Sovan's CBD25T Operation Manual

Electric pallet truck

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Download this manual

CBD25T/CBD30

Electric Pallet Truck

 Operation Manual

 Parts Catalogue

2012-01

Table of Contents

Need help?

Do you have a question about the CBD25T and is the answer not in the manual?

Questions and answers

Summary of Contents for Sovan's CBD25T

Page 1 CBD25T/CBD30 Electric Pallet Truck  Operation Manual  Parts Catalogue 2012-01...
Page 2 Welcome to choose “Sovan's” electric pallet truck! We hope our electric trucks will bring great convenience to your work!  Please read the manual carefully before operation. This manual is a common manual. We reserve the right to modify ...
Page 3: Table Of Contents
Content Brief introduction ……………………………………………………………………..……1 Ⅰ.Technical parameters …………………………………………………..…………..2 Ⅱ.Structure description …………………………………………………………………4 Ⅲ.Safety norms ……………………………………………………………………………..6 Ⅳ.Drive and operation ………………………………………………………..………..11 Ⅴ.Storage battery and charge ……………………………………………………..13 Ⅵ.Inspection before operation …………………………………………………..16 Ⅶ.Inspection after operation ……………………………………………….……...16 Ⅷ.Periodic maintenance and repair ………………………………………….….17 Ⅸ.The store and transportation of forklift …………………………………..22 Ⅹ.The tow of the pallet truck ……………………………………………...23...
Page 4: Brief Introduction
Brief introduction ： CBD25T/CBD30 series electric pallet truck is powered by storage battery, and driven by motor. This kind of truck travels by means of gear drive. The fork is lifted by means of DC motor and hydraulic transmission, which motivate hydraulic cylinder up and down to lift fork and goods together.
Page 5: Ⅰ.technical Parameters
Ⅰ.Technical parameters： 1． CBD25T/CBD30 Outline drawing：...
Page 6 2、 Main technical parameter Manufacturer(abbreviated) CBD25T CBD30 Model Driving model ： Electric(storage battery), motor-driven motor-driven diesel, gasoline, fuel gas Char Driving model （ Manual, Walking, Stand Stand driving Stand driving acter driving, Seat driving ,Order picking） istics Q(kg) 2500 3000...
Page 7: Ⅱ.structure Description
Ⅱ.Structure description： 1．Structure of the entire truck： 1 power switch； 2 lifting button； 3 horn button； 4 accelerator knob； 5 operation handle； 6 emergency reverse button； 7 multi-functional instrument 8 electric lock； 9 electric control unit； 10 driving unit； platform； 12 steering power unit；...
Page 8 2 Function introductions instrument operational control pieces: ⑴⑴ instrument: 1. battery capacity indicator； 2. fault indicator； 3. low-speed indicator； accumulative working time and fault code indicator This instrument is a combination battery capacity indicator, LCD hour meter, fault code low-speed indicator, with the battery capacity indicator of five segments of colorful LED display.
Page 9 When the operation handle is placed in area B or area C, the truck can conduct traveling operation as well as lifting operation. However, traveling and lifting operation can not realized at the same time, with the traveling operation as the preferential function。 ⑷Operation control: Lifting and lowering operation: Press the lowering button of the forks, the forks will descend.
Page 10: Ⅲ.safety Norms
Ⅲ. Safety Norms： Warning Please pay attention to the following items first before operation of the truck： ⑴ This electric truck is only limited to utilization indoor with a hard flat floor. Operation in inflammable, explosive environment or corrosive environment such as acid or alkaline condition shall be strictly forbidden.
Page 11 ⑷ Safety of working place： Notice This kind of electric truck is only limited to utilization indoor with a hard flat floor. Operation in inflammable, explosive environment or corrosive environment such as acid or alkaline condition shall be strictly forbidden。 A Good roadway condition shall be kept and the traffic should be smooth.
Page 12 2 Safety Operation Specification： ⑴ Check the safety condition around the truck Notice Before starting up the truck, please ensure that there is no person around it。 Notice If the driver’s view is shielded by the bulky goods carried, please drive backwards or drive under the guidance of other working personnel.
Page 13 Notice Observe all items of safety rules on working place. Decelerate and sound horn when travel by other truck or vehicles. Avoid driving in places with bad view。 Notice Ensure to provide certain clearance between truck and entrance （3） Never drive too close to roadside； Notice Ensure to provide enough distance between the truck and roadside or platform edge。...
Page 14: Ⅳ.drive And Operation
Make a record of charge. As for the charge method, refer to the part about storage battery operation。 Ⅳ.Drive and operation： 1．Prepare before operation： Warning Never use the faulty truck Before operation, check the truck to make sure: whether oil leakage of hydraulic pipe exists, whether all the supporting wheels work well, whether blocking phenomenon appears.
Page 15 The following procedures shall be observed for goods transportation ： Decelerate when approaching the goods area ① ； Inspect safety condition around the stacking area ② ； ③ Adjust position of the truck, placing it in front of place where goods locate ；...
Page 16 electrolyte should be added。 1．4 The sulfuric acid electrolyte is prepared with battery sulfuric acid complying with the state standard GB4554-84 and distilled water. Never use industrial sulfuric acid and running water. The standard temperature （25℃）and density of the electrolytic solution can be converted as follows: D25＝Dt＋0.0007(t－25) D25：...
Page 17: Ⅵ.inspection Before Operation
b. Avoid contact with any harmful substance. No metal impurity shall fall inside the battery. c. No inversion, no mechanical collision or heavy weight is permitted. d. Storage with electrolyte is forbidden. Under special cases that the storage with electrolyte is necessary, the density and solution level of electrolyte shall be adjusted to the specified value.
Page 18: Ⅶ.inspection After Operation
Charge Confirm the display state of the battery capacity. Storage Electrolyte The solution level and density of electrolyte. battery Connecting line The connecting line and socket shall be firm. Press down the horn button to check whether Horn Horn the horn sounds. Turn on the switch of electric lock to check Instrument Function...
Page 19 Notice No smoking. Arrange the self-protection work. Wipeout the effusive oil in time. Before adding lubricating oil, clean up the dirty oil or dust on the joint with brush or cloth. Except certain situation, turn off the key switch and pull off the power socket.
Page 20 6 The inspection and maintenance after 200 hours（Monthly） Besides the weekly maintenance, the following maintenance should be carried out, and when the parts must be adjusted and replaced, please contact with maintenance personnel of our company. (keep monthly maintenance record) ）...
Page 21 Maintenance for 1200 hours（every six months） During the maintenance for a half year, the maintenance process for three months shall be repeated. When the parts must be adjusted and replaced, please contact with maintenance personnel of our company。 Burnish the coarse surface of contacts using sand paper. Contactor Replace according to the status when the function is not well.
Page 22 10 Structure of lifting cylinder and wearing parts： 1. Dustproof ring DH60； 2. Seal ring UHS60X70X6； 3. Oil cylinder； 4. O-type seal ring 65X3.55； 5. Plunger 11 Maintenance period of consumables and partial parts： Items Maintenance content Maintenance period Remarks Bearings of fork Replacement 1200 hours...
Page 23 Ⅸ.The store, transportation and loading of truck: 1 The store of truck： If the electric pallet truck is not used for over two months, it should be placed in the room which is in good ventilation, no frost, clean and dry; also the following measures should be taken: Clean the truck thoroughly.
Page 24 Ⅺ.Common faults and trouble shooting:: Faults Possible cause Trouble shooting The oil-absorptive filter is blocked Clean or replace the oil-absorptive filter The oil-absorptive tube leaks and the oil Fasten the tie-in, check the oil level, or add are foaming. some oil. Abnormal noise Contact maintenance personnel of our Hydraulic pump or motor is damaged.
Page 25 Adjustment methods of safety valve pressure The pressure of safety valves has already been adjusted when the truck is ex-factory. Users shall not adjust the pressure at will. Otherwise it will bring danger to the truck’s hydraulic system and safety. If the oil pressure is not in accordance with specified value, please ask the professional personnel to adjust according to the test methods locknut pressure...
Page 27 schematic wiring diagram...
Page 28: Ⅻ.common Fault And Trouble Shooting
Ⅻ.Common faults and trouble shooting 一．failure and failure elimination of swing controller: 1) MICRO SLAVE KO CAN Bus code = 246 Lord Reason: Use in stepping moter.When the stepping moter direction which is tested by the , fault alarm. microprocessor doesn’t match with the direction which is tested by microprocessor Turning error of the Lord microprocessor doesn’t match with the direction which is tested by microprocessor.
Page 29 Handle: Should change the controller 8) NO SYNC CAN Bus code = 227 - Cause: Every 16 milliseconds, code to internal circulation 1 time，The Lord microprocessor signal up and then down, and then will signal transmission give from microprocessors（SYNC）。When microprocessors in greater than 100 milliseconds time not to the edge of the signal detection, can appear fault alarm ,this is the function of watchdog.
Page 30 3) POWER FAILURE #2 CAN Bus code = 72 Motor start to operation,but motor U phase current is - Cause: 0,then fault alarm. - Handle: Check the power insurance is normal or not. Check the battery and the wiring of positive controller. Check the wiring of motor U phase. Otherwise need to replace controller。...
Page 31 battery anode (stepping motor dormant) is very low (close to 30ohms). 2) Q LINE SENSOR KO CAN Bus code = 242 - Cause: When the average voltage of step motor( join CNA#8) is not zero cuase sfault: Stepping motor voltage is a sine wave of total null voltage. - Handle: Check the step motor connection,especially resistance measurement between CNA# 9 and battery anode (stepping motor dormant) is very low...
Page 32 correctly，set correctly with AUX FUNCTION 11 (see12.4.1.9), And check motor bearing sensor (encoder) whether slip (bearing sensor has two loop connection: one connects rotor shaft; another connecs electric cabinet) or not, no slip, check if the two road rate differential wiring structure reliable connect or not. 6) STEER SENSOR KO CAN Bus code =84 Cause:...
Page 33 CAN Bus code =83 - Cause: When the signal of the frequency and the electrical machine is opposite， use trigger switch will be fault. - Treatment: Interchange the two holding wire of encoder (CNB#7 with CNB#8). 14.1.4 Trouble light flickers 4 times 1) EEPROM KO CAN Bus code = 13 - Cause:...
Page 34 of motor voltage is not in 2.2-2.8 V range - Treatment: Need to change the controller. 3) LOGIC FAILURE #3 CAN Bus code = 17 Cause: Fault occurs in idle state.voltage amplifier drift of interphase voltage between Vu and Vw is more than ±0.25V. ±0.25 V.
Page 35 14.2 CAN BUS errir listing AC0（Device code06）See following fault codes： SERIAL ERR #1 EEPROM KO LOGIC FAILURE #4 LOGIC FAILURE #3 LOGIC FAILURE #2 LOGIC FAILURE #1 VMN NOT OK MAIN CONT. OPEN STBY I HIGH HIGH TEMPERATURE MOTOR TEMPERAT. HIGH CURRENT POWER FAILURE #3 POWER FAILURE #2...
Page 36 252: KS OPEN 253: KM CLOSED 254: KS CLOSED 2.Fault and elimination methods of walk controller The main menu alarm log records of controller fault alarm，controller has FIFO characteristics. ，that means when the database has full or new alarm occurs, then the first alarm fault record will be lostM。ALARMIM Alarm log consists of five information as follow.To distinguish these five types of alarm.：...
Page 37 Valve、pump motor， Traction electric machine is Motor output Request stopped ， VMN LOW Await for voltage lower start valve 、 lift or AL30 traction Master contactor than ideal value traction. disconnection, electromagnetic braking Valve、pump motor， Traction electric machine is Motor output Request stopped ，...
Page 38 Valve、pump motor， Main contactor Traction electric machine CONTACTOR lhas Request Await for stopped， ofvalve、 lift OPEN drove ,but the Start traction Master contactor switch can’t AL38 or traction disconnection, close. electromagnetic braking Valve、pump motor， Traction electric machine CONTACTOR Request stopped， Await for Main contactor...
Page 39 Valve、pump motor， LOGIC Request Await Hardware Traction electric machine Start ofvalve 、 FAILTUR# 、 stopped ， protectionfault Static state lift traction high current Master contactor is disconnection, AL17 traction electromagnetic braking STBY （ motor not have Valve、pump motor， HIGH Request Await current ）...
Page 40 Main Start、 static microcontroller Valve、pump motor， state detected from Traction electric machine Main （ micro controller stopped ， HW FAULT Await for contactor Restart the can't shut off the AL7* traction Master contactor closed and switch lock traction allow end disconnection, traction or main contactor...
Page 41 14.3 Main microcontroller alarm analysis and solution Home page for the handheld unit, press ENTER button to enter into the main menu 1) “CAPACITOR CHARGE” Power capacitor power Below is the power of capacitance charging system When closed electricity lock switch, inverter through power resistance to charge with power capacitor, testing the capacitor is charging in preinstall time , if not, there will be a fault display, main contactor disconnect。...
Page 42 “VMN HIGH” Motor voltage is too high Cause 1： before closed main contactor switch , with the software testing power bridge: alternate closed above power MOS tube, hope to increase phase voltage to power capacitor voltage value, if phase voltage not increase, will fault alarm Cause 2：...
Page 43 Cause：Main contactor coil driver shorted Solution ways ： A) Check the cathnode of main contactor coil（AMP saab type, on CNA#17end, AMP seal type, on CNA#12 end）whether shorted with the battery cathode or not.or if connected with a lower resistance value or not. 。...
Page 44 is 45V,limitation voltage is 9V in 24 controller undervoltage 。 Static or start-up failure solutions; Static or starting may arise when voltage fault, need to check A) The lock of the pulse signal input voltage drop (below the voltage limited voltage), the reason is external load, like start DC/DC converter, relays and contactor switch, incentive/disconnect solenoid。...
Page 45 The purpose is to test the diagnosis of digital-to-analog converters fault or code flow fault，Code flow may omit the process to update analog signals. Solution： If a fault persists, need to replace controller. 20）“ENCODER ERROR” Cause：In the following conditions caused a fault signal：Motor input frequency higher than 40 HZ, encoder signal feedback is higher than 40 HZ in 10 milliseconds .
Page 46 Solution ways： Internal fault of controller,should replace the controller. 26）“SAFETY FEEDBACK ”feedback of safety signal Cause： Security detection,fault feedback of tested by main microcontroller. Solenoid Valve Driving Solution ways： Controller fault,should replace the controller . 14.4 Give an alarm of main controller Error code of Error State of...
Page 47 damaged The motor temperature MOTOR Maximum current sensor disconnect TEMPERATU reduced by half, speed continuatio that is digital), or (if it is cuts simulated) more than AL65 limit voltage 150. ℃ THERMIC Controller of the Maximum current SENS KO temperature sensor continuatio reduced by half, speed temperature...
Page 48 14.5 Main controller alarm analyze and solution 1) “PUMP WARNING” lift request . Cause： Fault from controller. Solution：handheld unit and controller connection ,inspection alarm. 2）“SLIP PROFILE” Reason：Choice wrong preferences of slip profile. Solution：Check the parameter values of hardware setting。 3） FORW+BACK When activate back and forward request meanwhile will be happen alarm.
Page 49 8) “EEPROM KO”EEPROM damaged Reason：Built-in Storage controller parameters “eeprom” damaged or hardware or software fault. This alarm will not banned the operation of trucks and works according to default. Solution ways： Try to perform "CLEAR EEPROM" clear memory command (portable unit)。Disconnect the electric lock switch then closed, and check the result。If the alarm persists, need to replace controller。...
Page 50 Solution ways:get help from ZAPI, adjust of access to current procedure of parameters correctly. Obtained 16）“WAITING FOR NODE” Reason：controller can test another wrong controller through CANBUS,so the controller of traction cant enter into running status and await for controller get right. 14.6 Alarming from controller Fault Fault code...
Page 51 then 2.15V.Failure warning will be happen when the voltage sign is greater than 3V or less than Valve、pump motor， SAFETY Fault of drive feedback of Restart Awaiting Tractionelectricmachine stopped FEED（TG） maincontactor which is continuation electricity for node Master contactor disconnection, tested by microcontroller lock electromagnetic braking...
Page 52 Valve、pump motor， Tractionelectricmachine Restart NO CAN Information stopped ， Awaiting MSG #2 dropoutfrom main continuation for node Master contactor switch microcontroller disconnection,electromagneti lock sm brake. Start （test involved in Valve、pump motor， main microcontroller solenoid Tractionelectricmachine Restart valve） Tested from HW FAULT Awaiting stopped，...
Page 53 Appendix 1 ISO3691 Motor industrial vehicle—Safety Norms The Second Part Safety Norms of motor industrial vehicles in service, operation and maintenance Safety rules for the user and driver In order to use the motor industrial vehicle well, this part set up some rules. The 14.1 is applied to the user, the 14.2 is for the driver.
Page 54 The truck should painted the color differing from the surrounding circumstance. The driving type high –lift truck should be mounted with protection cabane, except for the condition where the load could not drop onto the driver. When convey the load maybe fall to the driver using high –lift truck, should adopt shielding shelf with enough height, weight and the opening size is small enough to prevent the entire load or part of them from falling onto the driver.
Page 55 maintain it well not to influence the truck operating safely. The transporting channel of the truck should have well visual field, and it is easy to turn, and no grade, steep slope, narrows channel and low roof board. The outline or the borderline must be clear.
Page 56 The road vehicle (trailer) and rail vehicle should endure the overall weight of vehicle, load and the drivers. It is necessary to inspect if the pavement is crushing, having holes or other damage. When the industrial truck is operating at high place or platform, should not use the industrial truck to move other vehicles.
Page 57 C） When conveying high and multi-piece piled goods, it is necessary to tilt the mast back ward a little (if can tilt back) to stabilize the load, and should be careful specially. When unloading the goods, it is necessary to descend carefully. If possible, tilt the mast forward a little (or limited)in order to put ready the load and draw out the fork.
Page 58 When the truck is operating with load, the driver must control turning equipment and brake system slowly and stably. In crossroads and the occasion that would obstruct the driver’s sight or some dangerous occasion, the truck must not exceed other truck moving at the same direction. The driver must avoid the truck rolling over some fluffy object in order to avoid article damages or personnel hurts.
Page 59 If possible, the truck should cross over the railway virgule. 14.2.3.6 The truck operating on the gangplank or transition board Before the motor industrial vehicle pass the gangplank or transition board, it is necessary to make sure the firm of the board. The overall weight of the truck should not excess the rated capacity of the gangplank or the transition board.
Page 60 It is necessary to using soap liquid to check the leak dictation. The truck driven by liquefied petroleum gas could not park near the heat source, open flame or the similar ignition, and not near to the open air pit, the entrance of the under crossing, the elevator well or other similar place, and could not change the removable container in the upper place.
Page 61 15.2.5 Inspection and maintenance shall be taken for storage battery, driving motor, contactor and controller, limit switch, protection device, lead wire and connecting assembly, which shall be kept within safe operation condition. Special attention shall be paid to electrical insulation state.
Page 62 Maintenance and repairing recording card Maintenance Maintenance Maintenance Items Material used Remarks time part personnel Customer advisement feedback:  Time Items Trouble location Fault cause Trouble-shooting Remarks occurred...

This manual is also suitable for:

Cbd30

Sovan's CBD25T Operation Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Sovan's CBD25T

Summary of Contents for Sovan's CBD25T

This manual is also suitable for:

Table of Contents