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SERVICE MANUAL

1. T T TS ai li S a ha OI H ET 2 i Pm xe TA D q m L usd 3 4 on a go H El OU D Y H m 3 HW EN Tet vt tr fe i Ha 2 pi 0 H B ckt H Fig5 1 Double lift mast with wide view Outer mast 2 Inner mast 3 Back rest 4 Fork arm carrier 5 Fork 6 Chain 7 Left lifting 8 Right lifting cylinder 9 Tilting cylinder 10 Idler wheel cylinder Fig5 2 Double full free lift mast 1 Outer mast 2 Inner mast 3 Chain 4 Free lifting cylinder 5 Fork arm carrier 6 Fork 7 Left lifting 8 Right lifting 9 Fork arms 10 Tilt cylinder cylinder cylinder 30 Fig 5 3 Container truck mast 1 Outer mast 2 Inner mast 3 Chain 4 Free lifting cylinder 5 Fork arm carrier 6 Fork 7 Sideway cylinder 8 Left rise cylinder 9 Right rise cylinder 10 Fork arms 11 Tilt cylinder Fig 5 4 Triple full free lift mast 1 Outer mast 2 Inner mast 3 Chain 4 Free lifting cylinder 5 Fork arm carrier 6 Fork 7 Sideway cylinder 8 Left rise cylinder 9 Right rise cylinder 10 Fork arms 11 Tilt cylinder 31 5 4 Lifting cylinder Plunger feeder lifting cylinder has dash control configur
2. 2 2 2 Trouble diagnoses corrections condition Probable cause Corrective action Unstable driving loose wheel nut wheel bearing out of adjustment improperly adjusted shims faulty steering system tighten adjust adjust refer to turning system section Noises insufficient lubrication loose bolts and nut improperly adjusting shim for axle end Shaft damaged joint bearing at two ends of rod Apply calcium grease tighten adjust replace 53904 PAN 5191101 01 award Ajdde 209 199 eye Zem S2981 pue Sitaitoi 03 award pddy u N 1 BU deeg Late sou siewood pue wa 3m di oi wask Aypddy vse MUS dogs es Hol ien Si 0510 sei G p ps ae Ure ig ez 26 810 SEMI WI rus IDO 184 imu sa pech arie vas again lagey ET Ba Y Puriweq Spear B pap ss ET ET T 2391003 xy sec D LE Huy zgaa AL eq po4 or osua de ek j o wwe N Q ssouxoru 1 wrys Burjsnfpe 334 3104 usnq Suriunog 16 2 2 3 Remove Wheel hub 1 Jack up and support forklift truck body with Wooden blocks 2 Remove tire 3 Remove hubcap 4 Remove steering spindle nut 5 Pull off hub assembles 6 Remove bearing inner race Caution a Not to drop bearing inner race b Be careful not to damage oil seal 2 2 4 Kingpin and steering spindle 1 Remove rod 2 Loose lock bolts See fig 2 2 3 Remove grease nipples o
3. 36 6 2 CPD10 15 20 25 30 35J C1 CPD10 15 18 20 25 30 35 C2 CPD40 45 50 C2 fork 6 2 1 Summarize CURTIS company procreates controller adopt international advanced closed loop system and advanced control technique Designing large screen instrument can clear display electric quantity speed total time of run and so on information Designation adopt code plus character manner increase maintain efficiency Four work models can be set through meter so as to suitable for different condition 1 Actuating motor Actuating motor adopt three phase alternating current frequency conversion electromotor increase conversion efficiency not have commentator brush in order not to maintenance 2 Lift motor Lift motor JC1 is direct current motor so is the motor of J series truck Lift motor JC2 adopts three phase alternating electromotor increase conversion efficiency not have commentator brush in order not to maintenance 3 SAFETY 8 PROTECTION FEATURES D Reverse Polarity of the battery 2Connection errors S All inputs are protected against connections errors Current overload protection Git have detecting element control peak current O Thermal protection If the controller temperature exceeds 85 C the maximum current reduces in proportion to the thermal increase The temperature can never exceed 115 C If the electric machinery temperature exceeds 145 C the maximum current reduces in proportion to the thermal
4. Ration m YDQ9 1 4HC 31 280 AC F ICO1 IP20 60 YDQ 8 6HC 31 248 AC F ICO0 IP44 5 CPD30 35J C2 Rated Voltage V Rated Current A Excitations Mode Insulation Grade Cooling Mode Protecting Grade Ration m YDQ11 75 4HC 51 180 AC F ICO1 IP20 60 YDO 10 51 CPD40 45 50J C2 Rated Voltage V 161 6 Rated Current A AC Excitations Mode F Insulation Grade ICO1 Cooling Mode IP44 Protecting Grade 15 Ration m YDQ16 6 4HC 51 250 AC 1C00 IP20 60 YDB25 4 4 51 CPD10 15J D1 387 Rated Rated Rated Power Voltage Current kw V A AC Mode Excitations Grade Insulation ICO0 Mode IP20 Cooling Protecting Grade 5 Ration m Weight Kg TSP180 4 180 48V 10 5 31 280 AC ICO1 IP20 60 135 TSW112 4 195 T 48V 11 31 285 CPD20 25J D1 Rated Rated Voltage Current V A Rated speed r m Mode Excitations Grade Insulation ICO1 Mode IP20 Cooling Protecting Grade Ration m Weight Kg TSP180 4 180 48V 31 280 1200 AC TCO1 IP20 60 135 TSW
5. Sen uuu J id wp 8 Y vg enGagelN instrument E m RU a HH J001 S H3 1 H f Im H2 1 DI EL2 H 2 H3 2 Hb 2 Hz 2 H3 4 er H3 3 RA 7 d rir kes B D e IE B B je B 8 e B 1B 8B B B D le e B L R L IR L R L L R R L R L R E 2 TR TR L 3 g 3 ze sea 3 m Ed x 2 8 zg E d 7 E x m Ss wo Zug 8 5 3 3 3 5 st ss fe a a gt E 8388 S B E r sees 3 E es ET 3 om Ld ma 358358238 y r AE 20 20m SE r 32 PUMP MOTOR il pump motor 1 15 J0Q1 3 relay AV 3 31 TRACTION MOTOR service motor 1 1 HH horn 24v 1 30 XL accumulator connector 1 13 SFI brake lamp switch 24v 3A f wire color Black white Red Green YellowBrows Blue Grey Purptd Orange Pink 29 FUS Juss BLX 10A 1 pipe core 104 17 sas red urgent stop button AV 1 symbol e w e 6 r er Ja eeu o Ie 28 FU eu So BLX 10A 2 pipecore 10A 11 SA4 deal switch n seat belt 27 FU2 fuse 2754 1 10 SA3 key switch 1 26 FUI te 225A 1 9 SA2 direction switch 1 drechon switch orba 25 SMS hand brake switch TM1308 600 1 8 SAT turning lamp switch 1 24 SM4 the 4th handle TM1308 G00 1 7 Su lamp switch Mm 23 SM3 side moving controller TM1308 600 1 6 KMI 2 main contactor 1 22 SM3 tilting controller TM1308 G00 1 SAET horn filter d 21 SMI Z lifting controller TM1308 600 2 4 H3 H4 three colors rear lamp 24y 2 20 SP hydraulic switch 1 3 H1 H2 side lamp ER 2 19 s horn button LA2 G00 1 foot pedal 2 EL1 EL2 head lamp 24v 70
6. 4mm commutation not Cooling insulation resistance When it approach work 45V 0 5MQ temperature please measure by 250Vmegohmmeter 45V 110V IMO JD1 Brush Metal plumbagin brush trade J201 chart No 5CZ 578 no 1 1 2 Failure diagnosis CPD10 30 Failure phenomenon Possible cause All of sheet copper nigrescence Brush s pressure is wrong Parts of commutator according to a certain order nigrescence parts is short circuit armature coil is short parts of commutator is not fasten to armature coils open circuit Parts of commutator are nigrescent but without definite rule commutator s center line location change commutator s surface is rough out of round Brush wear and tear change colors and break motor vibration clearance between brush and box is bigger working surface distance between the box and commutator is bigger mice between parts of commutator extrude material of the brush is bad trademark of the brush is wrong Sparkle strong motor overload commutator is unholy commutator is rough or out of round mica or parts of commutator extrude brush seat grinding is bad the pressure of brush is not enough big trademark of the brush is wrong the brush lock in the box the brush frame is loose or vibrational the polarity and tactic order of magnetic pole is wrong The brush and wire heat the sparkle of brush is strong the b
7. ACS heat sink temp gt 85 C KEY ON ON ON ON KEY OFF or Heat Lowest Accel will be used warning sink temp normal 49 5 Errors detected by pump ACS Warning Code Source Condition When Tract Main PS Reset Remark 303 Motor high temp Motor temp gt 145 C KEY ON ON ON ON KEY OFF See 1 2 2 2 Lowest Accel will warning i be used 304 Heat sink temp sensor ACS heat sink temp sensor KEY ON ON ON ON KEY 0FF error error 305 Motor low temp warning Motor temp lt 50 C KEY ON ON ON ON KEY OFF E ee Lowest Accel will e used 306 Motor temp sensor error Motor temp sensor not KEY ON ON ON ON KEY OFF or sensor connected or short circuit 2 connected Speed feedback sensor Speed feedback sensor not KEY ON ON ON KEY OFF or sensor ACS can not control speed 307 DUM ON Dm error connected short circuit connected correctly No driving allowed ACS high voltage ACS voltage gt 68V KEY 0N ON ON KEY 0FF or Lowest Accel will be used 308 warning ON voltage back to normal ACS low voltage ACS voltage 22 5V KEY 0N ON ON KEY 0FF or Lowest Accel will be used 309 warning ON voltage back to normal 310 ACS default values Default parameters are used in KEYZON ON ON ON KEY OFF Turn the key switch off and on loaded ACS 8 again 311 Power reduce Power is reduced by some KEYZON ON ON ON KEY OFF warning condition Checksum error Calibration par
8. B i AN HN e gt Fu EIE Ed E E pump L me van aa eel ul C filter tank The max input pressure 16MPa 16MPa 16MPa 16MPa of redirector Main safety valve pressure of multi spool 12 MPa 15 MPa 17 5 MPa 18 5 MPa control valve Rated pressure of gear 20 MPa 20 MPa 20 MPa 20 MPa pump 26 5 Lifting system 5 1 Data Inspection and adjustment Place Assembly clearance mm Repair clearance mm Mast to lift roller 0 1 0 8 0 21 Shims 0 5 1 Mast to back up metal 0 1 0 8 0 21 Shims 0 51 Inner mast to carriage side roller 0 1 0 6 0 21 Lift chain deflection 25 30 mm Tightening torque Place Model or Lifting N m 1 1 5t 127 157 M16 245 314 M20 single chain Lift chain lock nut 2 3t 176 216 M18 245 314 M20 1 1 5t 89 118 M14 Mast support cap blot 2 3t 176 216 M18 1 1 5t Tilt cylinder lock nut 89 118 M14 2 3t Lift cylinder bolt head 1 3t 76 107 M12 1 1 5t 22 29 M8 Lift cylinder bolt toe 2 3 5t 44 58 M10 Lift cylinder fixing bolt 1 1 5t 14 18 M8 CU type 2 3t 29 39 M10 Weight of basal mast Model of truck It L 1 8t 2t 2 5t 3t 4 4 5t 5t Weight of mast Kg 531 531 531 930 1000 1100 1450 1550 27 5 2 Fault Fault Probable cause Corrective action Fork arm carrier or 1 Tilt cylinder and ring abraded excessively Replace piston ring til
9. calico can dip alcohol when wiping stop process check all fasteners whether fastened brush s shelf must reliable fastened can t become flexible If need running or disassembly brush s shelf must make out marker can become flexible bolt When the brush s shelf reposition aim at marker line screw down bolt in order to keep brush in the former neutral location winding isolating resistance should check of fix a date when near work s temperature under rule data otherwise should put up dry fix a date open window shutter check inside part whether transmutation and reverse partial circs whether up to snuff you should often clean bed load and other dirt on the motor s shell in order to giving out heat quantity best Every half year check motor one time as follow a Inspect exterior and clean the dust for the motor b Clean or replace bearing during running it is permitted to giving off abnormal noise for bearing c Inspect the brush s abrasion if necessary replace it Burnishing for brush When replaces the brush using 00 thin emery cloth to burnishing it During burnishing you can haul the emery cloth leftward or rightward After burnish the brush and clean the commutator with emery cloth the motor should lowered voltage and limiting speed to running under load in order to safety till the brush s working face is shined CORRECT WRONG Brush Emery cloth CPD10 15 18 20 25 30 35J C1 CPD10
10. use the hand brake If it occurs for foot brake malfunction use hand brake to stop the truck condition Probable cause Corrective action Oil leakage in brake lines Correct and replenish Insufficient brake Air in brake lines Bleed air force Improper functioning of master cylinder or Correct or replace wheel cylinder Clogged oil lines Clean No free play of brake pedal Adjust Faulty piston cup Replace Weak or broken return springs Replace Brake dragging Clogged master cylinder returns port Clean Clogged oil lines Clean 22 4 Hydraulic system The high pressure oil from main pump goes to control valve and divide it to two parts by dividing valve inside control valve one of them goes to lifting cylinder or tilting cylinder another part goes to steering gear with invariable flow to control steering cylinder When lifting and tilting spool is in neutral high pressure oil return oil tank directly from pass way When pulling lifting spool high pressure oil goes by throttle valve and then push piston rod under lifting cylinder piston When pushing lifting spool it is that bottom of lifting cylinder piston connects with low pressure line and then piston rod drops by deadweight and weight of cargo In this time oil from lifting cylinder goes by unidirectional speed limiting valve so as to control the falling speed When operating tilting spool high pressure oil goes to front h
11. 104 2 tube core 104 amp KM main contactor sw200 1 27 Fuz fuse 425A 1 5 RCI horn filter 1 26 Fut fuse 300A 1 4 H3 H4 three colors rear lamp 24v 2 25 SM5 hand brake swifch TM1308 G00 1 3 HI H2 side lamp 24v 2 24 SM4 the 4th handle TM1308 G00 1 2 ELT ELZ head lamp WD 100x90 244 70 2 23 SM3 side moving controller TM1308 G00 1 1 66 acidic battery moulded case 22 SM2 tilting controller TM1308 G00 7 m di ET lifting controller TMI308 00 1 CODE NAME MODEL SPECIFICATION REMARK Wir ip ue Ut e LEFT HEAD LAP LEFT SIE LAP WIRING DIAGRAM OF CPD10 15 18 20 25 30 40 45 50 J D1 REVERSE WARNING LA ET HG EI Q stema va mune we sue ue Beake LP Q reverse Lane wi wn T BATTERY 24V iE Uv W Uv W TOWING DIL PUMP RAT LAP SWITCH Dn M CONTROLL ER BOX KEY SWITCH Slam ue vam Macc STE LAP e BRAKE Lage RED E amp stew ae VELLON DRECTUN SVUCI O RVRB B HAND BRAKE SWITCH FILTER 7 Maintenance record Date Maintain content Maintainer 57 lt H C HANGCHA GROUP CO LTD HANGCHA Address for OVERSEAS USERS Manufacturing site 88 Donghuan Road LinAn Econimic Development zone Zhejiang P R China m ZIP 311305 Registered Address 398 Shi Qiao Road Hangzhou P R China m ZIP 310004 Fax 0086 571 88926789 0086 571 88132890 Web http w
12. 15 18 20 25 30 35J C2 CPD40 45 50J C2 CPD10 15 18 20 25 30 D1 CPD40 45 50J D1 CPD10 15 18 20 25 30 35 C1 CPD10 15 18 20 25 30 35 C2 CPD40 45 50 C2 CPD10 15 18 20 25 30J D1 CPD40 45 50J D1 fork don t have commutator and brush not need maintain You must clear dust everyday 1 2 Gear box Gear box is two grades reduce speed gear one grade straight gear and one grade planet gear So the gear box is very small Trouble Probably cause Method of troubleshooting When traveling or change Gear clearance is too big Adjust direction Too much worn of gear Replace Oil level is low Add oil Too much noise when traveling Gear clearance is too big Adjust Too much worn of gear Replace 1 Box 2 Bearing pedestal 3 Bolt 8 Dual f 9 Axletree 6206 10 Axletree 6307 articulated gear SP 15 Positioning 13 axes 14 O joint ring board 18 Axletree 6208 19 Tank cap 20 Bolt 4 Bearing pedestal 5 0 joint ring 11 dual articulated 12 Axletree 6305 gear 16 Bolt 17 Pinion 21 Bolt 23 Pin 27 right differential 28 left differential 24 Girth gear 25 bolt 26 nut carrier carrier 29 Gear shaft I 30 Face gear 31 Gasket 32 Planetary gear 33 Thrust washer 34 Axletree 6211 35 Straight pin 36 Gear shaft ID 37 Paper gasket 38 pin 39 Lock plate 40 Lock washer 1 3 Driving axle 1 3 1 Data Driving axle type Full floating axle and truck body direct
13. Tere pec pum ek 4 sae le p eap E Bl wW puni E der of 2 ZE rsch S d we Ee meten oo v ales oo v E C Accelera D pos m v Bi v W BL Lo uds ome A ze en Relay swith ifcoil dd vd A Se ee xS UM S w Z CG ke CG SES Co 4 Hr He Inn H2 1 Et E2 H 2 H3 2 H 2 H2 2 H 4 A H 3 ileng RT lus opel an ND B can ech itx cor B cuv ml iu dE bh le a B B B B B B B B B B B B B B B B B B B L R je R Lope o je IR RE R8 L R oro i x B B 2 8 z EBEB 3 p 5 3 5 We a AAA S x ER SS Yv 2 vy a 3 3 5 E S 8 sere 2 H 3 a 3 bi 3 BEER zi g S 2 r i AE 3 8 8 3 EED N e e S y 3 184 o 1100 S a S a wi d s 88 n p 20 SP hydraulic switch 1 MEE PM E 19 SB horn button 29 on the steering wheel Du 18 HE warning lamp LTDIS2A MAY 1 17 HU Revese beeper DJB 248 24v 1 16 HT flasher S6224C 24v 1 15 HH horn DL224ED 24v 1 14 SF2 brake switch JK231 24V 3A 1 wire color Black White Red Green YelloWBrowr Blue Grey PurplgOrange Pink 13 SFI brake lamp switch JK231 24v 3A 1 Symbol 8 w 8 Gly 8 B ei 0 P 12 SAS red urgent stop button XB2BT440 24V 1 33 j0a1 3 relay MEA 26V 3 11 SA4 seat switch n seat belt 32 PUMP MOTOR oil pump motor 1 10 SA3 key switch JA TA 1 31 TRACTION MOTOR service motor 1 9 SAZ direction switch 7 drecton swith conbnafon 30 XL accumulator connector 1 8 SAT turning lamp swifc t 29 FUS fuse BLX 10A 1 tube core 104 7 St lamp switch Di 28 FU Su fise BLX
14. in incorrect sequence 2 Faulty wiring crimps or switches at KSI interlock direction or throttle inputs 3 See 1311 menu Monitor Inputs 4 7 Emer Rev HPD 1 Emergency Reverse operation has concluded but the throttle forward and reverse inputs and interlock have not been returned to neutral 4 9 Parameter Change 1 This is a safety fault caused by a change in certain 1311 parameter Fault settings so that the vehicle will not operate until KSI is cycled For example if a user changes the Throttle Type this fault will appear and require cycling KSI before the vehicle can operate 6 8 VCL Runtime Error 1 VCL code encountered a runtime VCL error 2 See 1311 menu Monitor Controller VCL Error Module and VCL Error This error can then be compared to the runtime VCL module ID and error code definitions found in the specific OS system information file 6 9 External Supply Out of 1 External load on the 5V and 12V supplies draws either too much or too 42 Range little current 2 Fault Checking Menu parameters Ext Supply Max and Ext Supply Min are mis tuned 3 See 1311 menu Monitor Outputs Ext Supply Current CODE PROGRAMMER COD DISPDAN POSSIBLE CAUSE 7 1 OS General 1 Internal controller fault 7 2 PDO Timeout 1 Time between CAN PDO messages received exceeded the PDO Timeout Period 7 3 Stall Detect 1 Stalled motor 2 Motor encoder failure 3 Bad crimps or faulty wi
15. increase The temperature can never exceed 165 C Low Battery charge When the battery charge is low the maximum current is reduced proportionally to the battery discharge External Agents Electric control is hermetical The chopper is protected against dust and spray of liquid to economy 9 Protection against accidental Start Up A precise sequence of operations is necessary before the machine will start Operation can not commence if these operations are not carried out correctly Requests for drive must be made after closing the Key Switch 4 OPERATIONAL FEATURES D Feedback control system make the vehicle speed follow accelerator whether low speed or not 37 high speed easy control 2 two archives speed and acceleration design can apply to most situation 3 regeneration technology make change direction of fork even smooth 4 three regenerative braking mode A acceleration pedal part release appear regenerative braking B direction reverse regenerative braking C ramp downslide appear regenerative braking Except increase security drive reclaim part of electric energy prolong work time of every time control speed during downgrade speed lie on accelerator if speed exceed set point controller may automatic braking this give optimal ramp Notice 1 Maintain electric control must first cut off electrical source then hold 10 1000hmic resistance join controller anode and cathode release residual vo
16. on vehicle 4 3 THERMAL CUTBACK i TUA 3 Improper mounting of controller 4 Operation in extreme environments 35 Fault table of lift oil pump controller PROGRAMMER LCD DISPLA Y EXPLANATION POSSIBLE CAUSE NO voltage or controller is not working enor such as MCII defective controller work normally no error EEPROM miss data EEPROM data check EEPROM defective S dis LE ee programmer 1311 to change parameter can delete the error Hardware defective 1 MOSFET short down 2 Motor circuit is an open circuit Low voltage Battery voltage is too low ining locks The function of lifting lock of controller is touch off Order fault Startup Any switch of SS1 SS4 closes earlier lockout than KSI or INTERLOCK 1 Main contact bonded Contact err 2 The set of parameter CONTACT CNTRL is wrong Pre charge circuit work with err OOO OOO Pre charge fault Motor short down The connection of main contact Contact has not been QOD COO coil loose installed or is not close 2 Main contact works abnormally The voltage of battery is lower than the ri bar n tect sisie oe OW E es set value of LOVOLT CUTBACK aaa OO Over voltage protect The battery voltage is too high 1 The temperature of controller is temperature rotect too high or too low nuu DO z p 2 Cover under temp Temperature sensor works abnormal
17. temp gt 115 C KEY ON OFF ON ON KEY OFF See 1 2 2 1 temjperature 353 Motor over Motor temp gt 185 C KEY ON OFF ON ON KEY OFF See 1 2 2 2 temperature 354 ACS current sensor ACS current sensor error KEY ON OFF ON ON KEY OFF ACS must be repaired error 355 Charging timeout ACS capacitors are not charged KEY ON OFF ON ON KEY OFF Check charging circuit within 10sec from power on 356 ACS no response ACS does not respond at startup KEY ON OFF ON ON KEY OFF Check CAN bus wiring 357 ACS PDO timeout ACS CAN open timeout detected KEYZON OFF ON ON KEY OFF Check CAN bus wiring by VMC20 358 ACS SDO error ACS SDO error wrong SW KEY ON OFF ON ON KEY OFF Check SW version version 359 CANopen timeout ACS CAN open timeout detected KEYZON OFF ON ON KEY OFF Check CAN bus wiring by VMC20 360 ACS low voltage trip ACS voltage 15V KEY ON OFF ON ON KEY OFF Instantaneous voltage 361 ACS high voltage ACS voltage gt 68V software KEY 0N OFF ON ON KEY OFF Instantaneous voltage trip 362 ACS high voltage ACS voltage gt 68V hardware KEY 0N OFF ON ON KEY OFF Instantaneous voltage trip 363 ACS PCB temp trip ACS PCB temperature gt 115 C KEY ON OFF ON ON KEY OFF none for GEN4 GENS only 364 Other error KEY ON OFF ON ON KEY OFF Any other EMCY form ACS 301 ACS low temp ACS heat sink temp lt 20 C KEY ON ON ON ON KEY OFF or Heat Lowest Accel will be used warning sink temp normal 302 ACS high temp
18. 112 4 195 T 48V CPD30J D1 31 285 Rated Rated Rated Power Voltage Current kw V A 2000 Rated speed r m Mode Excitations Grade Insulation ICO1 Mode IP20 Cooling Protecting Grade Ration m Weight Kg TSP180 4 180 80V 10 6 51 180 1200 AC TCO1 IP20 60 135 TSW112 4 195 T 80V 12 8 51 216 2000 TCO1 IP20 CPD40 45 50J D1 Rated Rated Rated Rated Power Voltage Current speed kw V A m Excitations Insulation Cooling Protecting Ration Weight Mode Grade Mode Grade m Kg TSP180 4 200 16 6 52 AC ICO1 IP20 60 TSP160 4 250 T 25 49 ICO1 IP20 Height above sea level No exceed 1200m Remark electromotor Environment temperature 7 0 40 C 25 C applied range highest lowest Relative temperature Until on the surface of motor dew 10096 Cooling air Must not contain volatile gas Three times of rated current admit most work Tractor motor A time is one minute current of the SEN 3 j One point eight times of rated current motor Lifting motor steering motor AA admit time is one minute Admit temperature Rolling bearing Environment temperature not exceed 40 C 95 From brush box catadrome side to surface of the JD1 2
19. ELI EL2 head lamp 2 HE warning lamp 66 acidic battery HU Revese beeper CODE NAME QTY REMARK HT flasher 54 ELECTRICAL SYSTEM PRINCIPLE DIAGRAM OF CPD10 15 18 20 25 30 40 45 50J C2 XL 1 Dt py mer 0 Ki 001 kd EN RW RW sas sas RW e 7 H 1003 Faster 1007 acidic battery D Light switch HT j tjw Turning lamp switch se SA entire wna PO TS Lo sat lr SA2 2 6 LA T 2 Broke lanp swith J avo p Er pan Reverse lang switch A m PM sara o o me ME ba zer gt EES AV Eg P 6 Ane hee e emk alle ME Ee EN de 1006 p al are enGagelV instrument EE DR 20 3 se am pol 1003 818 R 4 Aar i Jm 3 Ta sa 2 B W ale 7 EE Cam Zb no EER O QU W Bl I RCI e P al om A AR E T H3 1 Ber inet H2 1 ELI lez H 2 H3 2 m 2 H 2 Ha Ha H3 AC ae eet re M 21 tom E Du i TE E ks sa
20. Ka ols been Hii B Int mi DI E amp 2 HI 2 H3 2 M 2 H2 2 H3 HE Ft oek P Don B e le le le jg p s le p je e je B left right left right left Fighflleff Wett righf right left righ left D I 2 g T 3 3 amp 3 2 838 2 gt S8 EN lt amp 5835 8 3 S 3 E S vea d 2 5 3 3 3 8 ss ss 9 8 3 3 3 38388 e e UE Si S338 s g 8 3 R r D a 8 a gt 3 3 EER H 7 DW wj SSES v R es 120W 200 e r ta enGagel instrument 1 BDI 2 BDI EN HI wire color Black whife Red JGreen YelloWBrowr Blue Grey PurpidOrangel Pink 77 M2 Symbol 8 w R G Y B B Gr Pi 0 P 8 handbrake indicator 10 1244 error indicator 11 pump controler eror inate 13 key input 15 low power pretect 19 electrical heat relay PUMP MOTOR oil pump motor 1001 3 3 TRACTION MOTOR service motor HH horn 1 XL accumulafor connector SFI brake lamp switch 1 FUS fuse SAS red urgent stop button 1 FU3 FU fuse SAG seat switch n FU2 fuse SA3 key switch 1 Fut fuse 9 SA2 direction switch 1 SMS hand brake switch 8 SA1 turning lamp switch Hi SM4 the 4th handle 7 Se lamp switch D SM3 side moving controller 6 KMI 2 main contactor 2 SM3 tilting controller 5 RCI horn filter 1 SMI 2 lifting controller 4 H3 H4 Fhree colors rear lamp 2 sp hydraulic switch DICH side lamp 2 SB horn button 2
21. Loose of pressure adjust screw Readjusted and retighten Distorted or damaged pressure adjust spring Replace Worn or blocked relief valve core Replace or clean Pump abated Examine and repair pump Fork tilt forward when control lever Worn or damaged tilt lock valve Replace valve core and tilt lock valve as an assembly Broken tilting lock spring Replace spring is used while engine is off Damaged tilt valve plunger O ring Replace O ring Mest SE Malfunctioning tilt relief valve Replace tilt relief valve assembly when tilting forward Lowering distance of mast is big when spool valve is in the centre Valve body and spool valve is worn and clearance between them is too great Replace spool valve with specified clearance Spool valve is not in centre Keep being in the centre Cylinder seal abated Examine and repair cylinder Taper valve is worn or blocked by dirt Replace or clean taper valve Spool valve is not Damaged or distorted reposition spring Replace spring Dirt exist between valve body and spool Clean return neutral vale position Blocked control device Adjusted Not coaxial parts at reposition Reinstall be coaxial Damaged O ring Replace Faulty seal of joint Check and retighten Leakage LOOSE SEAL PLATE Clean seal plate and retighten blots Loosed lock nut of relief valve
22. Main contactor tips are welded closed Welded 2 Motor phase U is disconnected or open 3 An alternate voltage path such as an external precharge resistor is providing a current to the capacitor bank B connection stud 3 9 Main Contactor Did 1 Main contactor did not close Not Close 2 Main contactor tips are oxidized burned or not making good contact 3 External load on capacitor bank B connection stud that prevents capacitor bank from charging 4 Blown B fuse 41 CODE PROGRAMMER LCD HPAY POSSIBLE CAUSE 4 1 Throttle Wiper High 1 Throttle pot wiper voltage too high 2 See 1311 menu Monitor Inputs Throttle Pot 4 2 Throttle Wiper Low 1 Throttle pot wiper voltage too low 2 See 1311 menu Monitor Inputs Throttle Pot 4 3 Brake Wiper High 1 Brake pot wiper voltage too high 2 See 1311 menu Monitor Inputs Brake Pot 4 4 Brake Wiper Low 1 Brake pot wiper voltage too low 2 See 1311 menu Monitor Inputs Brake Pot 4 5 Pot Low Overcurrent 1 Combined pot resistance connected to pot low is too low 2 See 1311 menu Monitor Outputs Pot Low 4 6 EEPROM Failure 1 Failure to write to EEPROM memory This can be caused by EEPROM memory writes initiated by VCL by the CAN bus by adjusting parameters with the 1311 or by loading new software into the controller 4 7 HPD Sequencing Fault 1 KSL interlock direction and throttle inputs applied
23. Monitor Controller Temperature 1 6 Controller Severe 1 Controller is operating in an extreme environment Overtemp 2 Excessive load on vehicle 3 Improper mounting of controller 4 See 1311 menu Monitor Controller Temperature 1 7 Severe Undervoltage 1 Battery Menu parameters are misadjusted 2 Non controller system drain on battery 3 Battery resistance too high 4 Battery disconnected while driving 5 See 1311 menu Monitor Battery Capacitor Voltage 6 Blown B fuse or main contactor did not close 1 8 Severe Overvoltage 1 Battery Menu parameters are misadjusted 2 Battery resistance too high for given regen current 3 Battery disconnected while regen braking 4 See 1311 menu Monitor Battery Capacitor Voltage 2 1 Controller Undertemp 1 Controller is performance limited at this temperature Cutback 2 Controller is operating in an extreme environment 3 See 1311 menu Monitor Controller Temperature 39 CODE PROGRAMMER LCD DISPLAY POSSIBLE CAUSE 2 2 Controller Cutback Overtemp 1 Controller is performance limited at this temperature 2 Controller is operating in an extreme environment 3 Excessive load on vehicle 4 Improper mounting of controller 5 See 1311 menu Monitor Controller Temperature 2 3 Undervoltage Cutback 1 Normal operation Fault shows that the batteries need recharging Controller is performance limited at this voltage Batter
24. O Bh rmornerorwece y 7 29 2123 cay goo sten me oru can E 500000b0000000000000 imu Bail Jos sl avum n H Allee sy E voel dc amp meven mat lees zl aleg E b e e le le b B B je e B e e pP B 8 PPP 31 TL locas left right left right left righHleft left right right left right left right az Ed gt 3 amp E SZ SS 3 y ES a ee tog 03 m gt 3 uo 9 0 0 a amp 5 3 S 2 3 ZZ SS 9 8 a a gt 8 8 8 8 m7 xx E R 328 SS 2 3 R r w asa 3 3 EER 7 nd L7 858383 Y R A 20W 120W Ech Y EH 32 PUMP MOTOR oil pump motor 1 15 JDQ1 3 relay 3 enGagelV instrument 31 TRACTION MOTOR service motor 1 14 HH horn 1 7 BDI 30 XL accumulator connector 1 13 SFI brake lamp switch 1 2 BDI 29 FUS fuse 1 12 SAS red urgent stop button 1 MI wire color Black white Red GreenfYellod Brow Blue Grey PurptdOrange Pink i M2 28 FU3 FUS fuse 2 11 SA4 seat switch un Symbol B w R G Y Br B Gr Pa 0 P B handbrake indicator 27 Fu2 fuse 1 10 SA3 key switch 1 10 1244 error indicator 26 FUI fuse 1 9 SAZ direction switch 1 i puny controler error wie 25 SMS hand brake switch 1 8 SA1 turning lamp switch 11 key input 15 low power pretect 24 SM4 the 4th handle 1 7 SL lamp switch 1 19 electrical heaf 23 SM3 side moving controller 1 6 KMI Z main contactor 2 22 SM3 tilting controller 1 5 RCI horn filter 1 21 SM1 2 lifting controller 2 4 H3 H4 three
25. OSSIBLE CAUSE 1 2 HW FAIL SAFE1 2 3 self test or watchdog fault Controller defective M SHORTED internal M short to B 1 Controller defective D 1 Motor field wiring loose ll FIELD OPEN Field winding fault 1 2 Motor field winding open ARM SENSOR armature current sensor fault 1 Controller defective FLD SENSOR Field current sensor fault 1 Controller defective 1 VSC input wire open SPEED CONTROL 2 VSC input wire shorted to B 2 1 FAULT VSC signal exceed range or B 3 Throttle pot defective 4 Wrong throttle type selected 1 Improper seq of direction and throttle inputs 2 3 START LOCKOUT starting sequence wrong T WORSE TAISTDOGKOUT type selected 3 Misadjusted throttle pot 4 Sequencing delay too short 3 1 CONT DRVR OC cont driver output over 1 Contactor coil shorted current 3 2 MAIN CONT WELDED welded main contactor E Main contactor EE closed 2 Main contactor driver shorted internal voltage too low at 1 Controller defective 3 3 PRECHARGE FAULT startup 2 External short or leakage path to B on external B connection MISSING ae Sie 1 Any contactor coil open or not CONTACTOR E LIT connected 3 4 CONT DNC main contactor did not close Main contactor ing or wire to coil open 1 Battery voltage gt overvoltage shutdown limit 4 2 OVERVOLTAGE overvoltise 2 Vehicle operating with charger attached 3 Battery disconnected during regen braking Temperature 285 C or lt 25 C EE 2 Excessive load
26. P HC HANGCHA CPD10 15 18 20 25 30J CPD10 15 18 20 25 30J D1 CPD10 15 18 20 25 30 35J C1 CPD10 15 18 20 25 30 35J C2 CPD40 45 50J D1 CPD40 45 50J C2 1 5t J Series Counterbalanced Battery Forklift Truck SERVICE MANUAL LE Original Instruction HANGCHA GROUP CO LTD Dec 2010 3 edition FOREWORD Thanks for your purchasing our forklift truck 4 wheel counterbalanced battery forklift truck is our company s new product It has the character of small turning radius beautiful shape small dimensions low gravity This operation manual is the explanations that how to use 1 3tJ series forklift truck correctly It will instruct you how to operate safety and precautionary maintenance To ensure safety and exert the truck s potential all the personnel that in charge of operation maintenance and management must read this manual thoroughly before starting work with the forklift This manual is applicable to container trucks Forbid repairing the truck if you haven t been trained Our product design will update and perform better so the content in this manual may be not the same as the forklift you owned If you have any questions please keep touches with HANGCHA GROUP CO LTD sales department or let the agents know The meanings of model Truck model Tow electric Rise electric Rated capacity t control control load centre distance mm 1244 1254 CPD10 15 18 20 25 30 e
27. W 2 18 HE warning lamp LTDI52A AV 1 1 66 acidic battery 40 moulded case 17 HU Revese beeper DJB 248 24v 1 NO CODE NAME MODEL SPECIFICATION QTY REMARK 16 HT flasher SG224C My 1 WIRING DIAGRAM OF CPD10 15 18 20 25 30J DUR mue Ws wm FP TI AlAaFIFe B B Al Aa F1F2 TOWING AIE1 A2E2 DIL PUMP TR E BUE LAR al CONTROLL ER BOX KEY SWITCH RECTION aw O 9 waan LEFT HEAD LAP LEFT SIC LAP ELECTRICAL SYSTEM PRINCIPLE DIAGRAM OF CLPDT07 15 7 187 20 7257 307 35 J C f x 1 pus EVC255 4803 RA RW TN 0 Ei RW RW p RW RW mr b 4003 A m 002 aci battery Light switch HT een NOE aM i Turning lamp switch P sa o y sat er lazo je i Reese lamp sit AS dm n Ca P mal zm E entegelY instrument 66 gt gt Br Je panos 1 20 3 ER mme EZ 1003 8 8 R d E D i Bl wW 3 Y Y W 8l 224 roe cum Zo Ei Ee
28. ameter KEY ON ON ON KEY OFF 312 ON checksum error 313 PCB low temp warning D GE or KEY ON ON ON ON EEY OIE PCB temperature gt 100 C T SAN x KEY OFF 314 PCB high temp warning only GEN4 GEN5 not KEY ON ON ON ON 315 PCB sensor error d GE Ee iube KEY ON ON ON ON RE OE 316 une nu ES Current check default error KEY ON ON ON ON KEY OFF error 50 RINCIPLE DIAGRAM UF CPDO10 13 18 20 29 30 T E U ELECTRICAL SYS MI grow RELAY F D 01 eer PR Bint Pr EI EN m RW lew W X ae ui Pin T m SL 1003 Sil 1002 sed Light switch AT Pester En d sn 5i su ag pes e gat Jer dd e i DU Battery lo Reverser long switch Brake lomp switch eo D Pele DV FOR 3T ring lamp suid Cy EET 1254 bat 4002 E vvv AM ede gt EE n hs P 6 M et 66 B Bu 0 3 d se ias pe pz n pas 88 R hael TTT EREEEEREEI D D J
29. and connect nut between plate and plate Tighten 24 Adjusting the pressure of the main relieve valve The pressure of the main relieve valve is all ready adjusted in the factory and it can t be adjusted generally The following is an example of 3t truck to specify how to adjust the pressure 1 Put 125 percent of the rated load 2000kg on the forklift stable 2 Step the accelerated pedal to the end control the lift pole if the forklift can get the height of 300mm the main relieve valve is all right Otherwise adjust it as step 3 3 If the forklift can t work enhance the pressure main relieve valve remove the front soleplate loosen the tightening nut of the main relieve valve screw the adjusting nut clockwise to enhance the pressure of the main relieve valve If the height of lift is higher than 300mm screw the adjust nut anti clockwise to reduce the pressure 4 Step the accelerated pedal to the end to make the forklift in the height range of 0 300mm Otherwise adjust it as step 3 Warning The load should be put stably Don t adjust if the pressure is already adjusted correctly 25 Hydraulic system principle diagram steering cylinder lift cylinder tilting cylinder A B E iX R single direction al Ip throttle valve adjusting adjusting Mera cylinder cylinder Zi redirector multi spool control valve PT Al Bl AIR A3 B3 M B4 sd ad 1 i x amp
30. ation see fig 5 5 N 3 7 8 9 10 p 12 13 14 15 16 17 e Bi E Se D 2 j U 1 e Fig 5 5 Lifting cylinder 1 LBH dust proof 2 ISI ring 3 Plug screw 4 O Ring 5 Piston 6 Bolt 7 Guide 8 bush 9 Cylinder body 10 Piston 11 Snap ring 12 Piston 13 Support ring 14 Back up rings 15 OSI ring 16 Valve guide 17 Snap ring 18 Steel axletree 19 Blowout patch 20 Adjusting washer 5 5 Tilting cylinder 23 23 L2e 24 12 45 t 78 19 ID 11 13 1415161718 192 P DI HE ZA GZ oy A ww LZ e ML 1 E PSS e JUBA ii mar EEN i Fig 5 6 Tilting cylinder 1 Retaining 2 Knuckle bearing 3 Support 4 Lubrication 5 Nut ring nipple 6 Bolt 7 dust proof 8 Cylinder 9 Guide 10 U ring 11 O ring 12 Piston rod 13 O ring 14 Thimble 15 U ring 16 Piston 17 Cylinder body 18 Washer 19 Nut 20 Pin 21 bolt 22 Nylon tray 23 Snap ring 24 Snap ring 25 Adjusting washer 32 6 Electrical system 6 1 CPD10 15 20 25 30J fork 6 1 1summarize Curtis PMC 1244 MultiMode controllers are separately excited motor speed controllers designed for use in a variety of material handling vehicles These programmable controllers are simple to install efficient and cost effective Typical applications include low lifts stackers fork lifts reach trucks personnel carriers counterbalance trucks order pi
31. by VMC20 260 ACS low voltage trip ACS voltage 15V KEY 0N OFF ON ON KEY OFF Instantaneous voltage 261 ACS high voltage trip ACS voltage gt 68V software KEY 0N OFF ON ON KEY OEF Instantaneous voltage 262 ACS high voltage trip ACS voltage gt 68V hardware KEY 0N OFF ON ON KEY OFF Instantaneous voltage ACS PCB temp gt 115 C 263 ACS PCB temp trip KEY ON OFF ON ON KEY OFF only GEN4 GEN5not P Other urgency instance from 264 Other error KEY ON OFF ON ON KEY 0FF ACS 47 3 Errors detected by drive ACS Warning Code Source Condition When Tract Main PS Reset Remark 201 ACS low temp warning ACS heat sink temp lt 20 C KEY ON ON ON ON KEY OFF or Heat Lowest Accel will be used i sink temp normal 202 ACS high temp warning ACS heat sink temp gt 85 C KEY ON ON ON ON KEY OFF or Heat Lowest Accel will be used i sink temp normal 203 Motor high temp warning Motor temp gt 145 C KEY ON ON ON ON KEY OFF Lowest Accel will be used 204 Heat sink temp sensor error ACS heat sink temp KEY 0N ON ON ON KEY 0FF Lowest Accel will be used sensor error 205 Motor low temp warning Motor temp lt 50 C KEY ON ON ON ON KEY OFF Lowest Accel will be used 206 Motor temp sensor error Motor temp sensor KEY 0N ON ON ON KEY OFF or sensor Lowest Accel will be used not connected or short circuit i connected 207 Speed feedbac
32. ckers boom trucks and other industrial vehicles The 1244 MultiMode controller offers smooth silent cost effective control of motor speed and torque four quadrant full bridge field Winding control stage is combined with a two quadrants half bridge armature power stage to provide solid state motor reversing and regenerative braking power without additional relays or contactors The 1244 controller can also be specified to be compatible with CAN Bus communication systems These controllers are fully programmable by means of the optional handheld 1307 programmer Use of the programmer provides diagnostic and test capability as well as configuration flexibility Like all Curtis PMC motor controllers the 1244 offers superior operator control of the vehicle s motor drive speed Features include _ Full bridge field and half bridge armature power MOSFET design providing Infinitely variable forward reverse drive and brake control Silent high frequency operation High efficiency _ Regenerative braking providing longer operation on a single battery charge and reducing motor brush wear and motor heating _ Programmability through the 1307 handheld programmer _ Complete diagnostics through the 1307 programmer and the internal Status LED _ Two fault outputs provide diagnostics to remotely mounted displays Continuous armature current control reducing arcing and brush wear _ Automatic braking when throttle is reduced from either direction this p
33. colors rear lamp 2 20 SP hydraulic switch 1 3 H1 H2 side lamp 2 19 SB horn button 1 2 ELI EL2 head lamp 2 18 HE warning lamp 1 1166 acidic battery 17 HU Revese beeper 1 NO m TIPS PNE CODE NAME REMARK ELECTRICAL SYSTEM PRINCIPLE DIAGRAM OF CPD10 15 18 20 25 30 40 45 50J D1 Lr XL 1 L T FUL RW ow low ow 0 E lus Ejus m mi RW RW d CHARGING CIRCUIT KS Relay switch 3 m lid id lrrerlav Engen sviten SL y Gr roster Relay swilch Zlcoil wy Relay switch 1 gp A fe Light switch Ze Key switch lan E ddi Ste Broke lamp switch a La p LI Wier A ou CN map BOY FOR 3T 99 E a 48V FOR I 25T Relay switch 2 E ED ru vs Turning lomp switch P G mesm aa ZP E dE IG Vu ME VL zn 66 Br Am SC A mo E Lm rnm al p s 20 3 Puno SPEED3 eg aly sola o orp iT PME TE Relay switch coi R Horn switch
34. e controller So need apart form magnetic and radiation 45 6 3 2 Error code 1 Errors detected by VMC20 Code Source Condition When Tract Main PS Reset Remark 101 Switch startup error ACCEL switch active at startup KEY ON OFF ON ACC SWITCH 0FF Traction setspeed 0 102 Switch startup error FWIREV switch active at startup KEY ON OFF ON FW REV OFF Traction setspeed 0 103 Direction switch FW and REV ON at the same time KEY ON OFF ON KEY 0FF Traction setspeed 0 error 104 Accel pot error Pot voltage gt 95 or Pot voltage lt KEYZON ON ON i KEY 0FF Traction setspeed 0 5 of VX_out 105 Accel switch error Voltage gt 30 when ACC switch KEY ON ON ON KEY 0FF Traction setspeed 0 1s not active 107 Battery under 48V Less than 28 2V 8s KEY ON OFF OFF 7 KEY OFF Detected by VMC20 not by ACS voltage 36V Less than 24 8V 8s 108 ACS under voltage Voltage limit Parameter for KEYZON OFF OFF E KEY 0FF Detected by VMC20 not by ACS more than 0 8sec 109 Battery over voltage More than 65V 0 8s KEY ON OFF OFF KEY OFF Detected by VMC20 not by ACS 110 ACS over voltage Voltage gt limit Parameter for KEY ON OFF OFF KEY OFF Detected by VMC20 not by ACS more than 0 8sec 111 Communication See 5 2 1 KEY ON OFF ON KEY OFF Traction setspeed 0 error i KEY OFF Only happens at the place where the 112 PM brush wear wear and tear
35. eee me etes 33 6 2 CPD10 15 20 25 30 35J C1 CPD10 15 18 20 25 30 35J C2 CPD40 45 50J C2 FORK 37 6 3 CPD10 15 20 25 30F D1 FORK EE 44 T MAINTENANCE RECORD etre dette tee tek e hes en POE He D e Pen 57 1 Driving system Drive system is composed most components such as electrical engineering gear box driving axle detent tyre and wheel rim Gear box is two grades reduce speed gear one grade straight gear and one grade planet gear So the gear box is very small Detent is a hoof detent if you need know the particular content you can see relevant portion of the trig system 1 1 Engine for Forklift 1 1 1Data CPD10 15J 18J Rated Rated Voltage Current V A Excitations Insulation Cooling Protecting Ration Mode Grade Mode Grade m XQ 5 3A E 45 139 separate mi IP20 60 excitation XQD 82 3D 8 as Ico1 IP20 excitation CPD20 25J Rated Rated Voltage Current V A Excitations Insulation Cooling Protecting Ration Mode Grade Mode Grade m XQ 7A 45 180 ie Icol IP20 60 excitation XQD 8 6 3D i ae Icoo IP44 excitation CPD30J Rated Rated Voltage Current V A Excitations Insulation Cooling Protecting Ration Mode Grade Mode Grade m separate ICO1 IP20 60 XQ 10 2A 75 162 5 excitation XQD 10 3D 161 6 mu ICO1 IP20 excitatio
36. eering wheel upside steering column downside steering column bearings steering gear priority valve clamp bolt and hydraulic switch etc You can adjust the steering angle forward and backward by yourself Refer to fig 2 1 1 2 j 3 steering wheel neutral A Arotation C orientate rotation eN 20 e 1 Steering wheel 3 Upside steering 8 Gimbal 10 Down side 12 Bearing column steering axle 13 Snap ring 14 Down side 17 Steering gear 18 Priority valve 19 Clamp bolt steering column 22 Clamp lever 26 Hydraulic switch Fig 2 1 Steering device 14 2 2 Steering axle 2 2 1 General specifications Axle centre none for 4 5t Axle body Center support swing type type Vertical play mm 01 Inner 1 1 5t 79 5 wheel 2 3t 80 Turning 1 1 8t 56 Adjusting shim for end angle Outer shaft of axle thickness 0 5 1 0 1 6 wheel 2 3 55 7 mm Tyre 0 9MPa Part No N163 220020 000 pressure Kingpin wheel hub bearing Less than Tighten steering spindle nut until Kingpin axial play mm 0 20 drive wheel hub no longer Pre tighten rotates with one hand Then Kingpin adjusting washer loose 1 8 1 6 rotations Or wheel hub rotation starting thickness mm Part No torque at hub blot 10 29 8N Axial 0 10 0 30 0 70 N163 220012 000 Less than 0 10 play mm Truck type 1 1 8t 2 2 5t 3 3 5t 4 5t weight Kg 66 68 96 99 98 100 135 150
37. emp Cutback should be programmed Off 2 9 40 Motor Temp Sensor Fault 1 Motor thermistor is not connected properly 2 If the application doesn t use a motor thermistor Temp Compensation and Temp Cutback should be programmed Off 3 See 1311 menus Monitor Motor Temperature and Monitor Inputs Analog2 CODE PROGRAMMER LCD DISPLAY POSSIBLE CAUSE 3 1 Coil 1 Driver 1 Open or short on driver load Open Short 2 Dirty connector pins 3 Bad crimps or faulty wiring 3 1 Main Open Short 1 Open or short on driver load 2 Dirty connector pins 3 Bad crimps or faulty wiring 3 2 Coil2 Driver 1 Open or short on driver load Open Short 2 Dirty connector pins 3 Bad crimps or faulty wiring 3 2 EM Brake Open Short 1 Open or short on driver load 2 Dirty connector pins 3 Bad crimps or faulty wiring 3 3 Coil3 Driver 1 Open or short on driver load Open Short 2 Dirty connector pins 3 Bad crimps or faulty wiring 3 4 Coil4 Driver 1 Open or short on driver load Open Short 2 Dirty connector pins 3 Bad crimps or faulty wiring 3 5 PD Open Short 1 Open or short on driver load 2 Dirty connector pins 3 Bad crimps or faulty wiring 3 6 Encoder Fault 1 Motor encoder failure 2 Bad crimps or faulty wiring 3 See 1311 menu Monitor Motor Motor RPM 3 7 Motor Open 1 Motor phase is open 2 Bad crimps or faulty wiring 3 8 Main Contactor 1
38. ete 2 Start engine and raise carriage about 100mm 3 Place chocks behind rear wheels to prevent movement of forklift truck 4 Loosen wheel nuts two or three turns each 5 Tilt mast fully backward and place a wooden block under each side of outer mast NWARNING Do not allow wooden blocks to touch front tires 6 Tilt mast forward until front tires are raised from surface 7 Support forklift truck by putting additional wooden blocks under each side of front end frame 8 Stopengine 9 Remove wheel tire nuts and brake drum 10 Replace brake shoes with new ones 11 Install brake drum 12 Adjust shoe to drum clearance D Remove adjusting hole plug on the bottom of the brake assemble 2 Insert a flat blade screwdriver to adjusting hole turn adjusting ratchet wheel downward to expand the brake shoes until wheel hub can not be turned by hand 8 Move the ratchet wheel 2 3 notches to allow the wheel hub to be turned freely slight friction is allowed between the brake and shoe lining Replace the plug 5 Install wheels 8 Properly adjusting pedal stroke Remove blocks make sure no person or obstacle is around forklift then operate forklift in reverse at 2 to 3 km h set foot on brake pedal 2 3 times 21 3 3 Hand brake device The hand brake device adopts a hand pulling soft brake wire cable device It makes use of auto assist pressure linings type brake together with foot brake Only when parking truck
39. g 5 O ring 6 Guide sleeve 7 Glay ring 8 Crock 3 Brake system The brake system is the front two wheel braking type consisting of a master cylinder brakes and brake pedal 3 1 Master cylinder The master cylinder contains a valve seat check valve return spring primary cup piston and secondary cup which are kept in place with stop washer and stop wire The exterior of the cylinder is protected from dust by means of a rubber dust cover The piston is actuated through the push rod by operation of the brake pedal First as the brake pedal the push rod pushes the piston forwards The brake fluid in the cylinder flows back to the reserve tank through the return port until the primary cup blocks up the return port After the primary cup passes the return port the brake fluid in the cylinder is pressurized and opens the check valve flowing through the brake lines to the wheel cylinder Thus each wheel cylinder piston is forced outwards This brings the brake shoes into contact with the wheel drum and slows or stops the lift truck Meanwhile the cavity caused behind the piston is filled with brake fluid led through the return port and inlet port to lubricate the piston When the brake pedal is released the piston is forced back by the return spring At the same time the brake fluid in each wheel cylinder is pressurized by the force of the brake shoe return spring thus returning into the master through the check valve With the piston in its
40. g bracket and brake component apply a coat of calcium grease to axle tube 2 Apply 1 3 2 3 of volume of calcium grease to wheel hub then install them on axle tube 3 Install oil seal with its part number facing to the inside of forklift truck 4 attach seal tape PVC white to drain plug then installed after cleaned it 6 Replenish axle case with gear oil Tighten vent plug after clearing 2 8 1 1 8t GL 5 Gear oil L 32 2 3t 85W 90 4 5 4 5t 11 Vent plug should clear instantly to prevent pressure inside of wheel hub from rising 1 3 4 Axle shaft and wheel hub Remove 1 Raise the front end of forklift truck and support frame with wooden blocks 2 Remove front wheel and axle shaft 3 Remove lock nuts lock washers snap ring felt ring adjusting nut Use special tools 4 Remove brake drum refer to Fig 5 4 If brake drum is difficult to remove a Remove adjusting hole plug Then with flat blade screwdriver extend adjusting hole turn adjusting ratchet wheel by 10 notches To contract brake shoe lining refer to Fig 5 5 b evenly tapping on brake drum with brass bar or wooden mallet shoc backmg plate assembly adjusting nut adjusting hole plug ag Ee brake dust cover Fig 1 4 Fig 1 5 5 Remove wheel hub be careful not to drop bearing inner race 6 Remove oil seal and inner bearing as an assembly by evenly tapping on periphery of seal with a wooden mallet and bra
41. g soleplate bolt 76 107 118 147 157 176 nut connecting brake 324 373 drum and hub 260 347 324 373 Bolt and nut connecting 324 373 support plate and truck 260 347 324 373 body D Tyre nut E 157 176 441 588 441 588 1 3 3Driving axle assemble removal and installation Be careful when removal and installation driving axle as 1t is heavy 1 Raise front end of forklift truck and support frame with wooden blocks 2 Remove mast assembles 3 Slightly raise axle with a hoist and place wooden blacks under differential gear carrier and transmission case 4 After placing a pan under axle case loose oil plug drain oil from axle case 5 Disconnect brake nuts from left and right cylinders see fig 5 1 CAUTION Plug brake tube openings to prevent oil from flowing out 6 Disconnect brake cable at hand brake lever 7 Remove front wheels 8 Remove axle shaft 9 Support driving axle with wire ropes and lifting device 10 Remove bolts securing axle mounting bracket to frame see fig 5 2 11 Remove nuts securing axle case to differential gear carrier see fig 5 3 12 Remove driving axle assemble Fig 1 1 13 Remove brake drum remove wheel hub 14 Remove axle mounting bracket and brake component from axle tube 15 Remove oil seal from axle tube 16 To install driving axle assemble in the reverse order of removal Observe the following D When installing axle mountin
42. i CURTIS 1 0 500 1 5 500 1 8 500 SCH SCH 2 0 500 2 5 500 3 500 4 500 4 5 500 5 500 CPD 10 15 18 20 25 305 DI MOTIONS DE NT 1238 EVC255 1 0 500 1 5 500 1 8 500 CPD10 15 18 20 25 30 35J C1 CURTIS CURTIS 2 0 500 2 5 500 3 500 3 5 300 1238 1236 1 0 500 1 5 500 1 8 500 CPD10 15 18 20 25 30 55J C2 CURTIS CURTIS 2 0 500 2 5 500 3 500 3 5 300 1238 1238 CPD40 45 501 C2 aris curtis 4 500 4 5 500 5 500 Dec 2010 3 edition HANGCHA GROUP CO LTD CONTENT FOREWORD 1 DRIVINGSYSTEM nnt teet determi emet De GE RR Ge ee Maes 1 ENGINE FOR FORKEIPT e 2 2 3 de eet te pne tene ere 1 LECH ees ds 8 LS DRIVINGAXLE Sa duda tte ed eta tede ta rre Ft Deakins Po ea ek 9 2 S TEBRING SY STEM nd sshd thes boss p pre ele re bene o e bang epe bed exister otis 14 ALESTEERING DE VIEE tres geg ba 14 22S TEERING AXLE oie e Ina e e nee tee e oe eas 15 3 BRAKE SYSTEM eet br OP eite t eoe Prep 19 3 1 MASTER CYLINDER etre ete ree Ree eet et e o i sb ete 19 32 EOOT BRARKE 3 ed RR p HE d ie er pon i eo e e Rr IG 20 33HAND BRAKE DEV IGE etn tr teer eee nee ied i ae opens 22 4 HYDRAULIC SYSTEME 2h EE EE EE rn i rte re og rie leidas 23 SIPING SYS TEM ettet dis 27 SX DATA seen RP sb EE HEURE Ede 27 AS Bb EU 28 5 3 MAS KEE 30 SA EIETING CYLINDER ki pinan OR RR e Re EE N RE N 32 skeid di MEI LEO AR ICT EE 32 6 ELECTRICAL SYSTEM ED GE rp re gerer e re eae teri ere 33 6 1 PD1 0 15 20 25 3 OU FORK ER EE tne
43. install front Tire pressure 10 30MPa Wheel hub rotation starting torque at hub blot N 10 29 Axial play of wheel bearing mm less than 0 08 125 130 195 198 202 208 350 380 1 3 2 Trouble diagnoses and corrections condition Probable cause Corrective action loose driving axle and body connecting blots Tighten loose wheel nut Tighten worn or damaged wheel hub bearing Replace Abnormal noises wheel hub bearing not properly adjusted Adjust worn axle shaft spliner Replace insufficient lubrication Lubricate loose wheel nut Tighten deformed wheel Replace worn or damaged wheel hub bearing Replace Unstable driving loose driving axle and body connecting blots Tighten wheel hub bearing not properly adjusted Adjust improper tire pressure Adjust worn or damaged axle shaft oil seal Replace Oil leakage final drive improperly installed Replace gasket Joose drain plug Tighten O9 DY o gt p el ADA 9 X9 OE TIKAT E M ec Fig 3 1 Driving axle 1 Rim 2 Brake drum 3 wheel hub 4 Wheel nut 5 Wheel hub bolt 6 Bolt 7 Brake Assembly 8 Wash 9 Bolt 10 Half axle nut 11 Half axle 12 Bolt 13 Oil seal 14 Taper roller 15 Adjusting nut bearing 16 Lock nut 17 Pin 18 Paper shim 19 Oil seal 20 Axle case 21 Supporter Tighten torque N m 1 1 8t 2 3t 4 5t Axle shaft bolt A 44 58 73 5 88 3 105 156 Tri
44. ith bottom of cylinder body after inner mast is in touch with rubber pad 28 Fault Probable cause Corrective action Insufficient lift power or no lift movement 1 Excessive wear occurs between the oil pump body and gears causing too much clearance Replace the worn parts or the oil pump 2 The lifting jack piston Yx ring has worn resulting in excessive inner leaks Replace Y x ring 3 Springs of the multiple control valve and its relief valve are inoperative oil Replace leaks 4 Excessive wear occurs of the hydraulic control valve resulting in excessive oil Replace leaks 5 Oil leaks occur between the hydraulic control valve sections Dismantle for regrinding the joint surfaces and reassemble the valve 6 Leakage occurs in the hydraulic pipe Tighten the joint nuts and inspect the seal for damage 7 The hydraulic oil temperature is too high Oil viscosity is too low and the rate is insufficient Change the wrong hydraulic oil or stop operation for reducing the oil temperature Find out the reasons for high oil temperature and eliminate the trouble 8 The load carried is beyond the designed capacity Observe the lifting capacity limit 29 5 3 mast Basic mast is 3m high composed of inner and outer mast fork arm carrier fork arm chain and idler wheel etc
45. k sensor error Speed feedback sensor KEY 0N ON ON ON KEY OFF or sensor ACS can not control speed not connected short circuit E connected correctly No driving allowed 208 ACS high voltage warning ACS voltage gt 68V KEY ON ON ON ON KEY OFF or voltage Lowest Accel will be used i back to normal 209 ACS low voltage warning ACS voltage lt 22 5V KEY 0N ON ON ON KEY OFF or voltage Lowest Accel will be used back to normal 210 ACS default values loaded ee are used KEY ON ON ON ON KEY OFF Tum the key s witch offand on again in 211 Power reduce Power is reduced by KEY ON ON ON ON KEY OFF some warning condition 212 Checksum error Calibration parameter KEY 0N ON ON ON KEY 0FF checksum error E 213 j PCB temp lt 20 C KEY 0N ON ON _ KEY OFF PCB low temp warning onlyGEN4 GENS not ON PCB temp gt 100 C E 214 PCB high temp warning only GEN4 GENS not KEY ON ON ON ON KEY OFF 215 PCB sensor error o KEY ON ON ON ON KEY OFF 216 Current sensor default error Current check default error KEYZON ON ON ON KEY OFF 48 4 Errors detected by pump ACS EMCY Code Source Condition When Tract Main PS Reset Remark 351 Short circuit ACS is shorted or motor terminals KEY ON OFF OFF ON KEY OFF ACS may be damaged if short are shorted circuit is internal 352 ACS over ACS hs
46. ltage in the capacitor or else you may meet tip and run danger 2 Magnetic and radiation have some effect to inverter long time effect may mangle controller So need apart form magnetic and radiation 38 6 2 2 Error code CPD10 35J C1 EC ERROR CODE TABLE There are two LEDs including a yellow LED and a red LED The two LEDs have four different display modes indicating the type of information they are providing DISPLAY STATUS Controller is not powered on has a dead Neither LED illuminated f battery or is severely damaged Yellow LED flashing Controller is operating normally Yellow and red LEDs both on solid Controller is in Flash program mode Red LED and yellow LED flashing alternately Controller has detected a fault TOWING CONTROLLER ERROR CODE TABLE CODE PROGRAMMER POSSIBLE CAUSE LCD DISPLAY 1 2 Controller Overcurrent 1 External short of phase U V or W motor connections 2 Motor parameters are mis tuned 3 Controller defective 1 3 Current Sensor Fault 1 Leakage to vehicle frame from phase U V or W short in motor stator 2 Controller defective 1 4 Precharge Failed 1 External load on capacitor bank B connection stud that prevents the capacitor bank from charging 2 See 1311 menu Monitor Battery Capacitor Voltage 1 5 Controller Severe 1 Controller is operating in an extreme environment Undertemp 2 See 1311 menu
47. ly to the battery discharge External Agents Electric control is hermetical The chopper is protected against dust and spray of liquid to economy 8 Protection against accidental Start Up A precise sequence of operations is necessary before the machine will start Operation cannot commence if these operations are not carried out correctly Requests for drive must be made after closing the Key Switch 4 Operational features D Feedback control system make the vehicle speed follow accelerator whether low speed or not high speed easy control 2 Two archives speed and acceleration design can apply to most situation 3 Regeneration technology make change direction of fork even smooth 44 4 Three regenerative braking mode A acceleration pedal part release appear regenerative braking B direction reverse regenerative braking C ramp downslide appear regenerative braking Except increase security drive reclaim part of electric energy prolong work time of every time 6 Control speed during downgrade speed lie on accelerator if speed exceed set point controller may automatic braking this give optimal ramp Notice 1 Maintain electric control must first cut off electrical source then hold 10 1000hmic resistance join controller anode and cathode release residual voltage in the capacitor or else you may meet tip and run danger 2 Magnetic and radiation have some effect to inverter long time effect may mangl
48. n CPD10 15 18J C1 Rated Voltage V Rated Current A Excitations Mode Insulation Grade Cooling Mode Protecting Grade Ration m YDQ6 8 AHC 31 222 AC F TCO1 IP20 60 XOD 8 2 3D CPD20 25J C1 45 Rated Voltage V 172 8 Rated Current A series excitation Excitations Mode F Insulation Grade TCO1 Cooling Mode IP20 Protecting Grade Ration m YDQ9 1 4HC 31 280 AC F TCO1 IP20 60 XOD 8 6 3D CPD30 35J C1 45 Rated Voltage V 248 Rated Current A series excitation Excitations Mode F Insulation Grade 1C00 Cooling Mode IP44 Protecting Grade Ration m YDQ11 75 4HC 51 180 AC F ICO1 IP20 60 XOD 10 3D 75 CPD10 15 18J C2 Rated Voltage V 161 6 Rated Current A series excitation Excitations Mode F Insulation Grade ICO1 Cooling Mode IP20 Protecting Grade 15 Ration m YDQ6 8 4HC 31 222 AC F ICO1 IP20 60 YDQ 8 6 CPD20 25J C2 31 Rated Voltage 248 Rated Current A AC Excitations Mode F Insulation Grade ICO1 Cooling Mode IP44 Protecting Grade 5
49. n kingpin 4 Remove kingpin Caution Hold kingpin to prevent it from dropping See fig 2 3 5 Take off spindle thrust bearing and shim Fig 2 2 Fig 2 3 INSPECTION 1 Replace spindle if cracked 2 Replace bearing if its rollers or roller surfaces are rusted or nicked 3 Replace steel sleeve if it distortion out of round cracked 4 Replace thrust bearing and dust cap if them damaged Installation To install reverse the order of removal Careful observes the following 1 always insert kingpin from lower side 2 install thrust bearing set the tighten ring below the support and loosen ring Pack all grease between dust proof inside loosen ring and tighten ring 3 adjust axial play to specification with shims Axial plays less than 0 15mm 4 the character of seal tape faces outside Apple grease to roller of roller bearing also apply grease between lip and groove of seal tape 5 pack all grease nipple with a sufficient 2 2 5 Wheel bearing adjustment 1 Slowly rotate hub Tighten steering spindle nut until it can no longer be rotated with one hand 2 From that position turn back steering spindle nut 1 6 1 4 rotation Measure hub bolt force is 10 30N 3 Make sure that hub rotates smoothly and that its axial play is within specification Axial play is less than 0 10mm 2 2 6 Steering cylinder BI 2 4 Steering cylinder 1 Piston rod 2 LBH wiper 3 O ring 4 ISI seal rin
50. original position the fluid in the cylinder flows into the reserve tank through the return port The brake fluid in the brake lines and wheel cylinders has a residual pressure proportioned to the set pressure of the check valve which makes each wheel cylinder piston cup securely seated to prevent oil leakage and eliminates of vapor lock developing when the Lift truck is sharply broken ds ZZZ SE K 3 1 Master cylinder 1 Lock nut 2 Rod 3 Duct cover 4 Stop wire 5 Stop washer 6 Secondary cup 7 Piston 8 Primary cup 9 Spring 10 Check valve 11 Valve seat 12 Cylinder body 3 2 Foot brake 3 2 1 Brake The configuration of the 2 3t right detent can refer to fig 3 2 The configuration of 1 1 8t 4 5t right detent Configuration was similitude to 2 3t 7 24 14 1516 Fig 3 2 2 3t forklift truck right brake assembly 1 Brake mount 2 Wheel cylinder 3 Cylinder return 4 Rubber cap 5 Piston bracket body spring 6 Cylinder dust 7 Push rod 8 Air bleeder cap 9 Air bleeder 10 Brake shoe cover screw assemble front 11 Brake shoe 12 Guider 13 Adjuster cable 14 Adjusting bolt 15 Pawl assemble rear 16 Spring 17 Brake shoe 18 Return spring 19 Parking brake 20 Strut level return spring rod 21 Spring 22 Bolt 23 Washer 24 Snap ring 25 Guider 26 Spring support 27 Spring bracket 28 Spring 29 Plug 30 0il connector rod 31 Bush 32 Brake steel cable 20 3 2 2 Replace brake shoe 1 Place the forklift truck on level concr
51. ouse of tilting cylinder and another connects with low pressure line so as to make mast tilt forward or backward Main pump Trouble Probable cause Corrective action Low oil level in tank No oil from oil Add oil to specified level pump Clogged suction pipe or strainer Clean oil line and tank If oil is dirty change Worn bearing damaged backup ring and O ring Replace faulty parts Low discharge Maladjusted relief valve Readjust to specified pressure using pressure gauge pressure on oil Retighten suction side pipe Add oil in oil tank pump Air in oil pump Check pump oil seal Do not operate pump until bubbles in tank disappear Cavitation due to crushed suction Adjust or replace crushed hose and clean hose or clogged strainer strainer Air being sucked from loose EN Su Retighten each joint suction side joint Noisy oil pump replace with new oil having proper Cavitation due to too high oil viscosity for temperature at which pump is viscosity to be operate to operate when oil temperature is normal Bubbles in hydraulic oil Determine cause of bubbles and remedy Faulty oil seal on pump fault Oil leaking from KE E O ring or worn sliding surfaces on Replace faulty parts oil pump pump 23 Control valve Trouble Probable cause Corrective action Pressure of relief valve is not steady or too low
52. ring 4 Problems with power supply for the motor encoder 5 See 1311 menu Monitor Motor Motor RPM 8 7 Motor 1 Motor characterization failed during the motor characterization process Characterization Fault 8 8 Encoder 1 Encoder characterization failed during the motor characterization Characterization Fault process 2 Motor encoder pulse rate is not a standard value 32 48 64 80 ppr 8 9 Motor Type Fault 1 The Motor type parameter value is out of range 9 2 EM Brake Failed to 1 Vehicle movement sensed after the EM Brake has been commanded to Set set 2 EM Brake will not hold the motor from rotating 9 3 Limited Operating 1 Limited Operating Strategy LOS control mode has been activated as Strategy LOS a result of either an Encoder Fault Code 36 or a Stall Detect Fault Code 73 2 Motor encoder failure 3 Bad crimps or faulty wiring 4 Vehicle is stalled 9 4 Emer Rev Timeout 1 Emergency Reverse was activated and concluded because the EMR Timeout timer has expired 2 The emergency reverse input is stuck On Lifting pump controller error code table is the same as that of CPD10 30J CPD10 15 18 20 25 30 35 C2 CPD40 45 50J C2 EC ERROR CODE TABLE Lifting pump controller error code table is the same as that of CPD10 30J C1 Towing controller error code table is the same as that of CPD10 30J C1 43 6 3 CPD10 15 20 25 30J D1 fork 6 3 1 Summarize INMOTION company procrea
53. rovides a compression braking feel and enhances safety by automatically initiating braking in an operator hands off condition _ Deceleration Rate Load Compensation and Restraint features prevent downhill runaway conditions speed is controlled to within approximately 20 of level surface value _ MultiMode allows four user selectable vehicle operating personalities _ Programmable to match individual separately excited motor characteristics _ Meets or exceeds EEC fault detect requirements _ Vehicle top speed is controlled and limited in each mode 33 _ Linear temperature and under voltage cutback on motor currents no sudden loss of power under any thermal conditions High pedal disable HPD and static return to off SRO interlocks prevent vehicle runaway at startup _ Creep speed adjustable from 0 to 25 in each mode _ Continuous diagnostics during operation with microprocessor power on self test _ Internal and external watchdog circuits ensure proper software operation _ Programmable coil drivers provide adjustable contactor pull in and holding voltages _ Hour meter enable output is active whenever the controller is providing motor current _ Optional Electromagnetic Brake Driver provides automatic control of an electromagnetic brake or other similar function 34 6 1 2 Failure code CPD10 30J Fault table of tow controller LED code PROGRAMMER LCD DISPLAY EXPLANATION P
54. rush is not contacted with the cable the cable is thinner The brush have noise the surface of the commmutator is rough 1 1 3The marker sign and connecting type of exceed cable or terminal of motor Al motor armature s head series A2 motor armature s end excitation S D1 shunt excitation s head motor ON D2 shunt excitation s end Al motor armature s head A2 motor armature s end Separated T F1 Separated Excitation VES WEN Excitation excitation s head motor F2 Separated Excitation excitation s end Connection mode Series excitation motor DI 32 Di D2 Al A2 Separate excitation motor Al F1 1 1 1 4 Use and maintain CPD10 30J The commutator has four check windows with which you can observe and maintain the commutator and brush There are four average distributing magnetic poles in seat The magnetic pole coil is made of F state copper thread dipping with F state insulating varnish Parts of stator and neutral position of brush have been adjusted users mustn t unpack and adjust randomly Check armature for rotation and void frictionize Check outgoing line of electric machine for connection Brush should slide freely in the brush hold box Check reverse chip for neatness if need be clear canaliculus between the reverse chip or the commutator surface of powder can used cleanly calico of soft and no thread downy maybe surface had oil
55. sensor ON KEY ON option sensor install 113 PM thermal PMheat sensor ON KEY ON on EH Only HERONS BE Mic Dice girene option sensor install OFF ON Charge a battery 114 Battery low voltage batteryLED ON KEY ON 115 Startup error Startup interior error KEY ON OFF ON KEY OFF Connect with the engineer of Danaher 2 Errors detected by drive ACS EMCY Code Source Condition When Tract Main PS Reset Remark 251 Short circuit ACS is shorted or motor terminals KEY ON OFF ON OFF KEY OFF Beene be damaged if short are shorted circuit is internal 252 ACS over temperature ACS hs temp gt 115 degC KEY ON OFF ON ON KEY OFF Mot Motor t 185 d KEY ON 253 otor over otor temp gt 185 degC O OFF ON ON KEY OFF temperature 254 ACS current sensor ACS current sensor error KEY gt ON OFF ON ON KEY OFF ACS must be repaired error 255 Charging timeout od capacitors are not charged KEY ON OFF ON ON KEY OFF Check charging circuit within 10sec from power on 256 ACS no response ACS does not respond at startup KEY 0N OFF ON ON KEY OEF Check CAN bus wiring 257 ACS PDO timeout ACS CAN open timeout detected KEY ON OFF ON ON KEY OFF Check CAN bus wiring by VMC20 ACS SDO error ACS SDO error wrong SW KEY ON 7 8 Check SW version 258 OFF ON ON KEY 0FF version CANopen timeout ACS CAN open timeout detected KEY ON Check CAN bus wiring 259 OFF ON ON KEY 0FF
56. ss bar 7 Remove bearing outer race from wheel hub by evenly tapping on its periphery with a wooden mallet CAUTION Be careful not to damage oil seal and outer race Inspection Stepped wear or cracks on axle shaft splines Replace Seized scratched noisy or rusted bearing or improper rotation of Replace rollers Cracked or damage wheel hub Replace Damaged oil seal felt ring Replace Installation Install reverse order of removal 1 3 5 Bearing adjusting 1 Lubricate on taper roller bearing 2 Tighten roller bearing lock nut in wheel hub until wheel hub can no longer be rotated with one hand 3 From that position turn back lock nut approx 60 4 Turn back wheel hub two or three rotations so that bearing settles down 5 Again tighten lock nut until it can no longer be rotated with one hand then turn back approx 60 6 Install snap ring and settles down felt ring install lock washer so as to set its hole in the pin of snap ring Screw lock nut 7 Turn wheel hub back and forth two or three rotations to see if rotation starting torque is within specifications Rotation starting force 10 29N refer to Fig 1 6 8 Measure axial play of wheel hub to see if it is within specification Axial play is less than 0 08mm refer to Fig 1 7 Fig 1 6 Fig 1 7 2 Steering system Steering system include rear steering axle and steering device 2 1 Steering device It consists of st
57. t cylinder mast tilt by itself 2 The hydraulic control valve spring is i Replace it inoperative The fork arms 1 Caused by piston jamming or bent Replace the faulty parts carrier moves up piston rod and down 2 Too much dirt is accumulated in the Strip it down and clean sluggishly cylinder Forks are lifted or lowered unsmoothly 1 Carriage bracket assembly out of adjustment Adjust clearance with thrust metal and carriage side roller 2 Insufficient clearance between inner and outer masts or rollers and mast Adjust clearance with rollers 3 Biting foreign materials between moving part Remove foreign materials 4 Insufficient lubrication Apply grease on contact surfaces of sliding parts butter 5 Bent carriage bracket assembly Repair or replace Forks are lifted unevenly 1 Lift chains out of adjustable Adjust lift chains Lift roller does not rotate 1 Grease stiffened or dirt accumulated on lift roller and mast sliding surfaces Clean and lubricate lift rollers Excessive mast noise 2 Improperly adjusted lift roller Adjust 1 Insufficient lubrication Lubricate 2 Improperly adjusted lift roller side f Adjust roller and back up metal 3 Rubber pad on lower of outer mast is useless for container fork lift truck By adjusting shims and rubber pad piston rod is in touch w
58. tes controller adopt international advanced closed loop system and advanced control technique Designing large screen instrument can clear display electric quantity speed total time of run work time of drive work time of lift and so on information Designation adopt code plus character manner increase maintain efficiency It also through meter check periphery component to come true function of handset 1 Actuating motor Actuating motor adopt three phase alternating current frequency conversion electromotor increase conversion efficiency not have commentator brush in order not to maintenance 2 Lift motor Lift motor adopt three phase alternating electromotor increase conversion efficiency not have commentator brush in order not to maintenance 3 Safety amp protection features D Reverse Polarity of the battery Connection errors 3 All inputs are protected against connections errors D Current overload protection 6 It have detecting element control peak current 8 Thermal protection If the controller temperature exceeds 85 C the maximum current reduces in proportion to the thermal increase The temperature can never exceed 115 C If the electric machinery temperature exceeds 145 C the maximum current reduces in proportion to the thermal increase The temperature can never exceed 165 C Low Battery charge When the battery charge is low the maximum current is reduced proportional
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60. y parameters are misadjusted Non controller system drain on battery Battery resistance too high Battery disconnected while driving See 1311 menu Monitor Battery Capacitor Voltage M OU BUL D Blown B fuse or main contactor did not close 2 4 Overvoltage Cutback 1 Normal operation Fault shows that regen braking currents elevated the battery voltage during regen braking Controller is performance limited at this voltage Battery parameters are misadjusted Battery resistance too high for given regen current Battery disconnected while regen braking See 1311 menu Monitor Battery Capacitor Voltage 2 5 5V Supply Failure External load impedance on the 5V supply pin 26 is too low See 1311 menu Monitor outputs 5 Volts and Ext Supply Current 2 6 Digital Out 6 Overcurrent PIN AU A L N External load impedance on Digital Output 6 driver pin 19 is too low 25 d Digital Out 7 Overcurrent External load impedance on Digital Output 7 driver pin 20 is too low 2 8 Motor Cutback Temp Hot 1 Motor temperature is at or above the programmed Temperature Hot setting and the requested current is being cut back 2 Motor Temperature Control Menu parameters are mis tuned 3 See 1311 menus Monitor Motor Temperature and Monitor Inputs Analog 4 If the application doesn t use a motor thermistor Temp Compensation and T

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