HANGCHA TZ220XS30kW309VTQ Service Manual
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HANGCHA TZ220XS30kW309VTQ Service Manual

HANGCHA TZ220XS30kW309VTQ Service Manual

Lithium battery rough terrain forklift truck
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Lithium Battery Rough Terrain Forklift
Truck
Service Manual
Original Instruction
HANGCHA GROUP CO., LTD
08/2023

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Summary of Contents for HANGCHA TZ220XS30kW309VTQ

  • Page 1 Lithium Battery Rough Terrain Forklift Truck Service Manual Original Instruction HANGCHA GROUP CO., LTD 08/2023...
  • Page 3 Our product design will update and perform better, so the content in this manual may be not the same as the forklift you owned. If you have any questions please keep touches with HANGCHA GROUP CO., LTD. sales department or let the agents know.
  • Page 4 ） For the following inspections, maintenance and other situations, please be sure to consult and have Hangcha professional maintenance technicians to conduct on-site service processing ： --Involving the inspection, maintenance, and replacement of high-voltage components, components, and circuits;...

  • Page 5: Table Of Contents

    Content Foreword I. Safety Specifications ............................1 1.1 Brief introduction of high voltage components ................1 1.2 Safety precautions and operating specifications for high-voltage electric forklift trucks ....7 1.3 First aid for high-voltage accident ....................11 II. Drive system ............................... 12 2.1 Drive System Removing and Installation ..................
  • Page 6 7.4 Mast disassembly and installation ....................135 VIII. Electric system ............................141 8.1 Special safety rules for high-voltage electric forklift ..............142 8.2 Electric drive system ........................145 8.3 Safe operation specification ......................157 8.4 Control box assembly ........................163 8.5 Lighting system ..........................167 8.6 Switch ............................

  • Page 7: Safety Specifications

    I. Safety Specifications Brief introduction of high voltage components （ 1 ） Power battery assembly The forklift lithium battery assembly equips with 2 lithium battery boxes as standard, one master box and one slave box. Fig.1-1 Forklift power battery assembly (master box)
  • Page 8 Fig.1-2 Forklift power battery assembly (slave box)
  • Page 9 MSD maintenance switch, wait for 15-20 minutes and then the lithium battery will be powered off. The inspection and maintenance of the lithium battery must be done by the professional personnel designated by Hangcha, and other personnel are strictly prohibited to overhaul.
  • Page 10 （ 2 ） Two-in-one power supply Fig.1-4 Two-in-one power supply （ 3 ） Motor (traction/oil pump) Front drive motor Rear drive motor (4WD) Fig.1-5a Motor (traction/oil pump)
  • Page 11 Fig.1-5b Oil pump motor （ 4 ） National standard charging base Fig.1-6 National standard charging base...
  • Page 12 （ 5 ） High voltage connection cable Fig.1-7.High voltage connection cable WARNING Inspection and maintenance of high-voltage parts should be specially trained in high-voltage electrical appliances and obtain corresponding certificates. The internal inspection and maintenance of the lithium battery must be completed by a professional manufacturer.

  • Page 13: Safety Precautions And Operating Specifications For High-Voltage Electric Forklift Trucks

    2.Before repairing high-voltage components, connect the body with the ground wire to the ground wire of the dedicated repair station for the electric forklift. 3.High-voltage components and storage batteries are carried out by Hangcha or authorized institutions and personnel with special training (different from ordinary forklift training).
  • Page 14 6.When examining and repairing the high-voltage wiring harness, any removed high-voltage wiring should be immediately wrapped and insulated with green tape. 7.Do not touch the live parts of the high-voltage wiring harness connector with your fingers to avoid electric shock. In addition, prevent small metal tools or iron bars from contacting the live parts of the connector.
  • Page 15 、 Safety protective gear and equipment Safety protection equipment used for maintenance of high-voltage electric forklifts are shown in table 2-2. Part of the protective equipment is shown below Table 1-2 Safety protection appliances and equipment for maintenance of high-voltage electric forklifts name unit...
  • Page 16 Fig.1-10 Maintenance station warning sign and isolation fence ③ Safety operation specification for maintenance of high voltage electric forklift is pasted on the wall. ④ The dedicated maintenance station is equipped with a single-phase and effectively grounded standard three-hole socket with a rated voltage of 250V and a rated current of 16A in accordance with GB2099.1.

  • Page 17: First Aid For High-Voltage Accident

    First aid for high-voltage accident 1 、 First aid measures for electric shock accident When rescuing a person injured in an electrical accident, do not touch anyone who is still in contact with electricity. If possible, power off the electrical system immediately (turn off the key switch or pull out the maintenance switch immediately).

  • Page 18: Drive System

    II. Drive system The Drive system is composed of drive axle assembly, reduction gearbox, tire assembly, etc. WARNING a ） When repairing the transmission system, it is necessary to disconnect the high-voltage cable on the traction motor's electronic control 2-in-1, which involves the high-voltage part! Therefore, it is necessary to strictly follow the safety regulations in Chapter 1 for operation! b ）...
  • Page 19 Table 2-1 Tightening torque table of drive system Tightening torque N·m Conneting part Connect the drive axle 3 Screw （ M12 ） 110~130 assembly to the frame 6 Screw （ M10 ） 65 ～ 78 Connect the motor to the 7 Bolt （...

  • Page 20: Two-In-One Fwd Motor Controller

    Protecting Cooling Model Rated Power method Grade Grade 30kW Liquid cooling IP67 TZ220XS30kW309VTQ Rated current Rated voltage Rated speed Duty 127A(AC) 309V(DC) 11000r/min S2-60min Caution a ） AC motor does not have commutator and brush. No maintenance. But it needs regular inspection and dusty clearing.

  • Page 21: Drive Axle Assembly

    2.3 Drive axle assembly Fig.2-2 Drive axle assy Wheel reducer assy Oil feed plug seat Washer Vent nozzle Screw Short shaft Cylindrical pi Bleed plug Bleed plug seat Bolt Reduction box Washer Screw plug Screw plug Washer Bolt Guard assembly Electric push rod assy Bolt Axle housing assy...

  • Page 22: Reduction Gearbox

    2.3.1 Basic structure and working principle of drive axle 2.3.1.1 Basic structure and working principle The basic structure of the drive axle is shown in Figure 2-2: it is mainly composed of axle housing, reduction gearbox assembly, axle shaft, wheel reducer, wet brake, electric push rod, etc. Its working principle is shown in Figure 2-3: the drving torque is input to the reduction gearbox, through which the direction of the power is changed, the speed is reduced, the transmitted torque is increased, and transmits the power to the wheel through differential and axle shaft, and then...

  • Page 23: Main Technical Parameters

    2.3.1.4 Wet brake structure Wet brake is used for braking, and the wet brake is mainly composed of friction plates, brake pad assembly, and piston assembly. See 2.3.8 for details. 2.3.1.4 Main technical parameters Table 2-7 Drive axle assembly parameter table Drive axle type The axle body and the frame are directly installed Total reduction ratio...
  • Page 24 2.3.3 Method of refueling and oil draining and the refuel quantity of drive axle When refueling, open the oil level plug and filler plug on the axle, and fill lubricating oil at the filler port until the oil level hole overflows, as shown in Figure 1-5. Oil level hole Caution The specified refuel quantity is an approximate value.
  • Page 25 Fuel plug Vent plug Deflation Brake oil inlet nozzle Drain plug Oil level plug Drain plug Drain plug Fig. 2-4...
  • Page 26 2.3.4 Lifting of drive axle When hoisting the drive axle, pass through the sling at the position shown in Figure 1-7 for hoisting, and if shoveling, still shovel at the position shown by the arrow in Figure 2-5. Whether it is lifting or shoveling, collision or detachment is strictly prohibited.
  • Page 27 2.3.5 Fault diagnosis and corrections Table 2-9 Drive axle fault diagnosis table Condition Possible reason Corrections ·Drive axle supporting sleeve and frame Tighten connected bolt loose ·Wheel nut loose Tighten ·Other installing parts loose Tighten Abnormal noise ·Hub bearing damage or wear Replace Before correction, make sure noise is from axle shaft but not...
  • Page 28 2.3.6 Remove the reduction gearbox from the drive axle Caution Before disassembly, please place a container under the axle housing to drain the gear oil in the axle housing 1. Loosen the bolt (1, M8×16), washer (2), and remove the shield (3); 1:(28-32)N·m 2.
  • Page 29 3. Loosen the bolts (4, M10, 13 in total) and washers (5), remove the reduction gearbox from the drive axle, and remove the cylindrical pin (6). 4:(60-75)N·m 4. The installation process is opposite to the disassembly process.
  • Page 30 2.3.7 Wheel reducer Figure 2-6 Wheel reducer Cylindrical pin Lock nut Half-shaft bolt Locking plate Washer Bolts Hub bolt Hub nut Bearing Bearing Wheel hub Oil seal Supporting shell Limit block Planetary shelf assy Outer shaft Retaining Ring Retaining Ring...
  • Page 31 2.3.7.1 Removal of wheel reducer assembly 1. Loosen the inner hexagon screws (1, M14, 12 on each side, 24 in total), and then the wheel reducer can be removed from the drive axle. 1:(170-190)N·m Caution a ） Before disassembly, please place a container under the axle housing to drain the gear oil in the axle housing b ）...
  • Page 32 2.3.7.2 Disassembly of the wheel reducer assembly 1. Remove the planet carrier assembly (1). 2. Remove the support housing (4). 3. Remove the oil seal (3). Caution When installing the oil seal, apply a little lithium-based grease evenly on the lip.
  • Page 33 4. Remove the bearing (4). 5. Remove the half shaft bolt M12×1.25×40 (5, tightening torque (105~115) N·m). Caution Loctite 262 glue is applied to the threaded parts of the half shaft bolts to prevent loosening. 6. Remove the outer axle shaft (6), cylindrical pin (7), retaining ring (8), shaft retaining ring (9) and limit block (10) together.
  • Page 34 7. Remove the cylindrical pin (7), retaining ring 9 10 (8), shaft retaining ring (9) and limit block (10) from the outer axle shaft (6) in sequence. 8.Remove the bolt (11, tightening torque (8~12) N m), washer (12). 9. Remove the lock washer(13).
  • Page 35 10. Remove the lock nut (14). 11. Remove the bearing (15). Caution a ） Pre-tightening of the wheel bearing: tighten the lock nut while turning the wheel hub until the wheel hub turns difficult, then retract the lock nut until the starting torque of the wheel hub reaches 3.5N·m~6.3N·m (Apply tangential force of 30N-55N at the hub...
  • Page 36 2.3.7.2 Disassembly of the planet carrier assembly After removing the planet carrier assembly from the wheel reducer assembly 1. Remove the hexagon socket head cap screws M8×25 (1, tightening torque (27~35) N·m). 2. Remove the pressure plate (2). 3. Remove the bolt M10×45 (3, tightening torque (75~85) N·m).
  • Page 37 4. Remove the planet carrier (4). 5. Remove the planet gear washers (5). 6. Remove the planet gears (6).
  • Page 38 7. Remove the needle bearing (7). Caution When installing, first install the planetary shaft and steel ball, and then install the needle bearing. 8. Remove the planetary shaft (8) and steel ball (9). 9. Remove the planet gear washers (5). 10.
  • Page 39 2.3.8 Wet brake After removing the wheel reducer: 1, Remove the limit block (1), adjustment pillar (2) and axle shaft (3). 2. Remove the drive gear (4)
  • Page 40 3. Remove the screws (5, M8×25, tightening torque (28-32) N·m) 4. Remove the wet brake (6) 5. The installation process is opposite to the disassembly process.
  • Page 41 1.3.8.1 Disassembly of wet brake 1. Remove the cylinder body(1) 2. Remove the needle roller (2). 3. Remove the rectangular seal ring (3) and the rectangular seal ring (4). 。 4. Remove the piston (5). 5.The installation process is opposite to the disassembly process.
  • Page 42 Caution When installing the rectangular seal ring, apply a little lithium-based grease evenly on the sealing surface of the piston assembly to ensure that there is no damage to the sealing surface of the seal ring. 2.3.8.2 Disassembly of the friction plate assembly 1.
  • Page 43 Caution a ） Four sets of belleville springs are installed between each brake plate and friction plate, and each set has six pieces of belleville springs. b ） When the friction plate is worn down to the bottom of the grid pattern groove, the friction plate needs to be replaced.

  • Page 44: Steering System

    III.Steering system 3.1 Structure introduction The steering system is mainly composed of three parts: steering device, steering axle assembly and tire assembly, see Figure 3-1. The steering device is composed of steering wheel assembly, steering tube device, locking handle and the hydraulic steering gear. See figure 3-2. Both the steering column and steering wheel can be put forward and backward by an angle of 6°, which can meet the requirements of different operators.
  • Page 45 Steering device 转向装置 转向桥总成 Steering axle assembly Fig. 3-1B Schematic diagram of 2WD steering system...

  • Page 46: Steering Device Structure

    3.2 Steering device structure Fig. 3-2 Steering device 4-steering Steering Washer Lock Handle Snap ring tube wheel assy Lock sleeve Lock sleeve Lock shaft Bolt Washer Ⅱ Ⅰ Steering Washer Bolt Spacer Snap ring Dust cover device Adjusting Steering Bush Washer shim shaft...

  • Page 47: 4Wd Steering Drive Axle

    3.3 4WD steering drive axle Fig. 3-3 4WD steering drive axle Left steering knuckle Wheel reducer assy Drive shaft assy screws Upper main pin shaft Grease nippl Adjusting gasket Screw Steering cylinder Locating sleeve Cotter pin Bearing retainer for holes Pin shaft Washer Dust ring...
  • Page 48 Table 3-2 Tightening torque of relevant fasteners of steering device Specification Tightening torque Remarks 31N·m ～ 42N·m M14×1.5×57 Screw 343N·m~441N·m 441N·m~558N·m M12×1.5×40 Screw 512N·m~683N·m M14×1.5×35 Bolt 31.2N·m ～ 42.1N·m M14×1.5×70 Bolt 3.3.1 Basic structure and working principle of steering drive axle The basic structure of the steering drive axle is shown in Figure 2-3: it is mainly composed of axle body assembly, reduction gearbox, final drive assembly, wheel reducer, and steering cylinder assembly.
  • Page 49 axle tires, and increase the steering angle, so as to make the layout of the forklift truck more reasonable. The transfer device in the reduction box is composed of two-stage external meshing gear pairs. The motor shaft of the driving motor is connected with the internal spline of the first-stage driving gear, and the power is input into the reduction gearbox.
  • Page 50 ③ Check whether the axle body, wheel rim, final drive, and external fasteners are loose and tighten them. The tightening torque is in accordance with the requirements in Table 2-2. ④ Check each part oil leak condition and repair in time. All sealing elements are not allowed to reuse once dismantle.
  • Page 51 Heel Forward pressure surface Reversed bearing surface The contact surface is close to the center and slightly biased towards the toe Incorrect contact pattern and adjustment way to driven spiral 3.3.2.4 bevel gear Driven gear contact area Adjustment way Adjustment direction First reduce the thickness of bearing bush adjusting shim, get driving bevel gear close...
  • Page 52 First increase the thickness of bearing bush adjusting shim, move the driving bevel gear out from driven bevel gear, if the backlash is too big, move driven bevel gear inward. First reduce the thickness of bearing bush adjusting shim, get driving bevel gear close driven gear, if the backlash is too small, move driven bevel gear outward.
  • Page 53 3.3.3 Refueling, oil drain and refuel quantity of steering drive axle...
  • Page 54 1-Fill port of reduction gearbox 2- Oil observation port of reduction gearbox 3- Drain port of reduction gearbox 4- Fill port of final drive 5- Oil level observation port of final drive 6- Drain port of final drive 7- Fill port of wheel reducer: When the arrow turns to point directly downward, it is used as a fill port and an observation.

  • Page 55: Common Faults And Troubleshooting

    3.3.5 Common faults and troubleshooting Fault feature Reason Troubleshooting Sometimes there 1. Parts wear 1. Check and repair parts or abnormal 2. Bad gear replace parts sounds during engagement 2. Re-assemble and adjust work 3. Bad lubrication 3. Improve lubrication 1.
  • Page 56 2 ） Remove the nut (1). 3 ） Remove the tire (2). 4 ） Place wooden blocks under the reduction gearbox and steering drive axle to support the steering drive axle. 5 ） Remove the counterweight.
  • Page 57 6 ） Loosen the oil inlet and outlet pipes of the steering cylinder and the oil pipe of the reduction gearbox. 7 ） Remove the bolts connecting the gearbox and the rear drive motor.
  • Page 58 8 ） Remove the bolts connecting the steering drive axle to the frame. 9 ） Install the counterweight. 10 ） Lift the vehicle and separate the vehicle from the steering drive axle. 11 ） The installation process is the reverse of the removal process.
  • Page 59 3.3.7 Wheel reducer 1- Hub bolt 2- Rim nut 3- Ring gear support 4- Ring gear Planet gear 5- Planet carrier 6- Rolling bearing 8- Bearing 61911 retaining ring Planetary gear 9- Spline sleeve 10- Planetary gear 12-Screw sleeve Flattened wire 13-Bolt 14- Lock nut...
  • Page 60 3.3.7.1 Wheel reducer removal After removing the tire 1 ） Remove the screws (1, M8, tightening torque 30N·m-36N·m). 2 ） Remove the planet gear assembly (2). 3 ） Remove the bolts (3), planet gear retaining ring (4), needle bearing (5), and planetary gear (6) from the planet gear assembly (2) in sequence 4 ）...
  • Page 61 5 ） Remove the ring gear (10), remove the flattened wire retaining ring for hole(9), and the ring gear support (11) from the ring gear (11) in sequence 6 ） Remove the bearing (12), O-ring (13), wheel hub (14), bearing (15), and cassette seal (16) in sequence 7 ）...
  • Page 62 8 ） Remove the oil cup (19), lower kingpin shaft (20), and seal ring (21) in sequence. 9 ） Remove the cotter pin (22) and nut (23) in sequence. 10 ） Remove the lower connecting rod (24), dust seal (25) and washer (26) in sequence.
  • Page 63 11 ） Remove the hinge pin (27) and upper connecting rod (28) in sequence. 12 ） Remove the cylindircal pin (29), left/right knuckle arm (30), oil cup (31), upper kingpin (32), adjusting shim (33) and seal ring (34) in sequence.
  • Page 64 13 ） Pull out the steering housing (35) in the direction of the arrow. 14 ） Remove the oil seal (36), circlip for hole (37) and the spline sleeve (38) from the steering housing (35) in sequence. 15 ） Remove the circlip for shaft (39), bearing (40) and cylinder liner (41) from the spline sleeve (38) in sequence.
  • Page 65 3.3.8 Removal of half shaft removal After removing the wheel reducer assembly, remove the nuts (1, M10, tightening torque 200N·m-230N·m) and set screws (2) in sequence, and pull out the drive shaft (3) to the outside. Caution Before disassembly, please put a container under the final drive to drain the gear oil in the axle housing and the final drive.

  • Page 66: Steering Cylinder

    3.3.10 Steering cylinder 1- Cylinder barrel 2- Piston rod 3-Glyd ring 4- Guide sleeve 5-Inner clip 6-Sleeve 7-Retaining ring 8- Composite bushing 9-ISI seal 10-LBH wiper seal 11- O-ring 12-Screw Cylinder removal steps: 1 ） After the tires are removed, remove the upper and lower connecting rods on the left and right sides by referring to steps 9-11 for removing the wheel reducer assembly.
  • Page 67 3 ） Remove the steering cylinder (2) in the direction of the arrow. 4 ） The installation process is the reverse of the removal process. Cylinder disassembly steps: – Remove the retaining ring (7), sleeve (6) and inner clip (5) in sequence; –...

  • Page 68: Final Drive Assembly

    3.3.11 Final drive assembly Final drive 2- Fixed sliding sleeve 3- Final drive housing 4-Oil seal differential assy. 6- Differential adjusting 5- Adjusting shim 7-Locking plate 8-Washer 9-Bolt 10-Bearing seat 11-Bolt 12-Stopper 13-Bolt 14-Shim 15-Screw 16-Washer Tapered roller 17- Cylindrical pin 19-Oil seal cover 20-O-ring bearing...
  • Page 69 3.3.11.1 Final drive assembly disassembly steps: 1 ） After removing the left and right axle housing assemblies, remove the bolt (1, M20, tightening torque: 286N·m-350N·m), washer (2), washer (3). 2 ） The reduction gearbox and the final drive assembly are in live connection, and the final drive assembly can be removed by pulling it outward.
  • Page 70 3.3.11.2 Disassembly steps of final drive assembly 1 ） Remove the bolts (1, M8, tightening torque: 30N·m-36N·m). 2 ） Remove the bearing seat (2). Caution When installing, apply Loctite 598 sealant on the joint surface of the reduction gearbox housing and the bearing seat.
  • Page 71 5 ） Remove the nut (5, M26, tightening torque: 430N·m-460N·m) and the fixed sliding sleeve (6) in sequence. Caution When installing, apply Loctite 598 sealant on the joint surface of the nut and the fixed sliding sleeve. 6 ） Remove the driving spiral bevel gear (7).
  • Page 72 7 ） Remove the oil seal (8), bearing (9) and adjusting shim (10) in sequence. Caution When installing, evenly apply a little lithium-based grease to the lip of the oil seal. 8 ） Adjust the gasket (11) and bearing (12) in sequence. 9 ）...
  • Page 73 Caution a ） When installing the bolt (13), apply Loctite 263 thread glue on the surface. b ） When installing, select a suitable axle shaft gear spacer (15), so that the assembled axle shaft gear and the planetary gear have a meshing clearance of 0.1mm-0.2mm. 10 ）...
  • Page 74 3.3.12 Reduction gearbox Deep groove ball 2-Washer 3-Screw plug 4-Breather bearing 8- Primary driver gear 5-Vent plug seat 6- Right housng 7- Oil seal shaft Secondary driver 9- Cylindrical pin 10- Left housing 11-Screw gear shaft 14- Hexagon socket point 13- Primary driven gear 15- Rectangular seal 16- Rectangular seal...
  • Page 75 Reduction gearbox disassembly 1 ） After removing the screw (1, M10, tightening torque: 60N·m-75N·m), remove the left housing (2) and cylindrical pin (3) in sequence. Caution When installing, apply Loctite 598 sealant on the joint surface of the left and the right housings. 2 ）...
  • Page 76 3 ） Remove the bearing (4), primary driven gear (8) and secondary driver gear (9) from the reduction gearbox in sequence. 4 ） Remove the set screw (10) from the reduction gearbox. 5 ） Remove the bearing (11), secondary driven gear (12), bearing (13) and positioning pin (14) from the reduction gearbox in sequence.
  • Page 77 Caution When press-fitting the positioning pin (14), apply Loctite 598 sealant. 6 ） Remove the circlip for hole(15), spring retainer (16), spring (17) and piston assembly (18) from the reduction gearbox in sequence. Caution During installation, inject an appropriate amount of lithium-based grease into the joint between the piston assembly (18) and the right housing of the reduction gearbox and into the cavity.
  • Page 78 8 ） Remove the circlip for shaft (22), washer (23), sliding sleeve (24) and piston (25) from the piston assembly (18) in sequence. 9 ） The assembly process is the opposite of the disassembly process. Caution After the assembly is completed, a pressure test is required: 1 ）...

  • Page 79: 2Wd Steering Axle

    3.4 2WD steering axle Fig. 3-5 2WD steering axle structure 1.Nut 2.Steering axle body 3.Bolt 4. End cover 5.Bolt 6.Washer 7.Washer 8.Lock nut 9. Bearing 10.Steering hub 11.Bearing 12.Oil seal 13.Adjust shim 14.Left steering knuckle 15.Washer 16.Screw 17.Steering cylinder 18.Grease nipple 19.Grease nipple 20.Bearing 23.Bolt...

  • Page 80: Technical Parameters

    3.4.1 Technical parameters Axle type Centre bearing, rotary type Max. inner 72.4° Steering steering angle angle Max. outer 49.9° steering angle Steering kingpin Wheel hub bearing Tighten the knuckle nut until the Axial clearance of kingpin ≤0.20mm hub cannot be turned by hand, Steering kingpin adjusting shim then loosen it by 1/6 turn.
  • Page 81 – Dismantle the steering kingpin （ 42 ） ; Caution Push and hold the steering kingpin to prevent it from falling. – Remove the whole set of knuckle (including thrust bearing, dustproof shell, shim) Inspect ： – Replace knuckle if cracked; –...

  • Page 82: Steering System Installation Notes

    rotation initial torque: T=0.88 ～ 2.65N.m. – Place the protruding part of washer (31) into the knuckle groove, adjust the outer nut (32), align the notch at the outer protruding part of washer (31), then put the protruding part of washer (31) into the nut notch.

  • Page 83: Control And Brake System

    IV Control and brake system The braking system of this vehicle is divided into two parts: service brake and parking brake. The service brake is the front two-wheel hydraulic power-assisted brake, and the parking brake is the mechanical pull-wire brake. They work together on the wet brakes installed on the left and right sides of the front wheels.
  • Page 84 Data ： Free travel 1 mm ～ 3 mm Height from pedal to front base plate 135 mm±5mm Depress height when brake light switch is on 10 mm ～ 20 mm Full travel of brake piston 28 mm±1mm Highest work oil pressure 10MPa Brake fluid SAE10W or equivalent oil...

  • Page 85: Brake Pedal Assembly

    4.1 Brake pedal assembly Fig. 4-2 Brake control assembly 1- Brake bracket 2-Bolt 3-Washer 4-Washer 5-Hinge pin 6- Brake pedal 7-Thrust washer 8- Brake torsion spring 9-Bolt 10-Nut 11-Bolt 12-Oil cup 13- Hinge pin 14-Pin 15-Bolt 16-Nut 18- Brake master 17-Washer 19-Bushing 20-Pedal pad...
  • Page 86 Brake pedal adjustment ： 1 ） Adjust brake pedal stop bolt(9), make the pedal pad point P 135mm±5mm from the front base plate and screw down the nut(10); 2 ） Adjust the length of the brake valve push rod so that the empty stroke of point P in the Q direction is 1 mm to 3 mm, and tighten the nut.

  • Page 87: Foot Brake Piping System

    4.2 Foot brake piping system 4.2.1 Foot brake piping system The foot brake piping system is composed of brake control pipeline and brake hydraulic oil circuit. See Figure 3-4 for details. Fig. 4-4 Brake control pipeline 1-Bolt 2-Washer 3-Bolt 4-Washer 5-Washer 6- Oiler 7-Bracket...

  • Page 88: Brake Master Cylinder

    4.2.2 Brake master cylinder The master cylinder of 2.5-3.5t forklift contains a valve seat, a residual pressure valve, a return spring, cups and pistons. The ends are fixed with circlips and stop wires, and the exterior of the cylinder is protected against dust by means of a rubber dust cover. The piston is actuated through the push rod by operation of the brake pedal.
  • Page 89 Brake master cylinder disassembly 1 ） Separate the brake master cylinder from the brake pedal 2 ） Remove the snap ring, remove the piston, spacer, spring seat and return spring. Inspection Wash all parts in brake fluid and check their condition. Serial No.

  • Page 90: Troubleshooting

    4.2.4 Troubleshooting Condition Possible reason Corrections Low or no brake Brake drive fluid leaks. Repair the brake pressure Vehicle cannot Hydraulic system damage Repair hydraulic system move Repair or replace the piston Piston return spring damage return spring assembly. Check piston seal and seal Piston cannot return diaphragm for swelling or damage, replace if necessary...

  • Page 91: Hand Brake

    4.3 Hand brake The hand brake device adopts a hand-pulling soft brake wire cable device, and the hand brake is only used when the forklift is parked. See Figure 3-7. Fig. 4-7 Hand brake Condition Possible reason Corrections Friction lining wear Replace Large lever travel Adjust...
  • Page 92 Hand brake adjustment After using the parking brake for a period of time, if you find that the free travel of the parking brake control handle is too large and the braking effect becomes poor, please adjust it in time. The adjustment method is as follows: 1 ）...

  • Page 93: Truck Body System

    V. Truck body system The truck body system is mainly composed of frame, instrument panel, hood and other covering parts, overhead guard, counterweight and so on. Main function: Provide a solid support carrier for the forklift and protect the driver's personal safety. The body system adopts rigid suspension to ensure stability;...

  • Page 94: Hood And Base Plate Assembly

    5.1 Hood and base plate assembly Fig. 5-2 Hood and bottom plate assembly 1-Switch guard 2- Screw assy. 3- Instrument guard 4- Bolt assy. 5- Piston rod boot Worm drive hose 7-Bolt 8- Front base plate assy. clamp 9- Pedal pad 10- Multi-way valve guard 11- Rear base plate assy.

  • Page 95: Switch Guard And Instrument Guard

    5.2 Switch guard and instrument guard Fig. 5-3 Switch guard and instrument guard 1- Left guard 2- Rear guard 3- Right guard 4- Buckle 5- Piston rod boot 6- Cup 7-Cap 8- Front switch guard 9- Rear switch guard...

  • Page 96: Door And Battery Fixture

    5.3 Door and battery fixture Fig. 5-4 Door and battery fixture 1- Lever lock 2- Door assy. 3- Upper door panel assy. 4- Bolt M8×16 5-Bolt M8×25 6-Washer 8 7-Nut M 8-Hinge 9-Screw M8×16 10-Shim 11-Block 12-Bolt M6×12 13-Washer 6 14-Washer 6 15- Rubber pad 1 16- Battery fixture...

  • Page 97: Counterweight Assembly

    5.4 Counterweight assembly Figure 5-4 Counterweight assembly Counterweight 2-Bolt M8×20 3-Washer 8 4-Washer 8 grille 5- Left seal strip 6- Right seal strip 7- Counterweight 8- Plug 9-Bolt M36×220 10-Washer 36 11-Washer 12- Adjusting shim 13-Left seal gasket 14- Right seal gasket 15- Seal strip 16- Lock pin 17- Towing pin...
  • Page 98 Counterweight removal and installation 1 ） After unscrewing the fastening bolts, press the lever locks at the left and right ends to remove the front and rear radiator covers. 1 ： Tightening bolt 2 ： Front radiator cover 3 ： Rear radiator cover 4 ：...
  • Page 99 Caution a ） When installing, connection between the left and right sides of the weight and the truck body should be symmetrical and aligned; no single side protruding or dent should occur, and the gap difference should be less than 4mm. b ）...

  • Page 100: Frame, Overhead Guard, Battery Box

    5.5 Frame, overhead guard, battery box Fig. 5-5 Frame, overhead guard, battery box assy. 1-Bolt M8×35 2- Washer 8 3- Washer 8 4- Cushion 5- Sleeve 6- Bolt assy. 7- Beam assy. 8-Frame 9- Overhead guard 10- Bolt M8×20 11- Washer 8 12- Washer 8 assy.
  • Page 101 Overhead guard removal and installation 1 ） Remove the pedal pad. 1 ： Pedal pad 2 ） Use the Phillips bit to take out the bolt assy. on the front side. 2 ： Bolt assy. 3 ） After removing the bolt assy. on the rear side with a Phillips bit, remove the left guard.
  • Page 102 4 ） Remove the screw assembly and remove the back switch guard. 4 ： Screw assy. M5×16 5 ： Screw assy. M4×12 6 ： Back switch guard 5 ） Remove all hoses connected to the steering gear. 7 ： Steering gear oil return hose 8 ：...

  • Page 103: Hydraulic System

    VI Hydraulic system 6.1 Hydraulic system structure Warning a ） During the maintenance of the hydraulic system, it may be necessary to disconnect the high-voltage cable on the oil pump motor electric control two-in-one, which involves high-voltage parts! Therefore, it must be operated strictly according to the safety regulations in Chapter 1! b ）...

  • Page 104: Hydraulic System Principle

    6.2 Hydraulic system principle The high-pressure oil from the master oil pump goes to the multi-way valve, and is sent to the lift cylinder or tilt cylinder by the multi-way valve. When the lift slide valve is pulled, the high-pressure oil flows to the bottom of the lift cylinder piston and pushes the piston rod upward. When the lift spool valve is pushed, it is that bottom of lift cylinder piston connects with low pressure and then the piston rod drops by deadweight and cargo weight.

  • Page 105: Fault Diagnoses And Corrections

    6.3 Fault diagnoses and corrections Main oil pump Trouble Probable cause Corrective action Low oil level in tank Add oil to specified level No oil from oil Clean oil line and tank. If oil is dirty, pump Suction pipe or strainer plugged replace Bearing worn, retainer or O-ring Replace malfunctioning parts...
  • Page 106 Multi-way valve Trouble Probable cause Corrective action Loose of pressure-adjust screw Readjusted and retighten Distorted damaged Replace Pressure of relief valve pressure-adjust spring is not steady or cannot Replace clean be adjusted Worn or blocked relief valve spool reassemble Pump malfunction Examine and repair pump Replace the spool and tilt lock Worn or damaged tilt lock valve...

  • Page 107: Oil Pump Device

    6.4 Oil pump device Overview of oil pump device: It consists of oil pump, oil suction pipe, oil return pipe and so on. See Figure 6-3 Fig. 6-3 Oil pump device 1- Union elbow 2- Tee joint 3-Straight through coupling 4-Coupling 5-O-ring 6-Gear pump...
  • Page 108 Table 6-1 Thread tightening torque table Tool Tightening torque Remark S27 Wrench 60N·m ～ 66N·m S27 Wrench 60N·m ～ 66N·m S27 Wrench 60N·m ～ 66N·m S41 Wrench 160N·m~176N·m S16 Wrench 40N·m ～ 50N·m M10×30 S27 Wrench 45N·m ～ 50N·m 6.4.1 Gear pump The gear pump is a low-noise gear pump, and the housing is made of solid, compact two-piece cast iron gear pump.
  • Page 109 6.4.2 Oil pump disassembly and installation Caution Retract all cylinders before disassembly. 1 ） Unscrew the fastening bolt (1) and remove the radiator cover (2). 2 ） After removing the bolt assy. (3), remove the left panel assy. (4). 3 ） Remove the double wire hoop at both ends of the oil suction pipe (5) and then remove the oil suction pipe (5).
  • Page 110 4 ） Unscrew the joint connecting the oil pipe assy. (6) to the oil pump. 5 ） Remove the joint connecting the rubber hose assy. (7) and the tee joint (8). 6 ） Remove the oil pump fixing bolt (9), and remove the oil pump assembly.

  • Page 111: Multi-Way Valve

    6.5 Multi-way valve Fig. 6-4 Multi-way valve joystick 1-Lift joystick 2-Tilt joystick 3- Attachment joystick 4- Lift rod assy. 6-Attachment rod 7- Attachment rod 5- Tilt rod assy. 8-Washer assy. assy. 11- Mounting plate 9-Bolt 10-Connecting rod 12-Hinge pin assy. 13-Sleeve 14-Hinge pin 15-Pin...
  • Page 112 Fig. 6-5 Multi-way valve assembly Straight through 1- Multi-way valve 2-Coupling assy. 3-Union elbow coupling 5-Sleeve 6-Cushion pad 7-Washer 8-Washer 9-Bolt 10-Inching switch assy. 11-Washer 12-Potentiometer 13-Screw 14-Washer 15- Potentiometer bracket 16-Seat cushion 17-Shim 18-Gasket 19-O-ring 20-Gasket Multi-way valve coupling tightening torque ： Tightening torque N·m 90~105 40~44...
  • Page 113 6.5.1 Removal and installation of multi-way valve assembly Caution Retract all cylinders before disassembly. 1 ） After pulling the handle of the lock assembly upward, open the hood upward. 2 ） Remove all hoses connected to the multi-way valve. 1 ： Oil return hose for hydraulic steering gear (low pressure) 2 ：...
  • Page 114 4 ） Remove the lock pin, take off the hinge pin and washer. 11 ： Lock pin 12 ： Hinge pin 13 ： Washer 5 ） After removing the multi-way valve fixing bolts, remove the multi-way valve assembly. 14 ： Bolt 15 ：...
  • Page 115 6.5.2 Main safety valve pressure adjustment The pressure of the main safety valve has been adjusted before leaving the factory. Generally, the user is not allowed to adjust it casually. The adjustment method is as follows: 1 ） Park the vehicle on a solid and flat road, shift in neutral gear, pull the hand brake handle, tilt the mast back to the bottom, and lower the fork to the ground.
  • Page 116 locknut, adjust adjusting screw. If the reading is less than normal range: screw the adjusting screw in clockwise to increase main relief valve pressure; if the reading is larger than normal range, screw the adjusting screw in counterclockwise to decrease main relief valve pressure. 7 ）...

  • Page 117: Hydraulic Steering Gear

    6.6 Hydraulic steering gear It is a load sensing hydraulic steering gear with an integrated valve, which can be used after connecting to the priority valve by pipes. The LS port of the steering gear is connected to the LS port of the priority valve, by which, the steering load pressure signals from the gear can be sent to the priority valve and it controls the oil supply to the steering gear from the system.
  • Page 118 Attention on the steering gear installation and maintenance 1 ） Keep the steering gear and the steering column in the same axle. Make sure there is axial clearance. Check for the flexibility of the steering wheel. 2 ） Avoid any axial force applied on the input terminal of the steering gear during the installation.
  • Page 119 1 ） Remove the pedal pad 1 ： Pedal pad 2 ） Use the Phillips bit to take out the bolt assembly on the front side. 2 ： Bolt assembly 3 ） After removing the bolt assembly on the rear side with a Phillips bit, remove the left guard.
  • Page 120 4 ） Remove the screw assembly and remove the switch back cover. 4 ： Screw assembly M5×16 5 ： Screw assembly M4×12 6 ： Rear switch cover 5 ） Remove all hoses connected to the steering gear. 7 ： Steering gear oil return hose 8 ：...
  • Page 121 Common fault analysis and corrections of steering Gear Fault Probable reason Phenomenon Corrective action Combined part bolts Retighten these bolts loosen Combined face or journal Replace seal ring leakage sealing ring damage Washer damage Replace washer Insufficient supply Turn steering wheel slowly is light Check for oil pump work condition from oil pump and turn fast is heavy...
  • Page 122 Fault Probable reason Corrective action Steering pump efficiency is too low, cannot reach the required pressure. The pressure of system relief valve is low or spring intensity of relief valve decreased. The pressure of relief valve of steering gear is low or the valve core get stuck. The oil of steering system returns unsmooth.
  • Page 123 Fault Probable reason Corrective action Air in the steering system. Steer inaccurate or crawl Steering cylinder leaks Steering mechanism connection drops Trimmer valve or oil supply valve gets stuck Steering wheel can trun easily,but Cavities mixed of the steering cylinder. the rear wheels keep still or turn Piston falling off the cylinder lever slowly,just like no power to steer...
  • Page 124 The rear wheels make reverse Connect the steering pipeline turning when turning the steer A and B port connect reversely correctly wheel The inlet non-return valve of steering Maintain replace Steering wheel is blocked gear damaged, the oil flow back steering gear Bleed the air in the hydraulic Air in the pipeline...

  • Page 125: Steering Pipeline

    6.7 Steering pipeline Steering cylinder is di-functional. The piston rod can be connected with knuckle through the connecting rod. The fluid from hydraulic steering gear flows to the steering cylinder and drives the movement of piston rod to the left and right side, which drives the truck steer to left and right. See Figure 6-8 for the structure of the steering pipeline and Figure 6-9 for the structure of the steering cylinder.
  • Page 126 Fig. 6-9 Steering cylinder structure 1-Cylinder barrel 2-Piston rod 3-Glyd ring 4- Guide sleeve 5- Internal clip key 6-Sleeve 7-Retaining ring 8- Composite bush ring 9- ISI-ring 10-LBH Dust ring 11-O-ring 12-Screw plug See 3.3.10 for the removal and installation steps of the steering cylinder.

  • Page 127: Tilt Cylinder

    6.8 Tilt cylinder Fig. 5-10 Tilt cylinder structure Spherical 1-Earring 3-Oil cup 4-Washer 5-Nut bearing 6-Bolt 7-Piston rod 8- Scraper seal 9- Guide sleeve 10- O-ring 11- U-ring 12- Step seal 13- O-ring 14- Cylinder body 15- OSI seal ring 16-Retaining ring 17 O-ring 18-Piston...
  • Page 128 6.8.1 Disassembly of tilt cylinder Warning a ） Use the steel wire on the lifting device to fix the mast to prevent the mast from falling down after the tilt cylinder is removed. b ） Keep away from the truck. Never stand on the fork carriage when it’s fitted with forks.
  • Page 129 1 ） Lower down the fork carriage thoroughly. 2 ） After removing the pedal pad, remove the front base plate assembly fixing bolts, and then remove the front base plate assembly. 1 ： Bolt M8×20 2 ： Front base plate assembly 3 ）...
  • Page 130 4 ） Remove the bolts from the frame bracket and pull out the hinge pins and bushings. 5 ： Bolt M10×1.25×20 6 ： Hinge pin 7 ： Bushing 5 ） Remove the bolts, pull out the hinge pin, and remove the tilt cylinder. 8 ：...
  • Page 131 6.8.2 Disassembly of tilt cylinder 8 ） Remove the O-ring on the outer race of The structure of the tilt cylinder is shown in the guide sleeve. Figure 5-10 9 ） Remove the O-ring and Y- ring in the Steps ： inner hole of the guide sleeve (see the previous disassembly drawing of the lift 1 ）...
  • Page 132 6.8.3 Inspections on key components 3 ） After the piston is put in the cylinder, the movement in whole stroke should be 1 ） Check cylinder body smooth and no obstruction and not jammed. deformation and the scratch and corrosion of the inwall.

  • Page 133: Lift Cylinder

    6.9 Lift cylinder The lift cylinder is piston type applied with shock absorber. For the structure of lift cylinder, see figure 5-10. Fig. 6-11 Structure of left(right) lift cylinder upport ring uard ring 1- S 2- G 3- OSI seal ring 4- Valve sleeve 5- Retaining ring 6- Cylinder body...
  • Page 134 shown in Figure 6-11) 6.9.1 Disassembly of lift cylinder Procedures ： 1 ） Retain the tilt cylinder with a jaw vice. 2 ） Screw out the guide sleeve (12) with a hookwrench and take O-ring (14) and DKI scraper seal (16) and ISI seal ring (15) out of the guide sleeve.
  • Page 135 damaged or not. 5 ） If any seal ring is found over worn, aged or scratched or flaw lip, replace them timely. Installation and adjustment of lift cylinder 1 ） Clean up every part with gasoline and dry up with compressed air before installation. Smear some hydraulic fluid on the cylinder inwall, piston and piston rod surfaces and the surfaces of seals.

  • Page 136: Lifting System

    The forklift trucks produced by Hangcha can be installed with wide view duplex mast; full free lift duplex mast (including container mast) and full free lifting triplex mast. The mast type brings in the CL coordinated rolling type.
  • Page 137 1.Outer mast 2.Inner mast 3. Load backrest 4. Fork carriage 5.Fork 6.Chain 7. Left lift cylinder 8. Right lift cylinder 9.Tilt cylinder 10.Roller Figure 7-1 Wide view duplex mast...

  • Page 138: Data Of Assembly And Debugging

    7.2 Data of assembly and debugging Inspection and adjustment Repair (without replacement Position Assembly clearance parts) clearance Mast to lift roller 0.1 ～ 0.8 0.2 ～ 1.0 Gasket 0.5 / 1.0 / 2.0 Mast to support guide plate 0.1 ～ 0.8 0.2 ～...

  • Page 139: Troubleshooting And Corrective Action

    Troubleshooting and corrective action Fault Probable cause Corrective action Tilt cylinder and seal ring abraded excessively Replace piston seal ring or tilt cylinder Fork carriage or mast tilts The valve control rod spring of multi-way valve automaticly Replace disorder Fork carriage Piston jamming or piston rod bends Replace the damage parts raises up and...
  • Page 140 Tighten the joint nuts and check for Hydraulic pipeline leakage damage of seal and connecting nuts Change the faulty hydraulic oil or stop to High hydraulic oil temperature, low oil viscosity reduce the oil flow, and check for the and insufficient oil flow reason of high oil temperature trouble Overloaded Lift according to regulations...

  • Page 141: Mast Disassembly And Installation

    3 ） Tie up the fork carriage assembly with 7.4 Mast disassembly and installation steel wire and crane it with lifting equipment. Warning Be careful during the disassembly as the fork, fork carriage and mast are such heavy parts. 5.4.1 Dismantle the fork and mast assembly 1 ）...
  • Page 142 5 ） Dismount the carriage assembly from the inner mast. 8 ） Remove the bolt 1 from the left and right brackets on the outer mast, and pull out the hinge pin 2; 6 ） Remove the lifting high pressure hoses 18, 9 and the low pressure oil return hoses 4, 19, 8.
  • Page 143 bottom. Take out the main roller and the small side rollers. 2 ） If there is no bearing puller, unclench the 10 ） Lift out the inner and outer mast rollers carefully. (even unclenching power for all assemblies. directions). Otherwise, the rollers would be 11 ）...

  • Page 144: Assembly And Adjustment

    7.4.3 Assembly and adjustment Warning Be careful when assembling as the inner and outer masts are quite heavy. Install the inner mast into the outer mast and mount the roller securely. 内门架 Inside mast 2 ） Adjust the clearance A of left and right side evenly with a shim and make it 0.
  • Page 145 clearance. If it is over worn, replace the rollers. 7.4.4 Assemble the left and right lift 4 ） Smear some lubricating grease on the cylinders and adjust the cylinder position connecting surfaces of inner and outer mast 1 ） Install the left and right cylinders into and also on the rollers and channel rail.
  • Page 146 Thin adjusting shim ： 0.5mm 、 1mm 。 Caution a） Use equal quantity of washers on left and right sides. b） After the clearance is set. Slide the fork 7.4.6 Adjust the clearance of rollers on carriage on the inner mast upward and the fork carriage assembly downward.

  • Page 147: Electric System

    VIII. Electric system The high-voltage electric forklift has a maximum DC voltage of 317V, which provides relatively large electric energy during operation. The connecting wires of the high voltage part are orange, and there are warning signs on the high voltage parts. The high-voltage components of the truck are high-voltage lithium battery master box, high-voltage lithium battery slave box, two-in-one front traction motor electric control, two-in-one rear traction motor electric control, two-in-one oil pump motor electric control, two-in-one power...

  • Page 148: Special Safety Rules For High-Voltage Electric Forklift

    Warning a ） Parts involving high pressure are maintained by trained professional after-sales personnel. b ） Before any electrical maintenance, be sure to disconnect the MSD maintenance switch. Before checking any electrical parts, please remove conductive items such as jewelry to prevent short circuits, and turn off the start switch and disconnect the grounding wire.
  • Page 149 3.Dry insulating pads should be laid on the lower part of the truck body and the standing parts of maintenance personnel. 4.Place a warning triangle "Danger of touching during high-voltage operation". 5.Inspection and maintenance personnel are not allowed to carry or wear metal objects. 6.First confirm that there is no water (water accumulation, water droplets) in the ground and vehicle body.
  • Page 150 11.Before repairing high-voltage components, connect the body with the ground wire to the ground wire of the dedicated repair station for the electric forklift. 12.High-voltage components and storage batteries are carried out by Hangcha or authorized institutions and personnel with special training (different from ordinary forklift training).

  • Page 151: Electric Drive System

    TZ220XS30kW309VTQ ， with rated voltage of 309 (VDC) ， rated power of 30kW ； The rear drive traction motor model is a permanent magnet synchronous motor TZ180XS15kW307VT ，...
  • Page 152 Fault code Fault description Possible Cause (Remarks) E1:21 Discharge negative contactor welded E1:22 High voltage interlock fault E1:23 Communication fault E1:24 Charge heat contactor fault E1:25 Discharge heat contactor fault E1:26 Voltage cable falls off E1:27 Temperature cable falls off E1:28 Current cable falls off E1:29...
  • Page 153 DC-DC related monitoring information and fault codes Fault code Fault description Problem solving methods 1. Check the cooling water channel and remove faults (water pump, water channel, fan, water level, line, etc.); 2. Avoid the E2:01 DCDC overtempt long-term overload state of driving DCDC; 3. After the system drops down, it is powered on again 1 、...
  • Page 154 Fault code Fault description Problem solving methods restarts, the controller needs to be replaced 1 、 Check the hard-wire wake-up or NW E2:11 DCDC awake up missing fault wake-up line; 2 、 Power on again; 1 、 Check the wiring harness and plug-in; 2 、...
  • Page 155 Front wheel drive traction fault code Fault code Fault description Problem solving methods 1 、 Power on again; E3:02 Igbt error failing 2 、 If the fault is still reported after multiple restarts, the controller needs E3:03 Current sensor zero shift error to be replaced;...
  • Page 156 Fault code Fault description Problem solving methods E3:19 I2C check error E3:20 Communication loss fault E3:21 Battery failure E3:22 Bus voltage sampling circuit fault 1 、 Check the wiring harness and E3:45 MCU undervoltage warning plug-in; 2 、 Power on again; 3 、...
  • Page 157 Main oil pump fault code Fault code Fault description Problem solving methods 1 、 Power on again; E4:02 Igbt error failing 2 、 If the fault is still reported after multiple restarts, the controller needs E4:03 Current sensor zero shift error to be replaced;...
  • Page 158 E3:18 Bus off error E3:19 I2C check error E3:20 Communication loss fault E3:21 Battery failure E3:22 Bus voltage sampling circuit fault 1 、 Check whether the battery system E4:45 MCU undervoltage warning is over-voltage, if it is over-voltage, please do the battery maintenance before use;...
  • Page 159 VCU related monitoring information and fault codes Fault code Fault description Problem solving methods 1 、 Harness problem ； 2 、 Low-voltage power supply problem ； E5:101 Communication with DCDC fault 3 、 Vehicle controller failure ； 4 、 Communication interference. 1 、...
  • Page 160 Fault code Fault description Problem solving methods 1 、 Harness problem. Communication with Rear drive travel MCU 2 、 MCU (rear traction) failure; E5:114 fault severe 3 、 Vehicle controller failure ； 4 、 Communication interference 1 、 Harness problem. Forward switch &...
  • Page 161 Rear drive traction fault code Fault code Fault description Problem solving methods E7:01 Motor overspeed warning 1. Power on again E7:02 Motor overspeed 1. Power on again E7:03 Bus undervoltage warning E7:04 Bus undervoltage E7:05 Bus overvoltage warning E7:06 Bus overvoltage E7:07 Software filtering E7:08...
  • Page 162 plug-in; 2. Power on again; E7:21 Motor temperature sensor failure 3. If the fault is still reported after multiple restarts, the controller needs to be replaced; E7:22 Bus voltage sensor fault E7:23 Torque verification failure E7:24 Locked rotor fault 1. Power on again; E7:25 Bus off error...

  • Page 163: Safe Operation Specification

    Its high-voltage connection line is orange and the high-voltage components have warning signs. The maintenance personnel must obtain the authorization of Hangcha Group; they must have the national special occupation certificate. In addition, the maintenance personnel must strictly follow the operating requirements to carry out standardized operations;...
  • Page 164 Fig.8-5 MSD maintenance switc 7) The maintenance site should be equipped with fire extinguishing equipment, and the battery pack storage area should be ventilated and dry, and there should be no combustibles around. 8.3.2 MSD use: On and Off 1 ） It is located on the right side of the lithium battery main box. After removing the right panel of the body, the MSD maintenance switch can be seen (refer to steps 1 and 2 of 5.4.2 for removing the right panel of the body).
  • Page 165 MSD Maintenance swtich Figure 8-7 a ） Pull out the locking terminal of the MSD handle, as shown in the figure below: Locking terminal Fig. 8-8 b ） Rotate the MSD black handle to the position shown in the figure below. Handle Fig.

  • Page 166: Installation Safety Precautions

    d ） Pull out the MSD switch forcefully to disconnect the MSD. Fig. 8-11 e ） MSD installation can be done according to the order of steps d/c/b/a. 8.3.3 Safety precautions during maintenan 1) Identify the maintenance personnel of the high-voltage system and prevent other irrelevant personnel from touching the battery box during maintenance;...
  • Page 167 Wear protective equipment and use insulating tools during all disassembly and assembly processes; the MSD maintenance switch must be pulled out before maintenance It is forbidden to wear any metal jewelry during the entire battery system maintenance process to avoid accidental short circuit causing personal injury or death; It needs to be marked when disassembling, install in order.
  • Page 168 ④ When a large amount of leakage occurs, please collect them and treat them in accordance with hazardous chemicals. Add calcium gluconate solution to treat the generated gas; ⑤ When the human body accidentally touches the leaked liquid, rinse immediately with plenty of water (10-15) min.

  • Page 169: Control Box Assembly

    8.4 Control box assembly Fuse Disassembly 1 ） Turn the key switch to "OFF"; 2 ） Press the lock on the control box cover, and then open the cover; 3 ） Remove the fuse from the box; Note If the fuse or relay is broken, replace with a new one, refer to the below figure(Please refer to the interior of the forklift control box for details,): If the fuse is damaged, the cause must be identified before installing a new one;...
  • Page 170 Control box plug pin function details Function definition Function definition R9 （ 30 ） R2 （ 87 ） Ground wire R7 （ 87 ） R3 （ 87 ） R6 （ 87 ） R8 （ 87 ） R1 （ 85 ） R2 （...
  • Page 171 Relay R2,R3,R5-R9 Turn the multimeter to the ohm position and measure the resistance value between the corresponding terminals. Normal resistance Connection port Remark value （ 80-120 ） Ω...
  • Page 172 Turn the multimeter to the ohm position and measure the resistance value between the corresponding terminals. Normal resistance Connection port Remark value 85-86 （ 300-360 ） Ω Fusible line A melted fusible line is easily observed and touched with a finger. If you are not sure if it is broken, you can test it with a multimeter or light bulb.

  • Page 173: Lighting System

    8.5 Lighting system Fig. 8-14 Lighting system 3- Rear combination 1- Left headlight 2- Right headlight 4- Warning light light 5-LED rear work light...
  • Page 174 8.5.1 Headlight Fig. 8-15 Headlight assembly Port Function Color Remark Width lamp Green Turn signal Yellow Headlight Grounding Black Removal and installation of front combination light 1. Remove the bracket fixing screws. 2. Disconnect the wiring connector. 3. Replace with new LED lights. 4.
  • Page 175 Inspection Fig. 8-16 Turn the multimeter to the ohm range and measure the continuity between the corresponding terminals. Connection port Normal function Abnormal function Remark Show a certain value Resistance is 0 or ∞ Show a certain value Resistance is 0 or ∞ Show a certain value Resistance is 0 or ∞...
  • Page 176 8.5.2 Rear combination light Fig. 8-17 Rear light assembly Port Function Color Remark Grounding Black Left turn signal Blue Reversing lamp Grey Brake lamp Right turn signal White Width lamp Green Removal and installation of rear combination light 1.Remove the fixing screws of the rear combination light. 2. Disconnect the wiring connector. 3.
  • Page 177 Inspection Fig. 8-18 Turn the multimeter to the ohm range and measure the continuity between the corresponding terminals. Connection port Normal function Abnormal function Remark Show a certain value Resistance is 0 or ∞ Show a certain value Resistance is 0 or ∞ Show a certain value Resistance is 0 or ∞...

  • Page 178: Warning Light

    8.5.3 Warning light Fig. 8-19 Warning light Port Function Color Remark Power Grounding Black Inspection Fig. 8-20 Turn the multimeter to the ohm range and measure the continuity between the corresponding terminals. Connection port Normal function Abnormal function Remark Show a certain value Resistance is 0 or ∞...
  • Page 179 8.5.4 Rear work light Fig. 8-21 Rear work light Port Function Color Remark Power Grounding Black Inspection Fig. 8-22 Turn the multimeter to the ohm range and measure the continuity between the corresponding terminals. Connection port Normal function Abnormal function Remark Show a certain value Resistance is 0 or ∞...

  • Page 180: Switch

    8.6 Switch 8.6.1 Combination switch Fig. 8-23 Port Color Remark Left handle three-wire Blue plug Left handle three-wire Green plug Left handle three-wire Green yellow plug Right handle six-wire Green white socket Right handle six-wire Blue socket Right handle six-wire White socket Right handle six-wire...
  • Page 181 Disassebly 1. Remove the combination meter. 2. Unscrew the screws and disconnect the wiring connector. 3. Installation and removal steps are reversed. Inspection Left handle inspection Set the left handle to the forward position and measure the continuity of ports 1-3; then set the left handle to the reverse position to measure the continuity of ports 2-3.
  • Page 182 Right handle inspection Set the right handle position to the left turn signal position, and measure the continuity of ports 1-2; place the right handle position to the right turn signal position, and measure the continuity of ports 1-3; set the right handle position to the neutral, turn the light switch to the width lamp podition, and measure the continuity of ports 4-5;...

  • Page 183: Key (Starter) Switch

    8.7 Key (starter) switch Fig. 8-26 Disassembly 1 ） Remove the combination meter. 2 ） Disconnect the wring connector. 3 ） Remove the nuts, washers, spacers and instrument plate. 4 ） To install, reverse removal procedures. Adjust the protruding part of the switch to proper length when installing. Fig.
  • Page 184 Inspection Turn the key switch to the "ON" position, and measure the continuity of ports 1-2 with a multimeter (set to ohm range). Fig. 8-28 Connection port Normal function Abnormal function Remark Resistance is 0 Resistance is ∞ ON gear...

  • Page 185: Hand Brake Switch

    8.8 Hand brake switch Disassembly 1 ） Remove the hand brake. 2 ） Disconnect the wring connector. 3 ） Remove the screws and washers. 4 ） To install, reverse removal procedures. Adjust the protruding part of the switch to proper length when installing. Fig.
  • Page 186 Port Function Color Remark Connect to COM Black red public port Connect to NC Green normally closed end Connect to N0 Yellow normally open end Inspection Loosen the hand brake switch and measure the continuity of ports 1-2; then tighten the handbrake switch and measure the continuity of ports 1-3.

  • Page 187: Backup Buzzer

    8.9 Backup buzzer Disassembly and installation 1. Disconnect the wiring connector, and then remove the bolts. 2. To install, reverse removal procedure. Horn Disassembly and installation 1. Disconnect horn harness connector. 2. Remove the bolt and horn. 3. To install, reverse removal procedure.

  • Page 188: Electrical Schematic Diagram

    8.10 Electrical schematic diagram R1（ACC relay） R7（Air conditioning relay） S8-2 S2 Keyswitch R4（flasher） Low voltage communication Intelligent instrument DC+PDU signal of S1 Emergency stop S8-1 S9 S10 S11 accelerator Module S4 S5 battery switch S3-1 S3-2 proximity switch R10（Solenoid valve relay） R3（Armrest horn relay）...
  • Page 189 25mm2cable 50mm2Single core shielded wire 5mm2 50mm2Single PDU+DC core shielded wire 5mm2 50mm2 25mm2 25mm2 Single Single Single core core core 50mm2 shielded shielded shielded Single core wire wire wire shielded wire Traction motor Traction motor Oil pump motor controller (front controller (rear controller wheel drive)
  • Page 190 R1（ACC relay） R7（Air conditioning relay） S8-2 S2 Keyswitch R4（flasher） Low voltage communication Intelligent instrument signal of DC+PDU accelerator S1 Emergency stop S8-1 S9 S10 S11 S4 S5 Module battery switch S3-1 S3-2 proximity switch R2（Headlight R3（Armrest horn relay） relay） Diagnostic connector R5（Water pump R6（Low speed...
  • Page 191 25mm2cable 50mm2Single core shielded wire 5mm2 50mm2Single PDU+DC core shielded wire 5mm2 50mm2 25mm2 Single Single core core 50mm2 shielded shielded Single core wire wire shielded wire Traction motor Oil pump motor controller (front controller wheel drive) CPD25/30/35-XY2GE-RT2 High voltage electrical schematic diagram...

  • Page 192: Maintenance Records

    Maintenance records maintenance Date Repair and maintenance content personnel...
  • Page 193 杭叉集团股份有限公司 HANGCHA GROUP CO., LTD. 全国客服热线： 400-884-7888 ■ 地址：中国浙江临安经济开发区相府路 666 号 ■ 电话： 0571-88926666 （总机号） 85191117 ■ 传真： 0571-85131772 ■ 邮编： 311305 ■ 网站： http://www.zjhc.cn ■ 电子邮件： sales@zjhc.cn ■ Address For: OVERSEAS USERS ■ Address: 666 Xiangfu Road, Lin'an Economic Development Zone,Zhejiang, China ■...

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