ...se refer to Inspection Maintenance List for regular inspection and maintenance of the vehicles L Lubrication Under harsh conditions the lubrication intervals should be shortened by half Table 2 1 Inspection Maintenance List Continued Interval in days months years 7 d 60 d 90 d 6 m 1y Interval in hours 50 250 500 1000 2000 Braking System Check the braking functions A Check the brake fluid level A C...

Страница 13: ...nder harsh conditions the lubrication intervals should be shortened by half 2 2 3 Lubrication Improper operations may constitute hazards to the operator s health and life as well as to the surrounding environment When storing or adding lubricant use clean containers It is strictly forbidden to mix different types and specifications of lubricants with each other except for those can be mixed under ...

Страница 14: ... ZSM207DOT3 After the gas within the system is completely discharged add to 2 3 of the oil cup Brakes Table 2 3 Application Amount of Hydraulic Oil 1 2 Mast Series Lifting height mm Amount L Full Free 2 stage Mast 2000 30 2500 34 2700 34 3000 36 3300 36 3500 38 Wide view 2 stage Mast 2000 30 2500 34 2700 34 3000 36 3300 36 3500 38 3600 38 4000 42 4300 42 4500 44 Table 2 3 Application Amount of Hyd...

Страница 15: ... on the meter Identify if the battery voltage is normal according to the measured voltage As shown in the following table Battery Voltage Judgment 80V 65V 87 6V Normal 65V or 87 6V Battery Fault Enter TESTER Menu to check the battery voltage If the battery voltage is still abnormal after being charged open the battery compartment check the voltage of each battery and its connection circuit respect...

Страница 16: ...if there is blocking 4 Replace the controller 3 Drive axle Bearings noise or jammed Bearing fatigue damage or foreign 1 Replace the bearings Carry out trouble shooting in accordance with the order listed in the table it can help you quickly identify problems and resolve accordingly Travel Fault 4 Abnormal tyre wear cracking or degumming Improper use 1 Replace the drive wheel 2 Replace the rear ste...

Страница 17: ...internal assembly is normal 4 Clean or replace the valve 5 Replace the explosion proof valve Motor Fault 6 On load motor speed is turning slow Insufficient voltage of battery Overload U V W terminals with abnormal voltage input Speed encoder or its circuit failure 1 Check the voltage of battery 2 Refer to the rated capacity marked on the nameplate 3 Check the battery output 4 Replace the speed enc...

Страница 18: ...emove foreign materials 4 Apply grease on contact sur faces of sliding parts 5 Repair or replace Under the circumstances of normal lifting and lowering if failure occurs to any of other hydraulic actions forward backward shifting forward backward tilting and left right shifting perform troubleshooting to the corresponding control switch and its control circuit Table 3 1 Troubleshooting of Common F...

Страница 19: ...Causes Troubleshooting Lifting System Failure 1 Lift roller does not rotate Grease stiffened or dirt accumulated on lift roller and mast sliding surfaces Improperly adjusted lift roller 1 Clean and lubricate lift rollers 2 Adjust 2 Excessive mast noise Insufficient lubrication Improperly adjusted lift roller side roller and back up metal Rubber pad on lower of outer mast is useless for container f...

Страница 20: ...k Too low pressure setting of the relief valve in the dividing valve or blocking in valve Too high viscosity oil The steering fails to return to its natural position due to breakage of locking spring or insufficient spring pressure Break or deform of swivel pin Break or deform of coupling Wrong in spring or safety valve Too much internal leakage in the steering cylinder Deform of steering axle 1 A...

Страница 21: ...33 4 32 REV 09 2020 TROUBLESHOOTING 3 4 DRIVING SYSTEM ...

Страница 22: ...heels make the drive wheels off the ground Unscrew the six nuts 2 and remove the drive wheel assembly 3 Tyre wear can affect the stability of the truck replace the drive wheel 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 please use original spare parts provided by the equipment manufacturer to ...

Страница 23: ...jury CAUTION Unscrew the five bolts 1 remove the drive motor 2 from the gearbox 3 4 2 3 Checking and Testing U V W Terminals Identify if the motor windings are normal through measuring the resistance of U V V W and U W respectively if there is short circuit or breakage as shown in the following table Due to the small size of windings when measu ring with a multimeter put it on a low resistance ran...

Страница 24: ...e four bolts 5 and remove the bearing cap 4 then remove the drive assembly 6 from the chassis Loosen the oil drain plug and drain all gear oil Unscrew the twelve bolts 7 and remove the seal 8 then dismantle the drive axle 9 4 3 2 Component Installation Install according to the reverse order of rem oval After installing the new drive axle please add gear oil see Section 2 2 3 for specification and ...

Страница 25: ...he oil fill plug 2 Add Replace Gear Oil 4 3 3 Gear Oil 2 1 Fig3132 20011SM 3 Fig3132 20012SM Gear oil may damage truck parts and con taminate the environment When replace the gear oil place a clean container under the drive axle for discharge of gear oil CAUTION 4 4 Differential 4 4 1 Removal and Installation Removal Fig3132 20009SM Remove the drive assembly from the chassis and dismantle the driv...

Страница 26: ...3 Bearing Cap 7 Pin 11 Dual Gear 15 Housing Cover 4 O ring 8 Bearing 12 Seal Cap 16 Bracket 4 6 Accelerator Pedal 4 6 1 Removal and Installation 4 6 2 Interface Description Power off the truck and remove the key Remove the cushion Disconnect the connection between the accelerator pedal wiring 1 and main wiring harness Unscrew the two bolts 2 with wrench and remove the accelerator pedal 3 from the ...

Страница 27: ...iring harness with a multimeter Place the accelerator pedal at original position Measure the voltage between the interfaces with a multimeter as shown in the following table Testing Check if the accelerator pedal and its wiring harness are in good condition and if the connectors are connected securely Accelerator pedal at original position Connection interface Voltage Measurement A C 12 V A B 0 V ...

Страница 28: ...eels make the wheel off the ground Unscrew the eight nuts 1 Fig3530 10002SM and remove the steering wheel assembly 2 from the steering bridge 3 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 100mm to prevent the hazards to the maintenance personnel working under the vehicle for wheel r...

Страница 29: ... and remove the fix plate 3 then dismantle the steering bridge 5 from the chassis Remove the two damping pads 4 from the steering bridge 5 When removing the tubing and steering bridge the system will lose some hydraulic oil please refer to Section 2 2 3 for supplementary adding of hydraulic oil CAUTION Before going on with the next step please fix the steering bridge properly first Be sure to avoi...

Страница 30: ...clean environment to prevent impurities from enter ing into cylinder causing cylinder damage During the installation hydraulic oil of the same specifications must be used for cleaning or lubrication Secure the cylinder to hose clamp and gently clamp the cylinder middle Unscrew the cylinder cap 1 Fig3132 70005SM from side with cylinder wrench Remove the circlip 2 snap ring 3 dust ring 4 rubber ring...

Страница 31: ...ght brake cable on the parking brake Loosen the two nuts 2 and bolts 3 remove the parking brake 4 Install according to the reverse order of rem oval 6 1 2 Adjustment Prior to parking brake adjustment please use triangle wooden wedges to fix the wheels CAUTION Press and hold the button 1 push the parking brake lever 2 from A position brak ing to B position released Through adjusting bolt 3 to adjus...

Страница 32: ...brake fluid CAUTION After replacing the brake master cylinder or tubings the air within the entire brake pipeline must be discharged 6 2 2 Air Discharge Adding Brake Fluid Fill the oil cup with brake fluid Press the brake pedal repeatedly until the stepping pressure becomes heavy CAUTION Open the vent on brake cylinder of drum brake press the brake pedal pressure to the bottom discharge the residu...

Страница 33: ... repeatedly lifting and lowering of the mast If hydraulic 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 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 ...

Страница 34: ...en the clips on the clamp 5 remove the pipe 3 from the gear pump Unscrew the four bolts 4 and remove the pump motor gear pump assembly from the chassis Removal Installation Install according to the reverse order of rem oval When removing the tubing and pipe the system will lose some hydraulic oil please refer to Section 2 2 3 for supplementary adding of hydraulic oil CAUTION 7 2 Pump Motor Gear Pu...

Страница 35: ...amage truck parts and con taminate the environment When removing joints or tubings place a clean container under it for discharge of hydraulic oil CAUTION Remove the cotter pin 3 on pin shaft 4 remove the connecting rod 5 from the multi way valve Unscrew the three bolts 6 then remove the multi way valve 5 from the mounting plate 7 Remove the rubber cover 8 and unscrew the bolt 9 then remove the br...

Страница 36: ...oid personal injury or damage to the equipment Cylinder is the powered actuator in hydraulic system Therefore before removing the cylinder from the equipment the connection part must be supported with appropriate supporting to avoid personal injury or damage to the equipment Upon disassembly of the cylinder you should know the main structure of the cylinder to avoid sightless removal Due to the di...

Страница 37: ...tall the seals must be made of soft metal or suitable plastic without burrs and sharp edges on surfaces It is prohibited to use the tools that can easily damage the surface of seals such as screwdriver or other similar tools with hard front edges Where the hydraulic seals to be installed should be free of burrs sharp edges and cracks If the installation of seals needs to cross sharp edges grooves ...

Страница 38: ... the same specifi cations Replace the problem parts and assembly in reverse steps If the piston rode or cylinder tube is damaged please replace the entire cylinder If the seals are aged or damaged please replace the complete set of seals When replacing or repairing the cylinder please refill the lubricant through the grease nipples at both ends of the cylinder CAUTION CAUTION 7 6 Refueling Cap 7 6...

Страница 39: ...ervice line Supply line or return line Cylinder Double acting direction Control line Drain line Relief valve Connecting pipe Solenoid valve Two way two pass Port Test port Solenoid valve Three way four pass Motor Balancing valve Hydraulic pump Check valve 7 7 Hydraulic Symbol Symbol Description Symbol Description Manual valve Three way six pass Brake valve Speed requlating valve Explosion proof va...

Страница 40: ...71 70 8 8 MAST ...

Страница 41: ... B Unscrew the bolts 3 and remove the fixed plate 4 between the outer mast and chassis C and D Remove the mast from the truck 8 1 2 Lifting Chains Lower the mast to the bottom Press the emergency stop switch and discon nect the key switch 8 1 2 1 Chain Adjustment Switch off the power supply before any adjust ments or operations Loosen the lower jam nuts 2 on chain bolt 1 Fig3131 60003SM Through sc...

Страница 42: ...nd chain joint 6 Remove the cotter pin 3 pull out the pin shaft 4 separate the chains 5 from the chain joint 1 on outer mast Remove the chain assembly from the chain sprocket Replace with new chains and hang the new chain assembly onto the chain sprocket Put the chain connector 6 through the fork carriage chain hanging plate screw the jam nut 2 Put the chain connector 1 through the outer mast chai...

Страница 43: ...ing removal resulting in personal injury CAUTION Remove the regulator 6 from the three pass component 2 Unscrew the mounting bolt 7 from the bott om of the cylinder Unscrew the bolt 6 lift the cylinder 5 up and remove it from the truck Remove the three pass component 2 Fig3131 60005SM from the right cylinder 8 1 4 2 Cylinder Maintenance If the piston rode or cylinder tube is damaged please replace...

Страница 44: ... and side shift cylinder Check the hydraulic oil level and make sure that the liquid is at standard level CAUTION CAUTION 8 1 6 External Side Shifter 8 1 6 1 Side Shifter Removal Lower the mast to the bottom press the eme rgency stop switch and disconnect the key switch Block the truck wheel with wooden wedge Unscrew the four bolts 3 Fig3530 60004SM remove the retaining shelf 1 from the exter nal ...

Страница 45: ...een the outer mast and chassis C and D Remove the mast from the truck 8 2 2 Lifting Chains Lower the mast to the bottom Press the emergency stop switch and discon nect the key switch 8 2 2 1 Chain Adjustment Switch off the power supply before any adjust ments or operations Loosen the upper lock nut 3 Fig3131 60011SM and the lower lock nut 1 on chain bolt Through screwing upward the adjusting nut 2...

Страница 46: ...s 5 from the chain joint 4 on free middle cylinder Remove the cotter pins 8 pull out the pin shaft 9 separate the chains 5 from the chain joint 10 on fork carriage Remove the chain assembly from the chain sprocket Replace with new chains and hang the new chain assembly onto the chain sprocket Put the chain connector 10 through chain hole of fork frame insert the pin shaft 9 and pins 8 Put the chai...

Страница 47: ...t place sleepers at both ends for supporting Remove the tubing 1 Fig3131 60012SM to make it separate from the three pass component 2 Remove the regulator 4 from the three pass component 2 Unscrew the bolt 6 Fig3530 60006SM and remove the cylinder clamp 7 Unscrew the mounting bolt 8 from the bott om of the cylinder Unscrew the bolt 3 lift the cylinder 4 up and remove it from the truck Remove the th...

Страница 48: ...3 cover plate 7 and O rings 8 from the cylinder cap Remove the bearing 5 and guide bush 6 from the cylinder tube 17 Pull out the piston rod 9 from the cylinder tube 17 and remove the bushing 11 Remove the support ring 12 from the piston and unscrew the fixing screw on the piston then separate the piston rod from the piston 13 Remove the support ring 10 from the piston rod then remove the retaining...

Страница 49: ...table hose clamps to avoid cylinder deformation caused by severely tight hose clamp Carry out the maintenance work in a clean environment to prevent impurities from entering into cylinder causing cylinder damage During the installation hydraulic oil of the same specifications must be used for cleaning or lubrication Full Free Middle Cylinder Secure the cylinder to hose clamp and gently clamp the c...

Страница 50: ...apacity should be greater than the total weight of the vehicle WARNING 8 3 2 Lifting Chains Lower the mast to the bottom Press the emergency stop switch and discon nect the key switch 8 3 2 1 Chain Adjustment Switch off the power supply before any adjust ments or operations When the adjustment is completed there sh ould be an adjustable distance of at least three pitches over the chain bolts CAUTI...

Страница 51: ...et 17 Fig3131 60019SM Replace with new chains and hang the new chain assembly onto the chain sprocket Put the chain connector 10 through chain hole of fork carriage insert the pin shaft 9 and pins 8 Put the chain connector 4 through the middle cylinder chain hanging plate screw the adjusting nut 2 and lock nut 1 insert the pin shaft 7 and pins 6 Adjust the chains according to Section 8 3 2 1 Fork ...

Страница 52: ...REV 09 2020 REV 09 2020 MAST MAST 8 8 94 95 8 3 3 Mast Tubing Code Description A1 Lifting Lowering Mast Tubing Code Description A3 Right Shift Mast Tubing B1 Left Shift Mast Tubing ...

Страница 53: ...mm with lifting tools insert wooden block between it and the ground for supporting Loosen the joints 6 Fig3131 60020SM to separate the middle cylinder and rigid pipe assembly 5 Disconnect the connections between the tubings 2 Fig3131 60021SM around the middle cylinder and rigid pipe assembly 3 Remove the fork carriage chains according to Section 8 3 2 2 Remove the three pass component 2 Fig3131 60...

Страница 54: ... the cylinder according to the reverse order of removal according to 8 3 4 1 Add hydraulic oil of the same specifications into the tank see Section 2 2 3 Pull out emergency stop switch and turn on the key switch Repeat Lift Lower cylinder to discharge the air within the tubings and cylinder Check the hydraulic oil level and make sure that the liquid is at standard level 8 3 5 Built in Side Shifter...

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