EP Equipment CPD30L1-B Service Manual
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EP Equipment CPD30L1-B Service Manual

Electric forklift truck
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CPD30/35L1-B
CPD30/35L1-S
Electric Forklift Truck

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Summary of Contents for EP Equipment CPD30L1-B

  • Page 1 Service Manual CPD30/35L1-B CPD30/35L1-S Electric Forklift Truck...
  • Page 2 Service Manual CPD30/35L1-B CPD30/35L1-S Electric Forklift Truck...
  • Page 3 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.
  • Page 4 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...

  • Page 5: Table Of Contents

    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.
  • Page 6 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...
  • Page 7 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...
  • Page 8 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...
  • Page 9 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............
  • Page 10 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...
  • Page 11 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...
  • Page 12 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.

  • Page 13: Information & Specifications

    1. INFORMATION & SPECIFICATIONS...
  • Page 14 NOTE:...

  • Page 15: After-Sales Service Platform

    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.

  • Page 16: Introduction

    INFORMATION & SPECIFICATIONS 1.2 Introduction Name Name Drive wheel Driver Seat Battery Cover Warning Light Chassis Overhead Guard Steering wheel Headlight Counterweight Mast Rear Combination Lights Operate Lever Forks REV. 05/2020...

  • Page 17: Common Tools

    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.

  • Page 18: General Tightening Torques

    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.
  • Page 19 INFORMATION & SPECIFICATIONS Table 1.4.2 Metric Screws/Bolts Tightening Torque Table (n•m) Performance Level 10.9 12.9 Nominal Diameter (mm) Proof Stress (MPa) 10~12 14~17 17~20 16~18 25~30 34~41 41~48 M8×1 17~20 27~32 37~43 43~52 31~36 49~59 68~81 81~96 M10×1 35~41 55~66 76~90 90~106 55~64...
  • Page 20 INFORMATION & SPECIFICATIONS REV. 05/2020...

  • Page 21: Maintenance

    2. MAINTENANCE...
  • Page 22 NOTE:...

  • Page 23: Overview

    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.

  • Page 24: Maintenance

    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.
  • Page 25 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...
  • Page 26 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...
  • Page 27 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...
  • Page 28 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...

  • Page 29: Lubrication

    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.
  • Page 30 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...

  • Page 31: Structure & Functions

    3. STRUCTURE & FUNCTIONS...
  • Page 32 NOTE:...

  • Page 33: Structure & Functions

    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.

  • Page 34: Key Switch

    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;...

  • Page 35: Accelerator Pedal

    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;...

  • Page 36: Warning Light

    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;...

  • Page 37: Pump Controller

    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;...

  • Page 38: Multi-Way Manual Valve

    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;...

  • Page 39: Chassis System

    4. CHASSIS SYSTEM...
  • Page 40 NOTE:...

  • Page 41: Steering Wheel

    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.

  • Page 42: Faults And Causes

    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);...

  • Page 43: Seat

    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;...

  • Page 44: Parking Brake

    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;...

  • Page 45: Faults And Causes

    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.
  • Page 46 CHASSIS SYSTEM REV. 05/2020...

  • Page 47: Drive System

    5. DRIVE SYSTEM...
  • Page 48 NOTE:...
  • Page 49 DRIVE SYSTEM Drive System Name Drive Wheel Gearbox Drive Motor REV. 05/2020...

  • Page 50: Drive Wheel

    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.

  • Page 51: Drive Motor

    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;...

  • Page 52: Faults And Causes

    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.

  • Page 53: Checking And Testing

    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;...

  • Page 54: Control Circuit Troubleshooting

    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.
  • Page 55 DRIVE SYSTEM For CPD30/35L1-S (see Fig3131-20012SM) REV. 05/2020...

  • Page 56: Gearbox

    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.

  • Page 57: Component

    DRIVE SYSTEM 5.3.3 Component Name Name Name Bolt 10 Gear Shaft 19 Lock Plate Bolt 11 Snap Ring For Hole 20 Differential Case Housing Cover 12 Sealing Oil 21 Washer Bearing 13 Bearing Cover 22 Axle shaft gear O-ring 14 O-ring 23 Washer Shaft 15 Washer...

  • Page 58: Drive Axle

    DRIVE SYSTEM 5.4 Drive Axle 5.4.1 Removal and Installation See Section 5.3.1 5.4.2 Component For CPD30L1-B Name Name Name Bolt Wheel Nut 13 Sector Plate-R Lock Washer Wheel Bolt 14 Bridge Round Nut Bearing 15 Plug Rotary Shaft Lip Seal...
  • Page 59 DRIVE SYSTEM For CPD35L1-B, CPD30/35L1-S Name Name Name Bolt Half Axis 13 Wheel Brake-R Lock Washer Bearing 14 Sector Plate-R Round Nut Break Drum 15 Bridge Rotary Shaft Lip Seal 10 Wheel Hub Nut 16 Plug Half Axis Washer 11 Wheel Hub Bolt 17 Plug Half Axis Bolt 12 Rotary Shaft Lip Seal...

  • Page 60: Drive Axle Oil

    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.

  • Page 61: Operating System

    6. OPERATING SYSTEM...
  • Page 62 NOTE:...

  • Page 63: Control Lever

    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);...

  • Page 64: Horn Button

    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;...

  • Page 65: Checking And Testing

    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;...

  • Page 66: Travel Combination Switch

    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...

  • Page 67: Control Circuit Troubleshooting

    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;...
  • Page 68 OPERATING SYSTEM For CPD30/35L1-S ( Fig3131-30008SM) REV. 05/2020...

  • Page 69: Lighting Combination Switch

    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...

  • Page 70: Control Circuit Troubleshooting

    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;...

  • Page 71: Key Switch

    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 .

  • Page 72: Warning Light Switch

    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.

  • Page 73: Emergency Switch

    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.

  • Page 74: Parking Brake Switch

    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.

  • Page 75: Control Circuit Troubleshooting

    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.

  • Page 76: Control Switch

    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.

  • Page 77: Control Circuit Troubleshooting

    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-...
  • Page 78 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:...
  • Page 79 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:...
  • Page 80 OPERATING SYSTEM REV. 05/2020...

  • Page 81: Hydraulic System

    7. HYDRAULIC SYSTEM...
  • Page 82 NOTE:...

  • Page 83: Overview

    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...

  • Page 84: Hydraulic Schematic Diagram

    HYDRAULIC SYSTEM 7.1.1 Hydraulic Schematic Diagram REV. 05/2020...

  • Page 85: Hydraulic Power Unit

    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;...

  • Page 86: Faults And Causes

    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.

  • Page 87: Checking And Testing

    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;...

  • Page 88: Control Circuit Troubleshooting

    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...
  • Page 89 HYDRAULIC SYSTEM REV. 05/2020...

  • Page 90: Multi-Way Reversing Manual Valve

    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 -...

  • Page 91: Interface Description

    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.

  • Page 92: Gear Pump

    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.

  • Page 93: Redirector

    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.

  • Page 94: Tilt Cylinder

    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...

  • Page 95: Cylinder Installation Precautions

    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;...

  • Page 96: Removal And Installation

    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;...

  • Page 97: Cylinder Maintenance

    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...

  • Page 98: Hydraulic Troubleshooting

    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.

  • Page 99: Hydraulic Symbol

    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...
  • Page 100 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...

  • Page 101: Steering System

    8. STEERING SYSTEM...
  • Page 102 NOTE:...
  • Page 103 STEERING SYSYTEM Steering System Name Steering Wheel Displacement Sensor Steering Bridge REV. 05/2020...

  • Page 104: Steering Bridge

    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;...

  • Page 105: Component

    STEERING SYSYTEM 8.1.3 Component P l e a s e a d d g r e a s e ( s e e S e c t i o n 2 . 2 . 3 f o r specification ). Be sure to bend a cotter pin.

  • Page 106: Displacement Sensor

    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...
  • Page 107 STEERING SYSYTEM REV. 05/2020...

  • Page 108: Steering Cylinder

    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);...

  • Page 109: Electrical System

    9. ELECTRICAL SYSTEM...
  • Page 110 NOTE:...

  • Page 111: Controller

    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.
  • Page 112 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;...

  • Page 113: Controller Interface Function (Cpd30/35L1-B)

    ELECTRICAL SYSTEM 9.1.2 Controller Interface Function (CPD30/35L1-B) Traction Controller (ACE2) Pump Controller (ACE2) REV. 05/2020...
  • Page 114 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.
  • Page 115 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.

  • Page 116: Controller Interface Function (Cpd30/35L1-S)

    ELECTRICAL SYSTEM 9.1.3 Controller Interface Function (CPD30/35L1-S) Traction Controller (ACE3) Pump Controller (ACE3) REV. 05/2020...
  • Page 117 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.
  • Page 118 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.

  • Page 119: Fuse

    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...

  • Page 120: Checking And Testing

    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.

  • Page 121: Main Contactor

    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.

  • Page 122: Faults And Causes

    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...

  • Page 123: Control Circuit Troubleshooting

    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:...

  • Page 124: Accelerator Pedal

    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.

  • Page 125: Control Circuit Troubleshooting

    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...
  • Page 126 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...

  • Page 127: Dc-Dc Converter

    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.

  • Page 128: Combination Light / Headlight / Warning Light

    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.

  • Page 129: Control Circuit Troubleshooting

    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...

  • Page 130: Seat Switch

    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.
  • Page 131 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...

  • Page 132: Handheld Unit-A (Optional)

    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...

  • Page 133: Handheld Unit-B (Optional)

    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.

  • Page 134: Testing Truck Operation

    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.

  • Page 135: Adjustments

    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.

  • Page 136: Parameter Settings

    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...
  • Page 137 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.

  • Page 138: Tester Menu

    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).
  • Page 139 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.
  • Page 140 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.
  • Page 141 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...
  • Page 142 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.
  • Page 143 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...

  • Page 144: Controller Error Message

    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...
  • Page 145 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).
  • Page 146 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.
  • Page 147 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.
  • Page 148 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);...
  • Page 149 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,...
  • Page 150 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.
  • Page 151 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.
  • Page 152 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.
  • Page 153 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.
  • Page 154 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.
  • Page 155 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...
  • Page 156 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.
  • Page 157 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...
  • Page 158 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.
  • Page 159 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.
  • Page 160 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.
  • Page 161 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...
  • Page 162 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...

  • Page 163: Controller For Cpd30/35L1-B Ace2 Supervisor_Uc)

    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...
  • Page 164 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...
  • Page 165 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.
  • Page 166 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 ÷...

  • Page 167: Controller For Cpd30/35L1-S(Ace3 Master_Uc)

    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.
  • Page 168 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)
  • Page 169 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;...
  • Page 170 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.
  • Page 171 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.
  • Page 172 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;...
  • Page 173 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.
  • Page 174 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.
  • Page 175 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.
  • Page 176 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.
  • Page 177 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 ÷...
  • Page 178 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.
  • Page 179 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.
  • Page 180 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...

  • Page 181: Controller For Cpd30/35L1-S(Ace3 Slave_Uc)

    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...
  • Page 182 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...

  • Page 183: Electrical Schematic Diagrams

    ELECTRICAL SYSTEM 9.13 Electrical Schematic Diagrams (CPD30/35L1-B) REV. 05/2020...

  • Page 184: Cable Wiring Diagrams

    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...

  • Page 185: Wiring Harness And Connectors (Cpd30/35L1-B)

    ELECTRICAL SYSTEM 9.15 Wiring Harness and Connectors (CPD30/35L1-B) REV. 05/2020...

  • Page 186: Wiring Harness And Connectors (Cpd30/35L1-S)

    ELECTRICAL SYSTEM 9.16 Wiring Harness and Connectors (CPD30/35L1-S) REV. 05/2020...

  • Page 187: Troubleshooting

    10. TROUBLESHOOTING...
  • Page 188 NOTE:...

  • Page 189: Preparation Before Troubleshooting

    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;...

  • Page 190: Troubleshooting Solutions Of Common Faults

    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.
  • Page 191 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-...
  • Page 192 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.
  • Page 193 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.
  • Page 194 TROUBLESHOOTING REV. 05/2020...

  • Page 195: Appendix

    APPENDIX...
  • Page 196 NOTE:...

  • Page 197: A Service Manual - Mast

    A SERVICE MANUAL - MAST...
  • Page 198 NOTE:...

  • Page 199: A1 Wide-View Two-Stage Mast

    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;...

  • Page 200: A1-2 Lifting Chains

    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);...

  • Page 201: A1-2.2 Chain Replacement

    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.

  • Page 202: A1-3 Mast Tubing

    SERVICE MANUAL - MAST A1-3 Mast Tubing Code Description Lifting / Lowering Mast Tubing Right Shift Mast Tubing Left Shift Mast Tubing REV. 05/2020...

  • Page 203: A1-4 Lift Cylinder

    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;...

  • Page 204: A1-4.2 Cylinder Maintenance

    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.

  • Page 205: A1-5 Built-In Side Shifter

    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);...

  • Page 206: A1-6 External Side Shifter

    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);...

  • Page 207: A2 Two-Stage Full Free Mast

    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-...

  • Page 208: A2-2 Lifting Chains

    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;...

  • Page 209: A2-2.2 Chain Replacement

    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.

  • Page 210: A2-3 Mast Tubing

    SERVICE MANUAL - MAST A2-3 Mast Tubing Code Description Lifting / Lowering Mast Tubing REV. 05/2020...
  • Page 211 SERVICE MANUAL - MAST Code Description Right Shift Mast Tubing Left Shift Mast Tubing REV. 05/2020...

  • Page 212: A2-4 Lift Cylinder

    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.
  • Page 213 SERVICE MANUAL - MAST REV. 05/2020...

  • Page 214: A2-4.2 Cylinder Maintenance

    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.
  • Page 215 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.

  • Page 216: A2-4.3 Cylinder Installation

    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.

  • Page 217: A3 Three-Stage Full Free Mast

    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-...

  • Page 218: A3-2 Lifting Chains

    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;...

  • Page 219: A3-2.2 Chain Replacement

    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;...
  • Page 220 SERVICE MANUAL - MAST REV. 05/2020...

  • Page 221: A3-3 Mast Tubing

    SERVICE MANUAL - MAST A3-3 Mast Tubing Code Description Lifting / Lowering Mast Tubing REV. 05/2020...
  • Page 222 SERVICE MANUAL - MAST Code Description Right Shift Mast Tubing Left Shift Mast Tubing REV. 05/2020...

  • Page 223: A3-4 Lift Cylinder

    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.

  • Page 224: A3-4.2 Cylinder Maintenance

    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);...

  • Page 225: A3-4.3 Cylinder Installation

    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;...
  • Page 226 SERVICE MANUAL - MAST REV. 05/2020...

  • Page 227: B Service Manual - Battery

    B SERVICE MANUAL - BATTERY...
  • Page 228 NOTE:...

  • Page 229: B1 Lithium-Ion Battery

    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.

  • Page 230: B1-2.3 Charging

    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.
  • Page 231 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.

  • Page 232: C Schedule

    C SCHEDULE...
  • Page 234 Operator's Daily Checklist Date Operator Truck No. Department Runtime Meter Reading Daily Check Items O.K.( √ ) Remark Drive Wheel Steering Wheel Horn / Lights Lifting / Lowering Control Functions Optional Features Forward / Reverse Control Functions Steering control functions Braking Functions Check hydraulic system for leaks: cylinders, fittings, tubings, oil tank, etc.

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