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Service Manual CPD30/35L1-B CPD30/35L1-S Electric Forklift Truck...
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Service Manual CPD30/35L1-B CPD30/35L1-S Electric Forklift Truck...
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Release Date Version No. Changes (Serial number) 2020-05-23 SM-3131 05.20 Serial number V1 If there are any changes, revised version will be published once every 12 months; if there is no change, please follow the most recent version. Please refer to the corresponding version of the service manual against the purchase time of your vehicle.
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Please strictly adhere to these safety instructions to avoid personal injury. Please pay attention to the important safety instructions. Instructions. Copyright Copyright of Service Manual belongs to EP Equipment Co., Ltd. EP Equipment Co., Ltd. EP Industrial Park, Xiaquan Village, Dipu Town, Anji County, Zhejiang Province, P.R.China www.ep-ep.com...
TABLE OF CONTENTS TABLE OF CONTENTS SECTION PAGE 1. INFORMATION & SPECIFICATIONS ......1 1.1 After-sales Service Platform .........3 1.2 Introduction ..............4 1.3 Common Tools ..............5 1.4 General Tightening Torques .........6 2. MAINTENANCE ...............9 2.1 Overview..............11 2.2 Maintenance ...............12 2.2.1 Cleaning ................12 2.2.2 Inspection ..............12 2.2.3 Lubrication ..............17 3.
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TABLE OF CONTENTS TABLE OF CONTENTS SECTION PAGE 4. CHASSIS SYSTEM ............27 4.1 Steering Wheel ............29 4.1.1 Removal and Installation ..........29 4.1.2 Faults and Causes............30 4.2 Cover ................30 4.2.1 Removal and Installation ..........30 4.3 Seat ................31 4.3.1 Removal and Installation ..........31 4.4 Parking Brake .............31 4.4.1 Removal and Installation ..........31 4.5 Parking Brake .............32...
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TABLE OF CONTENTS TABLE OF CONTENTS SECTION PAGE 6.3 Travel Combination Switch .........54 6.3.1 Removal and Installation ..........54 6.3.2 Faults and Causes............54 6.3.3 Checking and Testing ............54 6.3.4 Control Circuit Troubleshooting ........55 6.4 Lighting Combination Switch ........57 6.4.1 Removal and Installation ..........57 6.4.2 Faults and Causes............57 6.4.3 Checking and Testing ............57 6.4.4 Control Circuit Troubleshooting ........58...
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TABLE OF CONTENTS TABLE OF CONTENTS SECTION PAGE 7.2.1 Removal and Installation ..........73 7.3 Pump Motor ..............73 7.3.1 Removal and Installation ..........73 7.3.2 Faults and Causes............74 7.3.3 Checking and Testing ............75 7.3.4 Control Circuit Troubleshooting ........76 7.4 Multi-way Reversing Manual Valve ......78 7.4.1 Removal and Installation ..........78 7.4.2 Interface Description............79 7.4.3 Faults and Causes............79...
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TABLE OF CONTENTS TABLE OF CONTENTS SECTION PAGE 9. ELECTRICAL SYSTEM ..........97 9.1 Controller ..............99 9.1.1 Removal and Installation ..........99 9.1.2 Controller Interface Function (CPD30/35L1-B)....101 9.1.3 Controller Interface Function (CPD30/35L1-S)....104 9.2 Fuse................107 9.2.1 Location of Fuses ............107 9.2.2 Checking and Testing ..........108 9.3 Main Contactor ............109 9.3.1 Removal and Installation ..........109 9.3.2 Faults and Causes............
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TABLE OF CONTENTS TABLE OF CONTENTS SECTION PAGE 9.9.5 Parameter Change ............123 9.10 Parameter Settings ..........124 9.11 TESTER Menu ............126 9.12 Controller Error Message ........132 9.12.1 Controller For CPD30/35L1-B(ACE2 master_uc) ..132 9.12.2 Controller For CPD30/35L1-B ACE2 supervisor_uc) 151 9.12.3 Controller For CPD30/35L1-S(ACE3 master_uc) ..155 9.12.4 Controller For CPD30/35L1-S(ACE3 slave_uc) ..169 9.13 Electrical Schematic Diagrams .......171 9.14 Cable Wiring Diagrams ..........172...
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TABLE OF CONTENTS TABLE OF CONTENTS SECTION PAGE A2-1 Removal and Installation ........195 A2-2 Lifting Chains ............196 A2-2.1 Chain Adjustment ............196 A2-2.2 Chain Replacement...........197 A2-3 Mast Tubing............198 A2-4 Lift Cylinder ............200 A2-4.1 Cylinder Removal .............200 A2-4.2 Cylinder Maintenance ..........202 A2-4.3 Cylinder Installation ...........204 A2-5 Built-in Side Shifter..........204 A2-6 External Side Shifter ..........204 A3 Three-stage Full Free Mast ........205...
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SAFETY WARNING For your own safety and that of others, please observe the following safety instructions: Thorough and normative maintenance is one of the most important prerequisites to ensure stable and reliable operation of truck. Neglecting regular maintenance could easily lead to the truck malfunction and failure, and potential threats to staff and operational safety.
INFORMATION & SPECIFICATIONS 1.1 After-sales Service Platform Claims/Replacement Parts Service Platform: After-sales Maintenance Service Platform: NOTE 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.
INFORMATION & SPECIFICATIONS This series are electric forklift trucks. Its impor- tant structure is as shown in Fig3131-00003SM. WARNING - Please refer to the nameplate 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.
INFORMATION & SPECIFICATIONS 1.4 General Tightening Torques Screws or bolts used on the truck are of 8.8 grade or higher performance level. When you are conducting truck maintenance, you can refer to Table 1.4.1 and Table 1.4.2 to select the suitable screws or bolts for replace- ment.
MAINTENANCE 2.1 Overview NOTE Only by performing regular vehicle maintenance Under harsh working conditions: such as, the and repair, can ensure the continuous and external temperature is too high or too low, reliable use of the truck. dusty, or implementing multiple shifts per day, Only specially trained and qualified personnel the maintenance and care interval should be shortened.
MAINTENANCE 2.2 Maintenance Regular inspection and maintenance under harsh conditions of use: 2.2.1 Cleaning Under harsh working conditions, especially: - Dusty environment Do not use flammable liquids to clean the - Corrosive environment truck. - Cold storage environment Before starting to clean, all necessary The maintenance intervals should be shortened security measures must be taken to prevent by half.
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MAINTENANCE Table 2.1 Inspection & Maintenance List Interval in days/months/years 60 d 90 d Interval in hours 1000 2000 Functions and Control Check the functions of the operation switches and display Check alarm system functions Check parking brake functions Check the emergency switch functions Check the steering wheel functions Check the cables for damage and if the terminals are secure...
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MAINTENANCE Table 2.1 Inspection & Maintenance List (Continued) Interval in days/months/years 60 d 90 d Interval in hours 1000 2000 Power Supply & Drive System Check the position of various bearings for noise Check transmission oil level Clean or replace the gear oil Replace once every 1000 hours Check the gearbox for abnormal noise or leaks Check the drive wheel and steering wheel for worn or...
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MAINTENANCE Table 2.1 Inspection & Maintenance List (Continued) Interval in days/months/years 60 d 90 d Interval in hours 1000 2000 Braking System Check the braking functions Check the brake fluid level Check the pump and piping connections for leaks Check the release of brake pedal is normal Check the braking distance of brake Mast System Check the mast for damages...
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MAINTENANCE Table 2.1 Inspection & Maintenance List (Continued) Interval in days/months/years 60 d 90 d Interval in hours 1000 2000 Other Check the fixation of battery and battery tray Check the seat fixation and adjustment functions Check the seat belt and functions Check the overhead guard and cabin Checking covering parts for damages Check if the optional features are functioning properly...
MAINTENANCE 2.2.3 Lubrication Please see Table 2.2 for the lubricants used in this truck. Lubricant CAUTION Improper operations may constitute hazards The use and disposal of lubricants must be to the operator's health and life, as well as to carried out in strict accordance with the manufa- the surrounding environment.
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MAINTENANCE Table 2.2 Lubricants Code Type Specification Amount Position Anti-wear hydraulic oil L-HM46 Hydraulic See Table 2.3 Low temperature anti-wear System L-HV32 hydraulic oil (cold storage) Sliding surface Multi-purpose grease Polylub GA352P Appropriate amount (See Table 2.4) Heavy duty gear oil 85W-90GL-5 0.5L (Align with oiling port) Gearbox After the gas within the...
STRUCTURE & FUNCTIONS 3.1 Structure & Functions 3.1.1 Travel Combination Switch Location: bottom left of steering wheel; Function: to output travel speed signal to the drive controller; Description: when the vehicle is powered on, the travel switch is at Middle position; Note: Unserviceable.
STRUCTURE & FUNCTIONS 3.1.5 Key Switch Location: bottom right of steering wheel; Function: for operator to switch on or off the truck; Description: remove the key to prevent opera- tions to the truck by unauthorized operator; Note: Unserviceable. Key Switch 3.1.6 Lighting Combination Switch Location: bottom right of steering wheel;...
STRUCTURE & FUNCTIONS 3.1.9 Accelerator Pedal Location: on foot switch cover; Function: to provide acceleration signal for the Brake Pedal travel of truck; Description: 12V operating voltage; Note: Unserviceable. 3.1.10 Brake Pedal Location: on foot switch cover; Function:to brake the truck under emergencies; Description: 12V operating voltage;...
STRUCTURE & FUNCTIONS 3.1.13 Warning Light Location: above the overhead guard; Function: to warn the surrounding personnel Combination Light that the truck is powered on, please keep clear of it; Description: 12V operating voltage; Note: Unserviceable. Combination Light 3.1.14 Combination Light Location: on the rear of overhead guard;...
STRUCTURE & FUNCTIONS 3.1.17 Pump Controller Location: electrical mounting plate; Function: to control the speed of pump motor Fuse for Traction Fuse for Pump through the signal input by the control switch; Controller Controller Description: 80V operating voltage, to control the pump motor circuit;...
STRUCTURE & FUNCTIONS 3.1.21 Multi-way Manual Valve Location: on the right of chassis; Function: connection and disconnection of oil passage; Description: manual valve control; Note: Unserviceable. 3.1.22 Pump Motor Location: on the bracket of the chassis; Function: to provide power for gear pump for lifting and tilting;...
CHASSIS SYSTEM 4.1 Steering Wheel (see Fig3131-10002SM) Unscrew the eight nuts (1) on the steering 4.1.1 Removal and Installation wheel assembly (2); Remove the steering wheel assembly (2) from Removal the steering bridge (3). Installation and Commissioning - Install according to the reverse order of rem- ova.
CHASSIS SYSTEM 4.1.2 Faults and Causes Floorboards (See Fig3131-10005SM) Fault Bearing noise or jammed Cause Bearing fatigue damage or foreign Abnormal tyre wear, cracking or Fault degumming Cause Improper use 4.2 Cover 4.2.1 Removal and Installation Battery Cover (See Fig3131-10004SM) Remove the cushion, then unscrew the ten screws (1);...
CHASSIS SYSTEM 4.3 Seat 4.4 Parking Brake 4.3.1 Removal and Installation 4.4.1 Removal and Installation Removal (See Fig3131-10006SM) Removal Remove the parking brake cover;(see section 4.2.1) Disconnect the connection between the parking brake switch and main wiring harness; Loosen the three nuts (1), then remove the parking brake assembly (2) from the chassis;...
CHASSIS SYSTEM 4.5 Brake Pedal 4.5.1 Removal and Installation Remove the sping (8), then unscrew one nut (9) and one bolt (10); Removal (See Fig3131-10008SM) Remove the shaft (11) and remove the brake Remove the floorboards;(see section 4.2.1) pedal (12); Disconnect the connection between the pedal Loosen the nut (13) and remove the pedal switch (14) and main wiring harness;...
CHASSIS SYSTEM 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.
DRIVE SYSTEM 5.1 Drive Wheel Installation - Install according to the reverse order of rem- 5.1.1 Removal and Installation oval. Removal - Jack up the vehicle with lifting equipment (1), CAUTION make the drive wheels off the ground; Screw the eight nuts as shown in Fig3131- 10003SM.
DRIVE SYSTEM 5.2 Drive Motor Remove the mast; (see Appendix A - Mast ) This truck obtains drive force through AC motor. Remove the two drive wheels; (see Section 5.1) Remove U, V and W cables on the drive motor; Disconnect the connection between the drive motor and main wiring cables;...
DRIVE SYSTEM Installation 5.2.2 Faults and Causes - Install according to the reverse order of rem- Fault Motor does not rotate oval. a. Cable U, V, or W is broken; b. Loosening connections to cable U, V or W ; CAUTION Cause c.
DRIVE SYSTEM Temperature Sensor 5.2.3 Checking and Testing Temperature sensor is used to monitor motor U, V, W Terminals temperature. - 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;...
DRIVE SYSTEM 5.2.4 Control Circuit Troubleshooting Testing Drive Motor Control Circuit Check if the circuit is broken by using a multi- meter: Set the multimeter to ON-OFF; Check if #19/#20/#30/#31 circuit (circuit between motor encoder and controller) is conducted; - Check if #39/#20 circuit (circuit between motor temperature sensor and controller) is conducted.
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DRIVE SYSTEM For CPD30/35L1-S (see Fig3131-20012SM) REV. 05/2020...
DRIVE SYSTEM 5.3 Gearbox 5.3.1 Removal and Installation 5.3.2 Faults and Causes Removal Fault Gearbox Abnormal Noise Remove the drive motor from the assembly; a. Supporting bearing wear; (see Section 5.2.1) Cause b. Gear wear, the gap is too big; Unscrew the ten bolts (1, Fig3131-20013SM) c.
DRIVE SYSTEM 5.4.3 Drive Axle Oil 5.4.4 Faults and Causes Check the drive axle oil level Fault Drive Axle Abnormal Noise Loosen the oiling port plug (2, Fig3131- a. Supporting bearing wear; 20017SM) and observe the oil level; Cause b. Gear wear, the gap is too big; c.
OPERATING SYSTEM 6.1 Control Lever Cut off the connection between the combina- tion switch (12 & 13) and the main wiring Removal harness; Pull out the rubber sleeve (10) from the com- Remove the floorboards;(see Section 4.2.1) bination switch; Remove the horn cover (1, Fig3131-30001SM); Unscrew the adjusting handle (5), remove the Unscrew the nut (3) and pull up the steering front cover plate (6);...
OPERATING SYSTEM 6.2 Horn Button Push button switch is the switch that makes the dynamic and static contacts ON or OFF to achieve the switching of circuits through push- button drive mechanism. Unscrew the four bolts (1,Fig 3131-30002SM) and remove the steering column (5) from the chassis;...
OPERATING SYSTEM 6.2.3 Checking and Testing 6.2.4 Control Circuit Troubleshooting Checking Control Circuit (Fig3131-30004SM) Check if the pushbutton switch and the Check if the circuit is broken by using a multi- appearance of cables are in good condition, meter: and if the plug connection is secure; Set the multimeter to ON-OFF;...
OPERATING SYSTEM 6.3 Travel Combination Switch For switching travel direction of truck: Forward (F) , Reverse (R) and Neutral (N). - Carry out ON/OFF test to combination switch with a multimeter: Travel combination switch should be at 0 position (N) of the lever Test Interface Status of Conduction #25 - #21...
OPERATING SYSTEM 6.3.4 Control Circuit Troubleshooting Control Circuit Check if the circuit is broken by using a multi- meter: Set the multimeter to ON-OFF; Check if #13 circuit (circuit between switch and DC-DC converter ) is conducted; Check if #15 circuit (circuit between switch and light) is conducted;...
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OPERATING SYSTEM For CPD30/35L1-S ( Fig3131-30008SM) REV. 05/2020...
OPERATING SYSTEM 6.4 Lighting Combination Switch Testing - Check if the combination switch circuit is For lighting of forklift signal indicators: turn connected; signal - left (L), turn signal - right (R), outline marker lights and headlights. - Carry out ON/OFF test to combination switch with a multimeter: Lighting combination switch should be at 0 position (F) of the lever...
OPERATING SYSTEM Lighting combination switch should be at the position ( ) of the knob Test Interface Status of Conduction #117 - #5 Conducted Circuit #6 - #5 Conducted Circuit 6.4.4 Control Circuit Troubleshooting Control Circuit (Fig3131-30011SM) Check if the circuit is broken by using a multi- meter: Set the multimeter to ON-OFF;...
OPERATING SYSTEM 6.5 Key Switch Testing Key switch is used to START / STOP the truck. Check if the key switch circuit is conducted; Carry out ON/OFF test to the key switch with 6.5.1 Removal and Installation a multimeter: key switch at “OFF” position, open circuit; See Section 6.1 .
OPERATING SYSTEM 6.6 Warning Light Switch 6.6.2 Faults and Causes The warning light switch of this truck is used to Operate the switch, but the vehicle Fault control the ON/OFF of warning light. responds with no action a. The switch failure; Cause b.
OPERATING SYSTEM 6.7 Emergency Switch 6.7.3 Checking and Testing Emergency switch is used for emergency cut-off Checking of the power supply to all the control circuits. - Check if the appearance of emergency switch its wiring harness are in good condition, and 6.7.1 Removal and Installation if the connectors are connected securely.
OPERATING SYSTEM 6.8 Parking Brake Switch 6.8.1 Removal and Installation 6.8.4 Checking and Testing See Section 4.4.1 . Checking Check if the appearance of control switch is in good condition, also check for deformation 6.8.2 Faults and Causes of handwheel; Check if the handwheel is working smoothly Parking brake switch triggered, the and if there is foreign body blockage.
OPERATING SYSTEM 6.8.5 Control Circuit Troubleshooting Parking brake switch Control Circuit Check if the circuit is broken by using a multi- meter: For CPD30/35L1-B (Fig3131-30017SM) Set the multimeter to ON-OFF; Check if #27/#109 circuit (circuit between parking brake switch and controller) is con- ducted.
OPERATING SYSTEM 6.9 Control Switch 6.9.3 Checking and Testing Control switch will provide the vehicle with input Checking signals for starting the pump motor. Check if the appearance of control switch is See Section 3.1 for mounting positions of contr- in good condition, also check for deformation ol switch.
OPERATING SYSTEM 6.9.4 Control Circuit Troubleshooting Lift Switch Control Circuit For CPD30/35L1-B (Fig3131-30020SM) Check if the circuit is broken by using a multi- meter: Set the multimeter to ON-OFF; Check if #52/#53/#56 circuit (circuit between control switch and controller) is conducted. Lift Switch Control Circuit For CPD30/35L1-S (Fig3131-30021SM) Check if the circuit is broken by using a multi-...
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OPERATING SYSTEM Tilt Switch Control Circuit For CPD30/35L1-B (Fig3131-30022SM) Check if the circuit is broken by using a multi- meter: Set the multimeter to ON-OFF; Check if #52/#53/#57 circuit (circuit between control switch and controller) is conducted. Tilt Switch Control Circuit For CPD30/35L1-S (Fig3131-30023SM) Check if the circuit is broken by using a multi- meter:...
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OPERATING SYSTEM Left Shifting – Right Shifting Switch For CPD30/35L1-B (Fig3131-30024SM) Check if the circuit is broken by using a multi- meter: Set the multimeter to ON-OFF; Check if #52/#53/#58 circuit (circuit between control switch and controller) is conducted. Left Shifting – Right Shifting Switch For CPD30/35L1-S (Fig3131-30025SM) Check if the circuit is broken by using a multi- meter:...
HYDRAULIC SYSTEM Hydraulic Oil The system pressure of the entire hydraulic system pressure is provided by hydraulic power Hydraulic oil for truck: unit system, which is used for lifting. While the Specifications: Anti-wear Hydraulic Oil L-HM46. hydraulic power unit is equipped with a relief valve to ensure that the entire system pressure * For cold storage: Low Temperature Anti-wear is always within the safety limits that can lift the...
HYDRAULIC SYSTEM 7.2 Hydraulic Power Unit 7.3 Pump Motor 7.2.1 Removal and Installation This truck obtains hydraulic power through the AC pump motor. For CPD30/35L1-S For CPD30/35L1-B Fig3131-40002SM Removal Remove the battery cover from the chassis; (see Section 4.2.1) Remove the AMP connector (1) on the pump motor and remove the cables U, V and W (2) from the motor;...
HYDRAULIC SYSTEM 7.3.2 Faults and Causes Speed Encoder Fault Motor does not rotate Removal a. Cable U, V, or W is broken; b. Loosening connections to cable U, V or W ; Cause c. Stator coil open circuit; d. Motor bearing damage; e.
HYDRAULIC SYSTEM 7.3.3 Checking and Testing U, V, W Terminals Temperature Sensor Temperature sensor is used to monitor motor - Identify if the motor windings are normal temperature. through measuring the resistance of U-V, V-W, and U-W respectively, if there is short circuit For CPD30/35L1-S or breakage;...
HYDRAULIC SYSTEM Speed Encoder 7.3.4 Control Circuit Troubleshooting Speed encoder is used to detect the speed Motor Control Circuit of the motor and covert the speed into fixed signals. For CPD30/35L1-B (See Fig3131-40009SM) Checking Check if the circuit is broken by using a multi- - Check if the motor encoder and the appear- meter: ance of cables are in good condition, and if...
HYDRAULIC SYSTEM 7.4 Multi-way Reversing Manual Valve Unscrew the four screws (16) and remove the multi-way valve and the mounting plate; The valve rod is driven by lever to switch the ON Remove the cotter pin on pin shaft (10), and OFF of tubing within the valve body, thus to remove the connecting rod (11) between control the Lifting - Lowering, Forward Shifting -...
HYDRAULIC SYSTEM 7.4.2 Interface Description 7.4.3 Faults and Causes The vehicle cannot perform the Fault hydraulic control instructions a. Valve failure; b. Valve seat blocked by large impurities; c. External leakage: sealing damaged; Cause poor threaded connection; valve body defects; d.
HYDRAULIC SYSTEM 7.5 Gear Pump Fault Oil leaks a. Pump body defects; Cause b. Seal skeleton spring off; c. Shaft sealing surface scratched. Pump is not functioning properly or Fault blocked a. Pump body defects; b. Pressure valve malfunction; Cause c.
HYDRAULIC SYSTEM 7.6 Redirector 7.6.3 Checking and Testing Checking 7.6.1 Removal and Installation Check the redirector body for leakage and See Section 6.1 . damage; Check if the connection of redirector and tub- ings is normal. CAUTION If the redirector is found with failure, it is recom- mended to replace the redirector directly.
HYDRAULIC SYSTEM 7.7 Tilt Cylinder Upon removal, the damage to cylinder threads, oil port threads, cylinder cap threads, 7.7.1 Cylinder Removal Precautions piston rod surface and inner cylinder wall should be prevented. Before removing the cylinder, be sure to reli- In order to prevent piston rod from bending or eve the hydraulic circuit first, which is to lower deformation, support it wooden block when...
HYDRAULIC SYSTEM CAUTION Cylinder Cap O-ring is quite flexible and easy to install, but it must not be pulled up to the extent of permanent deformation, nor scroll it while installing; Y-ring or X-ring needs to be identified if it is Cylinder Wrenches for shaft or hole to avoid misplacement;...
HYDRAULIC SYSTEM 7.7.3 Removal and Installation CAUTION Cylinder is installed on the chassis and outer mast. Hydraulic oil may damage truck parts and con- Fix the masts, block the truck wheel with a taminate the environment. When removing wooden wedge, press the emergency stop joints or tubings, place a clean container under switch and turn off the key switch;...
HYDRAULIC SYSTEM Pull out emergency switch and turn on the key switch; Repeat tilt 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. 7.7.4 Cylinder Maintenance CAUTION Use suitable hose clamps to avoid cylinder deformation caused by severely tight hose...
HYDRAULIC SYSTEM 7.8 Hydraulic Troubleshooting Fault Symptom Failure Causes Troubleshooting Measures a. Insufficient oil; 1. Check the hydraulic oil level. b. High viscosity of oil; 2. Replace the hydraulic oil. c. Oil suction pipe air leak; 3. Check the oil suction pipe. Noisy pump d.
HYDRAULIC SYSTEM 7.9 Hydraulic Symbol Symbol Description Symbol Description Tank Pipe end below liquid Proportional valve level Tank Pipe end above liquid Check valve level Cylinder Filter Single-acting direction Service line Cylinder (Supply line or return Double-acting line) direction Control line (Drain line) Relief valve Solenoid valve...
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HYDRAULIC SYSTEM Symbol Description Symbol Description Manual valve Brake valve Three-way six-pass Speed requlating valve Explosion-proof valve Solenoid valve Solenoid valve Three-way four-pass Two-way two-pass REV. 05/2020...
STEERING SYSYTEM 8.1 Steering Bridge Remove the two tubings (2, Fig3131- 70003SM) from the steering bridge; 8.1.1 Removal and Installation Remove the steering displacement sensor; (See Section 8.2) Removal - Fix the wheels with triangular wooden wedge; Lift the counter-weight (1) slightly, unscrew two bolts and remove the counter-weight (1) Unscrew the four bolts (3) and remove the from the chassis;...
STEERING SYSYTEM 8.2 Displacement Sensor 8.2.1 Removal and Installation 8.2.2 Faults and Causes Removal Truck does not travel (the - Remove the counter-weight from the chassis; controller reports for error, and Fault fault information is displayed on (see section 8.1.1) the meter: STEER SENSOR KO) Displacement Sensor or its circuit Cause...
STEERING SYSYTEM 8.3 Steering Cylinder 8.3.1 Removal and Installation Remove the collar (3), snap ring (4), dust ring (5), O-ring (6 & 7), retaining ring (8 & 9) and See Section 8.1.3 seal (11) from the cylinder cap (17); Pull out the piston rod (18) from cylinder block (19);...
ELECTRICAL SYSTEM 9.1 Controller 9.1.1 Removal and Installation Controller Functions Fix the wheels with triangular wooden wedge; Turn the switch lock to “STOP” and remove Electrical control of this truck is mainly driven by the key, pull up the emergency stop switch; traction controller and pump controller.
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ELECTRICAL SYSTEM For CPD30/35L1-B Unscrew four screws (1, Fig3131-50007SM) and remove the electrical mounting plate (2) from the chassis; Unscrew four screws (1, Fig3131-50008SM) Unscrew the bolts on copper (3) and copper and remove the flashing (2); (4), remove the coppers from the controller; Unscrew four screws (3) and remove the Remove the wiring harness, cables on the electrical mounting plate (4) from the chassis;...
ELECTRICAL SYSTEM 9.1.2 Controller Interface Function (CPD30/35L1-B) Traction Controller (ACE2) Pump Controller (ACE2) REV. 05/2020...
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ELECTRICAL SYSTEM A Interface Pin No. Signal Name Description Input of the key switch signal. Positive supply for external device (Encoder, PPOT potentiometers, etc.) (+5V 100mA maximum). Analog input 1. CPOT1 The default function is as accelerator reference (wiper contact of the accelerator potentiometer). The input is activated when it is connected to +5V.
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ELECTRICAL SYSTEM A Interface - Continued Pin No. Signal Name Description Negative supply for the encoder and for potentiometers. A#15 Output of main-contactor driver (driving to -B); PWM A#16 voltage controlled; 1.5A maximum continuous current. Connect the positive supply of coils (MC, EB, AUX) to A#17 PCOM this pin.
ELECTRICAL SYSTEM 9.1.3 Controller Interface Function (CPD30/35L1-S) Traction Controller (ACE3) Pump Controller (ACE3) REV. 05/2020...
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ELECTRICAL SYSTEM A Interface Pin No. Signal Name Description Connected to the power supply through a microswitch (CH) with a 10 A fuse in series. Potentiometer positive: 12 V / 5 V output; keep load > PPOT 1 kohm / 0.5 kohm. CPOT Accelerator potentiometer wiper.
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ELECTRICAL SYSTEM A Interface - Continued Pin No. Signal Name Description Main contactor coil output. The coil is driven to A#16 negative reference. Connect the positive supply of electrovalves (EB and EVP) to this pin. Take the positive supply immediately A#17 after the main contactor.
ELECTRICAL SYSTEM 9.2 Fuse The entire vehicle is installed with eight fuses altogether. When there is fuse failure, the truck may not be able to run properly due to that. Status Function Main Battery Fuse 1 Fuse 2 Fuse 3 Fuse 4 Fuse Fuse...
ELECTRICAL SYSTEM 9.2.2 Checking and Testing Checking - Check the fuses for damage, check the connectors at terminal lugs for loosening or poor connection of leads. Testing Turn the key switch to "OFF", remove key; pull out the battery plug and disconnect the power supply.
ELECTRICAL SYSTEM 9.3 Main Contactor This truck is using DC contactors with normally- o p e n c o n t a c t s . A n d t h e O N / O F F o f t h e contactors is controlled through controller, thus to achieve the control of ON/OFF of the vehicle.
ELECTRICAL SYSTEM 9.3.2 Faults and Causes Fault Contact adhesion or slow release a. Contact fusion welding; b. Contact spring pressure is too low; Cause c. Mechanical moving parts blocked, shaft rusted or crooked; d. Anti-force spring damaged. Contact not absorbed or not fully Fault absorbed Contact Checks...
ELECTRICAL SYSTEM 9.3.4 Control Circuit Troubleshooting Main Contactor Control Circuit For CPD30/35L1-B Check if the circuit is broken by using a multi- meter: Set the multimeter to ON-OFF; Check if #41/#42 circuit (circuit between con- tactor and traction controller) is conducted. For CPD30/35L1-S Check if the circuit is broken by using a multi- meter:...
ELECTRICAL SYSTEM 9.4 Accelerator Pedal 9.4.2 Faults and Causes 9.4.1 Removal and Installation Press the accelerator pedal, Fault operate travel switch, the vehicle Removal cannot go forward or backward See Section 3.1 for mounting position of acce- a. Accelerator pedal failure; lerator pedal.
ELECTRICAL SYSTEM - Check if the accelerator pedal and its wiring - Press the accelerator pedal. Measure the vol- harness are in good condition, and if the tage between the interfaces with a multimeter. connectors are connected securely. as shown in the following table: Testing Press the accelerator pedal Press the accelerator pedal, if the accelerator...
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ELECTRICAL SYSTEM For CPD30/35L1-S (Fig 3131-50019SM) Check if the circuit is broken by using a multi- meter: Set the multimeter to ON-OFF; Check if #21/#26/#36/#120/#121 circuit (circuit between accelerator pedal and traction con-troller) is conducted. REV. 05/2020...
ELECTRICAL SYSTEM 9.5 DC-DC Converter 9.5.3 Checking and Testing DC-DC converter provides converted voltage Checking for lights, horn and accelerator. - Check if the appearance of converter and its Working performance: 80V DC to 12V wiring harness are in good condition, and if the connectors are connected securely.
ELECTRICAL SYSTEM 9.6 Combination Light / Headlight / 9.6.3 Checking and Testing Warning Light Checking This truck is equipped with two combination - Check if the appearance of combination lights, two headlights and one warning light. warning light / headlight / warning light and its See Section 3.1 wiring harness are in good condition, and if the connectors are connected securely.
ELECTRICAL SYSTEM 9.6.4 Control Circuit Troubleshooting Light Control Circuit (Fig3131-50026SM) Check if the circuit is broken by using a multi- meter: REV. 05/2020...
ELECTRICAL SYSTEM 9.7 Seat Switch 9.7.3 Checking and Testing Seat switch is mounted under the seat. Checking Check if the appearance of seat switch and its wiring harness are in good condition, and 9.7.1 Removal and Installation if the connectors are connected securely; Removal Repeatedly press the seat switch to check if it can reset properly.
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ELECTRICAL SYSTEM For CPD30/35L1-S (Fig3131-50028SM) Check if the circuit is broken by using a multi- meter: Set the multimeter to ON-OFF; Check if #23/#18 circuit (circuit between seat switch and traction controller) is conducted. REV. 05/2020...
ELECTRICAL SYSTEM 9.8 Handheld Unit-A (Optional) 9.8.2 Handheld Unit Menu Options Handheld unit must be used together with con- Start troller, if necessary, it can be purchased from 启 动 our company or dealer. * CONS AFG ZP100 * RS232 CONSOLE CAN CONSOLE AUTOSCAN CAN Display...
ELECTRICAL SYSTEM 9.9 Handheld Unit-B (Optional) Previous Page A Zapi Handset is available that is designed specifi- cally for use with the Zapi controller. It serves multiple functions of reading diagnostic data, testing truck operation,setting options,adjustments and parameter * MAIN MENU * changes of the controller.
ELECTRICAL SYSTEM 9.9.2 Testing Truck Operation The Zapi Handset can be used to test certain truck operations as follows: 1. Connect the Zapi Handset, refer to paragraph 9.9.1.1. 2. Press the ROLL up button (1, Fig0000-90005SM) and the ENTER button (3) at the same time to enter the MAIN MENU.
ELECTRICAL SYSTEM 9.9.4 Adjustments To change an adjustment proceed as follows and refer to Table 4-3: 1. Connect the Zapi Handset, refer to paragraph 9.9.1.1. 2. Press the ROLL up button (1, Fig0000-90005SM) and the SET up button (5) at the same time to enter the CONFIG MENU.
ELECTRICAL SYSTEM 9.10 Parameter Settings H&S CUTBACK CAUTION CTB. STEER ALARM Without the written permission of equipment manufacturer or its agent, it is strictly prohibit- CURVE SPEED 1 ed to change any of the parameters in "PARA- CURVE CUTBACK METER CHANGE". FREQUENCY CREEP Traction Controller (ACE2) TORQUE CREEP...
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ELECTRICAL SYSTEM Traction Controller (ACE3) Pump Controller (ACE3) Parameter Setting Parameter Setting ACC.TORQUE DEL. ACC.TORQUE DEL. DEC. TORQUE DEL. DEC. TORQUE DEL. ACCELER. DELAY ACCELER. DELAY RELEASE BRAKING RELEASE BRAKING TILLER BRAKING MAX SPEED LIFT INVERS. BRAKING HYD SPEED COARSE DECEL.
ELECTRICAL SYSTEM 9.11 TESTER Menu The parameters in TESTER Menu are real- time presentation of the running status of the equipment. Controller (ACE2) Parameters Description Remark KEY VOLTAGE Key voltage measured in real time. Volt (0.1 V) Battery voltage measured in real time (across BATTERY VOLTAGE Volt (0.1 V) the DC bus).
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ELECTRICAL SYSTEM Parameters Description Remark Maximum value of the q-axis current component, according to braking-related IQIMAX LIM. BRK Ampere (1 A) settings, expressed in root-mean-square Ampere. Flag for any current limitation being active, FLAGS LIMITATION for example thermal current cutback, ON, OFF maximum current reached, etc.
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ELECTRICAL SYSTEM Traction Controller (ACE3) Parameters Description Remark Voltage value with 1 decimal digit. Key KEY VOLTAGE voltage value measured at the key on. Voltage value with 1 decimal digit. Battery BATTERY VOLTAGE voltage value measured at the key on. Percentage value.
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ELECTRICAL SYSTEM Parameters Description Remark This is the temperature of the motor windings MOTOR picked up with an analog sensor inside the TEMPERATURE motor. - ON GND = When it is closed to GND , the Seat input is active. A6/SEAT SWITCH - OFF +VB = When it is not connected to ON/OFF...
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ELECTRICAL SYSTEM Pump Controller (ACE3) Parameters Description Remark Voltage value with 1 decimal digit. Key KEY VOLTAGE voltage value measured at the key on. Voltage value with 1 decimal digit. Battery BATTERY VOLTAGE voltage value measured at the key on. Percentage value.
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ELECTRICAL SYSTEM Parameters Description Remark This is the temperature of the motor windings MOTOR picked up with an analog sensor inside the TEMPERATURE motor. - ON GND = When it is closed to GND , the Seat input is active. A6/SEAT SWITCH - OFF +VB = When it is not connected to ON/OFF...
ELECTRICAL SYSTEM 9.12 Controller Error Message code (see Chapter 10 - Troubleshooting); while the when the components failures which may Electrical faults are mainly caused by electrical affect the ON/OFF of control circuit occur to components failure or electrical circuit failure. the electrical circuit, the controller will alarm for Wherein, when some components failures error, and fault information will be displayed on...
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Check if there is a short circuit or a low-impedance conduction path between the negative of the coil and -BATT. - Collect information about: - The EVP driver is shorted (output o the voltage applied across the A19).
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error Fault at startup or in standby: - Fault can be caused by a key input signal characterized by pulses below the undervoltage threshold, possibly due to external loads like DC/DC converters starting-up, relays or contactors during switching periods, solenoids energizing or de-energizing.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Check the wiring, in order to verify if LC coil is connected to the This fault appears when no load is right connector pin and if it is not connected between the NLC output interrupted.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error Cause1: Before switching the LC on, the - If the problem occurs at start-up software checks the power bridge: (the LC does not close), check: it turns on alternatively the low-side o motor internal connections power MOSFETs and expects the (ohmic continuity);...
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Verify LC coil is properly connected. - Verify CONF. POSITIVE LC parameter is set in accordance with the actual coil positive supply (see paragraph 8.2.5). Software, The voltage feedback of LC driver depending on the parameter POSITIVE LC (A16) is different from expected,...
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Check if the SET KEY VOLTAGE parameter in the ADJUSTMENT list is set in accordance with the key voltage. WRONG KEY The measured key voltage is not - Check if the key voltage is ok VOLT.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Check if an external load in parallel to the capacitor bank, which sinks current from the capacitors-charging circuit, thus preventing the caps from charging When the key is switched on, the well.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error The LC coil driver is not able to This type of fault is not related to CONTACTOR drive the load. The device itself or external components; replace the DRIVER its driver circuit is damaged.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Check that the sensor used is compatible with the software release. - Check the sensor mechanical This alarm occurs if the absolute installation and if it works properly. position sensor is used also for - Also the electromagnetic noise SPEED FB.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Check that the battery has the same nominal voltage of the The logic board measures a key inverter. VDC OFF voltage value that is constantly - Check the battery voltage, if it is SHORTED out of range, above the maximum out of range replace the battery.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Check the battery charge and charge it if necessary. - If the battery is actually charged, measure the battery voltage The battery charge is evaluated through a voltmeter and compare to be lower than 10% of the full it with the value in the BATTERY BATTERY LOW...
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error The EVP driver (A19) is not able to This fault is not related to external EVP DRIVER drive the EVP coil. The device itself components. Replace the logic OPEN or its driving circuit is damaged.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Check the EVs conditions. This alarm occurs when there is an - Check the wiring. overload of one or more EV driver. - Collect information about COIL SHOR. As soon as the overload condition characteristics of EV coils and EVAUX...
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Check if there is a short or a low impedance path between the - The EB driver is shorted. negative coil terminal and -BATT. - The microcontroller detects - Check if the voltage applied is in EB.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Check that LIFT and LOWER requests are not active at the same time. - Check the LIFT and LOWER Both the pump requests (LIFT and input states through the TESTER LIFT + LOWER LOWER) are active at the same function.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error The CPOT BRAKE input read Check the mechanical calibration BRAKE RUN by the microcontroller is at its and the functionality of the brake maximum value without the hand- potentiometer. If the alarm is still brake request.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Check the wirings. At key-on and immediately after - Check the mechanical calibration that, the travel demands have been and the functionality of the turned off. accelerator potentiometer. This alarm occurs if the - Acquire the maximum and VACC NOT OK...
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error Upload the correct software WRONG SLAVE Wrong software version on version or ask for assistance to supervisor uC. your dealer technician. The maximum current gain Ask for assistance to your dealer parameters are at the default technician in order to do the CURRENT GAIN...
ELECTRICAL SYSTEM 9.12.2 Controller For CPD30/35L1-B (ACE2 supervisor_uc) Error Message Possible cause Fault elimination Error text Error This is a safety related test. It is This alarm could be caused a self-diagnosis test that involves by a CAN bus malfunctioning, WATCHDOG the logic between master and which blinds master-supervisor...
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error This fault is displayed when the controller detects an undervoltage condition at the key input (A1). Undervoltage threshold is 11V for 36/48V controllers and 30 V for 80V controllers. - Fault can be caused by a key input signal characterized by pulses If the alarm occurs during motor...
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error The algorithm implemented to check the main RAM registers Try to switch the key off and WRONG RAM finds wrong contents: the register then on again, if the alarm is still MEM.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - Acquire the maximum and The voltage read by the minimum values from the steering microcontroller at the steering- potentiometer through the STEER sensor input is not within ACQUIRING function. STEER SENS the STEER RIGHT VOLT ÷...
ELECTRICAL SYSTEM 9.12.3 Controller For CPD30/35L1-S (ACE3 Master uc) Error Message Possible cause Fault elimination Error text Error - Check that the controller SET BATTERY parameter value matches the battery nominal voltage. At start-up, the controller checks - Check that TESTER MENU / the battery voltage and verify it is Wrong set bat.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - If the problem occurs at start Cause1: up (the LC does not close at all), Before switching the LC on, the check: software checks the power bridge: it - Motor internal connections turns on alternatingly the Low side (ohmic continuity)
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error Before switching the MC on, the software checks the power bridge: it turns on alternatingly the Low side and High side Power Mosfets This type of fault is not related to Power mos and expects the phases voltage to external components;...
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error Fault displayed at startup or in standby: - Key input signal down-going pulses (below under voltage threshold) due to external loads, like DC/DC converters starting- up, relays or contactor switching, solenoids energizing / de- energizing.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error This type of fault is not related to HW Fault Hardware problem in the logic card external components, so, when 11/12/13 circuit for MC driver management. it is present it is necessary to replace the ACE logic board.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error Before driving the MC coil, the controller checks if the contactor is stuck. The controller drives the It is suggested to verify the power bridge for some tens milliseconds, Contactor closed contacts of LC;...
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error This type of fault is not related to This fault is signaled when the external components, so, when No CAN msg. 09 communication with the supervisor it is permanently present it is uC is not present necessary to replace the ACE logic board.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error This type of fault is not related to HW Fault EB Hardware problem in the logic card external components, so, when 01/02/03 circuit for EB driver management. it is present it is necessary to replace the ACE logic board.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - The typical root cause for this error code to be displayed is in This alarm occurs when there is a the harness or in the load coil. So short circuit of the EB/AUX coils the very first check to carry out connected to CNA#18 output.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error - The EVP driver is shorted. Check if there is a short or a low - The microcontroller detects impedance between the negative EVP driv. short a mismatch between the valve of the coil and -BATT.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error Acquire the maximum and minimum potentiometer value The CPOT input red by the through the PROGRAM VACC microcontroller is not comprised function. If the alarm is still Vacc out of range in the range Vacc_min ÷...
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error The alarm ends when the acquisition Data acquisition Acquisition of the current gains. is done. If a CLEAR EEPROM was mode before the last keyon-recycle, this warning just means that the EEPROM was correctly cleared.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error Check the thermal sensor inside the motor (use the MOTOR TEMPERATURE reading in the This warning occurs when the TESTER menu); check the sensor temperature sensor is opened (if ohmic value and the sensor wiring.
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error Get the battery charged. If it doesn’t It occurs when the battery charge is work, measure with a voltmeter calculated being less than or equal the battery voltage and compare Battery low to 10% of the full charge and the it with the value in the BATTERY...
ELECTRICAL SYSTEM 9.12.4 Controller For CPD30/35L1-S (ACE3 slave uc) Error Message Possible cause Fault elimination Error text Error This is a safety related test. It is a This alarm could be caused by a self diagnosis test within the logic Watch dog canbus malfunctioning, which blinds between...
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ELECTRICAL SYSTEM Error Message Possible cause Fault elimination Error text Error Fault displayed at start-up or in standby: - Check the connection of power cables to the battery terminal, positive and negative, to LC and to controller +Batt and –Batt, which must be screwed with a torque comprised in the range This fault is displayed when the...
ELECTRICAL SYSTEM 9.14 Cable Wiring Diagrams Name Name Lithium Battery Pump Motor cable U Contactor + Pump Motor cable V Controller + Pump Motor cable W Controller to controller + Power Discharging cable Controller to controller - Power Charging cable Assembly Controller - Plug head Traction Power Cable U...
TROUBLESHOOTING 10.1 Preparation Before Troubleshooting Park the truck on level ground and block the CAUTION wheels with wooden wedges; Fully lower the forks and press the emergen- If the battery voltage is still abnormal after being cy stop switch. charged: open the battery compartment, check the voltage of each battery and its connection Turn off the key switch;...
TROUBLESHOOTING 10.2 Troubleshooting Solutions of Common Faults Table 10.1 lists the common faults that may occur and handling methods. Mainly consists of the following items: Table 10.1 Troubleshooting of Common Faults Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures Power supply 1.
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TROUBLESHOOTING Table 9.1 Troubleshooting of Common Faults (continued) Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures Hydraulic 1. The vehicle cannot 1. Pump motor does not work: 1. Pump motor does not work: Failure lift a. Parking brake switch and seat 1) Check if parking brake switch switch or its circuit connection and seat switch or the connec-...
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TROUBLESHOOTING Table 9.1 Troubleshooting of Common Faults (continued) Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures Lift Failure 3. Slow Lifting of a. Overload 1) Refer to the rated capacity Vehicle marked on the nameplate; b. Hydraulic pipeline leakage 2) Check the pipe and hydraulic c.
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TROUBLESHOOTING Table 9.1 Troubleshooting of Common Faults (continued) Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures Other Failures 1. Lights do not light a. Light failure or circuit not 1) Check the light and its circuit conducted connection; 2) Check Lighting combination b.
SERVICE MANUAL - MAST A1 Wide-View Two-stage Mast Unscrew the shafts (3) and remove the fixed plate (4) between the outer mast and chassis A1-1 Removal and Installation (C and D); Remove the mast from the truck. Removal Installation Disconnect the connections between lifting - lowering tubing, left shifting tubing and right - Install according to the reverse order of rem- shifting tubing and mast tubing;...
SERVICE MANUAL - MAST A1-2 Lifting Chains A1-2.1 Chain Adjustment Lower the mast to the bottom; Press the emergency stop switch and discon- nect the key switch; CAUTION Switch off the power supply before any adjust- ments or operations! Loosen the lower jam nuts (2) on chain bolt (1, Fig3131-60003SM);...
SERVICE MANUAL - MAST A1-2.2 Chain Replacement - Block the truck wheels with wooden wedges, raise the fork carriage with lifting tools to make the chains loose for the following rem- oval; CAUTION Please place supporting under the fork carriage to prevent it from falling, resulting in personal injury.
SERVICE MANUAL - MAST A1-4 Lift Cylinder supporting; Remove the tubing (5, Fig3131-60005SM) A1-4.1 Cylinder Removal (with mast on to make it separate from the three-pass the vehicle) component (2); Left Cylinder Removal CAUTION Lower the mast to the bottom, press the em- ergency stop switch and disconnect the key Hydraulic oil may damage truck parts and cont- switch;...
SERVICE MANUAL - MAST A1-4.2 Cylinder Maintenance CAUTION Use suitable 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.
SERVICE MANUAL - MAST A1-5 Built-in Side Shifter A1-5.1 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 (1, Fig3131-60008SM), remove the retaining shelf (2) from the built-in side shifter (3);...
SERVICE MANUAL - MAST A1-6 External Side Shifter A1-6.1 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, Fig3131-60009SM), remove the retaining shelf (1) from the exter- nal side shifter (2);...
SERVICE MANUAL - MAST A2 Two-stage Full Free Mast Unscrew the bolts (3) and remove the fixed plate (4) between the outer mast and chassis A2-1 Removal and Installation (C and D); Remove the mast from the truck. Removal Installation Disconnect the connections between lifting - lowering tubing, left shifting tubing and right - Install according to the reverse order of rem-...
SERVICE MANUAL - MAST A2-2 Lifting Chains A2-2.1 Chain Adjustment Lower the mast to the bottom; Press the emergency stop switch and discon- nect the key switch; CAUTION 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;...
SERVICE MANUAL - MAST A2-2.2 Chain Replacement - Block the truck wheels with wooden wedges, raise the fork carriage with lifting tools to make the chains loose for the following rem- oval; CAUTION Please place supporting under the fork carriage to prevent it from falling, resulting in personal injury.
SERVICE MANUAL - MAST A2-4 Lift Cylinder CAUTION A2-4.1 Cylinder Removal Before going on with the next step, please fix the cylinder properly first. Be sure to avoid the Left Cylinder Removal (with mast down) falling of cylinder during removal, resulting in Remove the mast from the chassis according personal injury.
SERVICE MANUAL - MAST CAUTION CAUTION Before going on with the next step, please fix Use suitable hose clamps to avoid cylinder the cylinder properly first. Be sure to avoid the deformation caused by severely tight hose falling of cylinder during removal, resulting in clamp.
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SERVICE MANUAL - MAST Right Lifting Side Cylinder CAUTION Use suitable 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.
SERVICE MANUAL - MAST Full Free Middle Cylinder Secure the cylinder to hose clamp and gently clamp the cylinder bottom; CAUTION Unscrew the cylinder cap (4, Fig3131- 60017SM) with cylinder wrench; Use suitable hose clamps to avoid cylinder Remove the dust ring (1), cover plate (2), deformation caused by severely tight hose seal (3), O-ring (5), bearing (6) and O-ring (7) clamp.
SERVICE MANUAL - MAST A3 Three-stage Full Free Mast Unscrew the bolts (3) and remove the fixed plate (4) between the outer mast and chassis A3-1 Removal and Installation (C and D); Remove the mast from the truck. Removal Installation Disconnect the connections between lifting - lowering tubing, left shifting tubing and right - Install according to the reverse order of rem-...
SERVICE MANUAL - MAST A3-2 Lifting Chains A3-2.1 Chain Adjustment Lower the mast to the bottom; Press the emergency stop switch and discon- nect the key switch; CAUTION Switch off the power supply before any adjust- ments or operations! Loosen the upper lock nut (1,Fig3131-60011SM) and the lower lock nut (3) on chain bolt;...
SERVICE MANUAL - MAST A3-2.2 Chain Replacement A3-2.2.2 Fork Carriage Chains A3-2.2.1 Mast Chains - Block the truck wheels with wooden wedges, raise the fork carriage for 500mm, insert - Block the truck wheels with wooden wedges, wooden block between inner mast and the raise the inner mast (2, Fig3131-60018SM) ground for supporting;...
SERVICE MANUAL - MAST A3-4 Lift Cylinder CAUTION A3-4.1 Cylinder Removal Hydraulic oil may damage truck parts and contaminate the environment. When removing Left Cylinder Removal (with mast down) joints or tubings, place a clean container under Remove the mast from the chassis according it for discharge of hydraulic oil.
SERVICE MANUAL - MAST Unscrew bolt (18, Fig3131-60019SM) and remove the middle cylinder roller guard (16); Unscrew the nut (19), remove the middle cylinder tube shaft (12) and middle cylinder tube roller (11); Unscrew the bolt (9) and remove the middle cylinder fixing plate (10) and sprocket seat (13) from the cylinder (14);...
SERVICE MANUAL - MAST CAUTION 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. Full Free Middle Cylinder Reference Section A2-4.2. A3-4.3 Cylinder Installation Install the cylinder according to the reverse order of removal according to A3-4.1;...
SERVICE MANUAL - BATTERY B1 Lithium-ion Battery B1-2 Use of Battery B1-2.1 Pre-use Checks B1-1 Safety and Warnings Check if the plug is tight. Unplugged may Do not short the positive and negative cause the output to be disconnected or the terminals of the battery.
SERVICE MANUAL - BATTERY B1-3 Maintenance & Care B1-2.3 Charging When charging, only DC can be used. Con- Daily Maintenance nect the battery with proper charger for Charge the discharged battery; specification and size to avoid overload of circuit and interface. Check the appearance of batter for damage or leaks after the charging.
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SERVICE MANUAL - BATTERY Display Description Troubleshooting LED red on Battery is charging Running normally. LED green on The charging is completed Running normally. The battery voltage is less than 26V or greater LED yellow on Battery failure than 65V. a.
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