Page 1 202408000 CPD40/45/50L/50 BATTERY FORKLIFT TRUCK E SERIES ( 英文 ) OPERATION AND MAINTENANCE MANUAL...
Page 3: Important Safety Information
Operations that could cause damage to the machine are marked both in this manual and on the machine itself using the labels “Caution” or “Warning”. LiuGong cannot predict every hazard in the work environment; therefore the warnings in this manual and on the machine should not be considered exhaustive. When using a tool, procedure, working method, or operation technique that is not explicitly recommended by LiuGong, you must pay special attention to the safety of yourself and others.
Page 5: Table Of Contents
CONTENTS August 6, 2024 CPD40/45/50L/50 CONTENTS Preface Operation Manual Before Operating the Machine ......69 Machine Number and Frame Number....5 Operator Controls and Instrument Panels ..71 Main Structural Component .......6 Machine Starting ..........86 Safety Information Battery sleep state enabled ......86 Safety Decals and Decal Locations ....13 Operation Techniques ........
Page 6 CONTENTS August 6, 2024 CPD40/45/50L/50...
Page 7: Preface
Skill and techniques develop as the Use this machine only for the purpose described operator gains knowledge of the machine and its in this manual. Contact your Liugong dealer for capabilities. approval before making any modifications or Maintenance adding attachments to the machine.
Page 8 10 service hours or daily. All the information, figures, tables and specifications are the latest product information obtainable at the time of publication. Guangxi LiuGong Company will reserve the right to make change without notice. Declaration The forklifts manufactured by LiuGong are...
Page 9: Main Components
Preface August 6, 2024 CPD40/45/50L/50 Main Components 1. Mast 5. Seat 9. Rear wheel 13. Drive axle 2. Chains 6. Overhead guard 10. Engine hood 14. Tit cylinder 3. Lift cylinder 7. Counterweight 11. Frame 15. Fork arm carrier 4. Steering wheel 8.
Page 10 Preface August 6, 2024 CPD40/45/50L/50 Serial Number of the Machine and Parts Manufactures Name Guangxi Liugong Machinery Co., Ltd Product Identification Number (PIN) Serial Number of Battery Serial Number of Reduction Box Serial Number of Rear Axle Serial Number of Frame...
Page 11: Machine Number And Frame Number
Preface August 6, 2024 CPD40/45/50L/50 Machine Number and Frame Number Machine Number and Frame Number The frame number (1) is located above the pedal on the left side of the frame. The machine number (2) is located under the pedal on the left side of the frame.
Page 12: Main Structural Component
Preface August 6, 2024 Main Structural Component CPD40/45/50L/50 Main Structural Component 1. Mast 2. Carriage 3. Fork 4. Frame...
Page 13 Preface August 6, 2024 CPD40/45/50L/50 Main Structural Component Mast 1. Outer mast 2. Inner mast 3. Chains 4. Main roller 5. Side roller Fork arm carrier 1. Carriage 2. Main roller 3. Side roller...
Page 14 Preface August 6, 2024 Main Structural Component CPD40/45/50L/50 Fork 1. Lock mechanism 2. Upper hook 3. Fork body 4. Lower hook Frame 1. Frame 2. Antislip pedal 3. Front plate...
Page 15 As proof that the requirements are met, the machines marketed within the EU/EEA) machine is supplied with an EU Declaration of Conformity, issued by LiuGong CE for each This CE marking is located on the left side of the separate machine. This EU declaration does not front instrument stand.
Page 16 Preface August 6, 2024 Main Structural Component CPD40/45/50L/50...
Page 17: Ec Declaration Of Conformity
CPD40/45/50L/50 Main Structural Component EC DECLARATION OF CONFORMITY Original Declaration MANUFACTURER: Name: GUANGXI LIUGONG MACHINERY CO., LTD. Address: No. 1 Liutai Road, Liuzhou, Guangxi 545007, P.R. China AUTHORIZED REPRESENTATIVE (TECHNICAL DOCUMENT WAS COMPILED BY): Name: Liugong Machinery Europe B.V. Address: P.J.
Page 18 Preface August 6, 2024 Main Structural Component CPD40/45/50L/50 COMPLIES WITH THE PROVISIONS OF THE FOLLOWING STANDARDS: EN ISO 3691-1:2015+A1:2020 EN 16307-1:2020 EN 1175:2020 EN 12895:2015+A1:2019 SOUND POWER LEVEL: Category to Noise Directive 2000/14/EC: Article 13 Annex I, item 36 (other counterbalanced lift trucks, with rated capacity Definition: not more than 10 tonnes) Measured Sound Power Level...
Page 19: Safety Information
Safety Information August 6, 2024 Safety Decals and Decal Locations CPD40/45/50L/50 Safety Information Safety Decals and Decal Locations Safety Warning Symbols Safety decals can be found on the machine. This section describes the locations of these decals and explanations of the safety hazards they Safety warning symbols are important indicate.
Page 20 Safety Information August 6, 2024 Safety Decals and Decal Locations CPD40/45/50L/50 Decal Location 1. INFORMATION DECAL 6. WARNING DECAL 11. WARNING DECAL 16. DANGER DECAL 2. LUBRICATION CHART 7. INFORMATION DECAL 12. INFORMATION DECAL 17. INFORMATION DECAL 3. DANGER DECAL 8.
Page 21 Safety Information August 6, 2024 Safety Decals and Decal Locations CPD40/45/50L/50 Decal Information 1. INFORMATIOM DECAL (Located on the mast.) 74A2864 2. LUBRICATION CHART (Located on the left side of mast.) Lubrication system diagram. 16G2811 3. DANGER DECAL (Located on left side of mast.) No passengers on or under fork.
Page 22 Safety Information August 6, 2024 Safety Decals and Decal Locations CPD40/45/50L/50 Decal Information 4. DANGER DECAL (Located on left side of mast.) No passengers on or under fork. 74A3301 5. INFORMATION DECAL (Located near the tires.) The front tire air pressure is 0.83Mpa. 79A5466 6.
Page 23 Safety Information August 6, 2024 Safety Decals and Decal Locations CPD40/45/50L/50 Decal Information 8. WARNING DECAL (Located on the left side of instrument panel.) Read the Operation and Maintenance Manual before operation. 74A3080 9. CAUTION DECAL (Located on left side of seat.) Fasten seat belt securely.
Page 24 Safety Information August 6, 2024 Safety Decals and Decal Locations CPD40/45/50L/50 Decal Information 12. INFORMATION DECAL (Located on the rear left of frame.) Charge position indication decal. 79A7488 13. INFORMATION DECAL (Located on the left of engine hood.) The air spring self-locking function must be cancelled before closing the engine hood.
Page 25 Safety Information August 6, 2024 Safety Decals and Decal Locations CPD40/45/50L/50 Decal Information 16. DANGER DECAL (Located on right side of mast.) No passengers on or under fork. 74A3300 17. INFORMATION DECAL (Located on the hydraulic tank) Filler position indication decal (hydraulic oil). 74A1701...
Page 26: General Hazard Information
Safety Information August 6, 2024 General Hazard Information CPD40/45/50L/50 General Hazard Information Be familiar with all safety cautions, failure to observe could result in property damage, serious injury or even death. Only trained and qualified personnel should be allowed to operate or maintain the machine. Wear relevant personal protective equipment (PPE) such as a hard hat, ear protection, safety glasses, safety shoes and gloves when...
Page 27 Secure all loose items such as lunch boxes, tools around the machine . and others. Guangxi Liugong bears no responsibility for Pay attention when opening fluid compartments failures caused by modifications to machine to prevent foreign materials from entering the structure without Liugong’s permission.
Page 28 Safety Information August 6, 2024 General Hazard Information CPD40/45/50L/50 Compressed Air Compressed air can cause personal injury. When using compressed air for cleaning, wear a protective face shield, protective clothing, hearing protection and protective shoes. Never aim compressed air at yourself or others. Compressed air could penetrate your skin and cause serious injury or death.
Page 29: Crushing And Cutting Prevention
Safety Information August 6, 2024 Crushing and Cutting Prevention CPD40/45/50L/50 Crushing and Cutting Prevention Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin. Don't put hands, arms, or any other parts of the body in the way of removable parts.
Page 30: Fire & Explosion Prevention
Flammable materials leaked or split onto hot tubes or hoses. Leaks can cause fires. Contact surfaces or electrical components can cause a Liugong or your Liugong Dealer for factory fire. authorized replacement parts. Do not smoke where flammable materials are If you see evidence of any of the following stored.
Page 31: Fire Extinguishers And First-Aid Kit
Safety Information August 6, 2024 Fire Extinguishers and First-aid Kit CPD40/45/50L/50 Fire Extinguishers and First- Electrical Storm Injury aid Kit Prevention A fire extinguisher that meets with all local fire When lightning is striking in the vicinity of the extinguisher laws and regulations should be machine, the operator should never attempt to available on the machine.
Page 32: Information On Attachments
Face the machine when getting on and off. Hold the handrails, step on the steps, and maintain three points of contact (two feet and one hand or LiuGong can provide pneumatic or solid tires two hands and one foot). according to your specific needs.
Page 33 Safety Information August 6, 2024 Cautions about Machine Operation CPD40/45/50L/50 Remember that rain, snow, ice, gravel and soft Replace all damaged or lost parts and carry out earth may change the performance of the lubrication according to the maintenance interval machine.
Page 34 Safety Information August 6, 2024 Cautions about Machine Operation CPD40/45/50L/50 Do not start the machine until seated in the Operating the Machine operators seat and the seat belt is firmly Before driving on public roads, check that the fastened. machine meets the requirements of local traffic laws and regulations, and obtain a road driving permit from the relevant authority.
Page 35 Safety Information August 6, 2024 Cautions about Machine Operation CPD40/45/50L/50 The driver has an important responsibility to protect the safety of pedestrians. Pedestrians often have the right-of-way. Pay special attention, especially when turning corners. The driver should not startle pedestrians to give way by flashing lights or honking the horn.
Page 36 Safety Information August 6, 2024 Cautions about Machine Operation CPD40/45/50L/50 Check whether the load on the loading platform is loose. Strap down the load securely before transporting it. Use appropriately-sized loading platforms. Check the loading platform’s condition, strength, and safe loading capacity. The load must be balanced properly on the fork.
Page 37 Safety Information August 6, 2024 Cautions about Machine Operation CPD40/45/50L/50 Always use the load backrest and overhead guard when stacking loads up high. Pay special attention to avoid dropping loads when stacking. Check whether the items at the top of the stack are loose before stacking on top of them.
Page 38 Safety Information August 6, 2024 Cautions about Machine Operation CPD40/45/50L/50 Maintain a safe distance so that you can stop the Slow down on wet or slippery surfaces. vehicle safely under any conditions. Drive slowly in areas with poor visibility. Mirrors Overtaking is prohibited.
Page 39 Safety Information August 6, 2024 Cautions about Machine Operation CPD40/45/50L/50 Do not drive over any surface obstacles that are not firm. It is best to exit the vehicle, clear the obstacles, and then continue driving. To prevent loads from loosening, avoid driving over bumps or potholes.
Page 40 Safety Information August 6, 2024 Cautions about Machine Operation CPD40/45/50L/50 When the load is so large that it blocks the view in front, drive in reverse or have an assistant guide you. Always shut off the power when leaving the machine.
Page 41 Safety Information August 6, 2024 Cautions about Machine Operation CPD40/45/50L/50 Take the following procedures when the fault If it is necessary to park the machine on a slope is occurred: or incline, place chocks under the wheels at the downhill side on both sides to prevent the 1.
Page 42: Maintaining The Machine Safely
Safety Information August 6, 2024 Maintaining the Machine Safely CPD40/45/50L/50 Maintaining the Machine Safely Prepare the Work Area Select a clean and level area with sufficient space, and make sure it has adequate lighting and ventilation. Make sure the floor is clean. Wipe up any fuel, oil, lubricants, or water.
Page 43: Stability And Center Of Gravity
Safety Information August 6, 2024 Stability and Center of Gravity CPD40/45/50L/50 Stability and Center of Gravity Maintain proper ventilation of the welding site. Clean up all flammable materials and always have a fire extinguisher at the site. Load Center Confirm the position of center of gravity according to the shape of the load.
Page 44 Safety Information August 6, 2024 Stability and Center of Gravity CPD40/45/50L/50 Relationship Between Center of Gravity and movement status: accelerating, stopped, or ● Stability moving The forklift’s stability is determined by its center surface condition and slope ● of gravity. When unloaded, that is the center of Center of Gravity Stability Range gravity of the vehicle itself.
Page 45: Sound And Vibration Level
Safety Information August 6, 2024 Sound and Vibration Level CPD40/45/50L/50 Sound and Vibration Level Sound The sound performance offered for this machine has met the requirements in 2000/14/EC sound directive. A-Weighted emission sound pressure level at the operator's position measured according to work cycle procedures specified in “EN12053:2001+A1:2008 Safety of industrial trucks-Test methods for measuring noise...
Page 46: Key Spare Parts To Be Periodically Changed
Safety Information August 6, 2024 Key Spare Parts to be Periodically Changed CPD40/45/50L/50 Key Spare Parts to be Periodically Changed Key spare parts to be periodically changed Q’ty Changing intervals Every year or every 2000h (To see which one Hydraulic oil tank filter element comes earlier) Internal seals of steering system Hose assembly (from pump to steering gear)
Page 47: Applications And Specifications
Applications and Specifications August 6, 2024 Applications CPD40/45/50L/50 Applications and Specifications Applications This machine is an industrial vehicle used to transport goods over short distances. It is suitable for driving on smooth and hard surfaces (asphalt, cement, etc.). The machine is intended for use in warehouses, railway stations, shipping ports, construction sites, open-air freight yards, etc.
Page 48: Main Specifications
Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Main Specifications All rated operating/lift capacities specification are collected from the machine operation on a hard and flat ground. When the machine is operated in conditions that different from the above-mentioned condition (e.
Page 49: Machine Specifications
Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Machine Specifications 1 CPD40-EMT CPD40-EMT-FR Model Power Type Lithium Lithium General Base Capacity rated load center 4000 4000 Load Center Service Weight unloaded 5990 6280 Weights loaded (front/rear) 8725/1265 8920/1360 Axle Load unloaded (front/rear) 2725/3265 2920/3360...
Page 50 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Travel Speed loaded/unloaded km/h 18/19 18/19 Lift Speed loaded/unloaded mm/s 460/500 460/500 Acceleration loaded/unloaded 5.5/5 5.5/5 speed (10m) Performance Lower Speed loaded/unloaded mm/s 520/480 520/480 Max. Drawbar 5 min. rating (loaded) 23.5 23.5 Pull...
Page 51 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Machine Specifications 2 CPD45-EMT CPD45-EMT-FR Model Power Type Lithium Lithium General Base Capacity rated load center 4500 4500 Load Center Service Weight unloaded 6340 6640 Weights loaded (front/rear) 9510/1330 9720/1420 Axle Load unloaded (front/rear) 2760/3580 2970/3670...
Page 52 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Travel Speed loaded/unloaded km/h 18/19 18/19 Lift Speed loaded/unloaded mm/s 430/500 430/500 Acceleration loaded/unloaded 5.5/5 5.5/5 speed (10m) Performance Lower Speed loaded/unloaded mm/s 520/480 520/480 Max. Drawbar Pull 5 min. rating (loaded) 23.5 23.5 Max.
Page 53 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Machine Specifications 3 CPD50L-EMT CPD50L-EMT-FR Model Power Type Lithium Lithium General Base Capacity rated load center 5000 5000 Load Center Service Weight unloaded 6580 6880 Weights loaded (front/rear) 10210/1370 10420/1460 Axle Load unloaded (front/rear) 2710/3870 2920/3960...
Page 54 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Travel Speed loaded/unloaded km/h 18/19 18/19 Lift Speed loaded/unloaded mm/s 400/500 400/500 Acceleration loaded/unloaded 5.5/5 5.5/5 speed (10m) Performance Lower Speed loaded/unloaded mm/s 520/480 520/480 Max. Drawbar Pull 5 min. rating (loaded) 23.5 23.5 Max.
Page 55 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Machine Specifications 4 CPD50-EMT CPD50-EMT-FR Model Power Type Electric Electric General Base Capacity rated load center 5000 5000 Load Center Service Weight unloaded 7150 7320 Weights loaded (front/rear) 10680/1470 10800/1520 Axle Load unloaded (front/rear) 2940/4210 3065/4255...
Page 56 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Travel Speed loaded/unloaded km/h 18/19 18/19 Lift Speed loaded/unloaded mm/s 400/500 400/500 Acceleration loaded/unloaded 5.5/5 5.5/5 speed (10m) Performance Lower Speed loaded/unloaded mm/s 520/480 520/480 Max. Drawbar 5 min. rating (loaded) 23.5 23.5 Pull...
Page 57 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Main Components Specifications 1 Item CPD40-EMT CPD40-EMT-FR CPD45-EMT LiuGong PDM number 31B1142 31B1142 31B1142 TZ250X24.5-3100- TZ250X24.5-3100- TZ250X24.5-3100- Model 80Q3 80Q3 80Q3 Rated power (kw) 24.5 24.5 24.5 Rated voltage (V) AC53...
Page 58 2-70×50×1495 2-70×50×1495 2-70×50×1495 stroke (mm) Tilting cylinder quantity, bore × rod diameter × 2-90×45×202.5 2-90×45×202.5 2-90×45×202.5 stroke (mm) LiuGong PDM number 52C0880 52C0880 52C0880 Brand Jindao / Zhongchai Jindao / Zhongchai Jindao / Zhongchai JETH45C/HDCS50C Ⅱ JETH45C/HDCS50C Ⅱ JETH45C/HDCS50C Ⅱ...
Page 59 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Item CPD40-EMT CPD40-EMT-FR CPD45-EMT LiuGong PDM number 57C6613 57C8195 57C6613 Model 76.8V560Ah 76.8V840Ah 76.8V560Ah Rated voltage (V) 76.8 76.8 76.8 Battery Heating Rated capacity (AH) Weight (kg) LiuGong PDM number 57C6637...
Page 60 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Main Components Specifications 2 Item CPD45-EMT-FR CPD50L-EMT CPD50L-EMT-FR LiuGong PDM number 31B1142 31B1142 31B1142 TZ250X24.5-3100- TZ250X24.5-3100- TZ250X24.5-3100- Model 80Q3 80Q3 80Q3 Rated power (kw) 24.5 24.5 24.5 Rated voltage (V) AC53...
Page 61 2-70×50×1495 2-70×50×1495 2-70×50×1495 stroke (mm) Tilting cylinder quantity, bore × rod diameter × 2-90×45×202.5 2-90×45×202.5 2-90×45×202.5 stroke (mm) LiuGong PDM number 52C0880 52C0880 52C0880 Brand Jindao / Zhongchai Jindao / Zhongchai Jindao / Zhongchai JETH45C/HDCS50C Ⅱ JETH45C/HDCS50C Ⅱ JETH45C/HDCS50C Ⅱ...
Page 62 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Item CPD45-EMT-FR CPD50L-EMT CPD50L-EMT-FR LiuGong PDM number 57C8195 57C6613 57C8195 Model 76.8V840Ah 76.8V560Ah 76.8V840Ah Rated voltage (V) 76.8 76.8 76.8 Battery Heating Rated capacity (AH) Weight (kg) LiuGong PDM number 57C6637 Model 76.8V690Ah...
Page 63 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Main Components Specifications 3 Item CPD50-EMT CPD50-EMT-FR LiuGong PDM number 31B1142 31B1142 Model TZ250X24.5-3100-80Q3 TZ250X24.5-3100-80Q3 Rated power (kw) 24.5 24.5 Rated voltage (V) AC53 AC53 Rated current (A) Rated speed (rpm)
Page 64 Lifting cylinder quantity, bore × rod 2-70×50×1495 2-70×50×1495 diameter × stroke (mm) Tilting cylinder quantity, bore × rod 2-90×45×202.5 2-90×45×202.5 diameter × stroke (mm) LiuGong PDM number 52C0880 52C0880 Brand Jindao / Zhongchai Jindao / Zhongchai JETH45C/HDCS50C Ⅱ JETH45C/HDCS50C Ⅱ...
Page 65 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Item CPD50-EMT CPD50-EMT-FR LiuGong PDM number 57C6637 Model 76.8V690Ah Rated voltage (V) 76.8 Battery Heating Rated capacity (AH) Weight (kg) LiuGong PDM number 31B0732 31B1113 Model APSP-80V200A TRL-D80V200A Rated input voltage AC380V±15%...
Page 66 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 Work Scope Please operate the machine according to the rated load capacity in the load curve chart. (The load chart used for CPD40, 2-stage mast and single tire.) (The load chart used for CPD40, 3-stage mast and single tire.)
Page 67 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 (The load chart used for CPD40, 2-stage mast and double tires.) (The load chart used for CPD40, 3-stage mast and double tires.)
Page 68 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 (The load chart used for CPD45, 2-stage mast and single tire.) (The load chart used for CPD45, 3-stage mast and single tire.)
Page 69 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 (The load chart used for CPD45, 2-stage mast and double tires.) (The load chart used for CPD45, 3-stage mast and double tires.)
Page 70 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 (The load chart used for CPD50L, 2-stage mast and single tire.) (The load chart used for CPD50L, 3-stage mast and single tire.)
Page 71 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 (The load chart used for CPD50L, 2-stage mast and double tires.) (The load chart used for CPD50L, 3-stage mast and double tires.)
Page 72 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 (The load chart used for CPD50, 2-stage mast and single tire.) (The load chart used for CPD50, 3-stage mast and single tire.)
Page 73 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 (The load chart used for CPD50, 2-stage mast and double tires.) (The load chart used for CPD50, 3-stage mast and double tires.)
Page 74 Applications and Specifications August 6, 2024 Main Specifications CPD40/45/50L/50 (The load chart used for attachments.) Demountable components: size and weight External size Model Components Qty. Weight (Kg) (length width height) (mm) × × 1042×540×2190 Mast assembly (without fork) CPD40 Overhead guard 1600×1352×1570 Counterweight 965×1409×1096...
Page 75: Operation Manual
Operation Manual August 6, 2024 Before Operating the Machine CPD40/45/50L/50 Operation Manual Before Operating the Machine Pre-Operation Inspection Check the condition of the battery, including electrolyte levels and specific gravity. Check the tire air pressure. Check the wheel nuts. Check the hydraulic oil level. Check the steering system functionality.
Page 76 Operation Manual August 6, 2024 Before Operating the Machine CPD40/45/50L/50 Check before initial start-up of the machine Before the initial start-up of the machine, it is needed to check each system of the machine so as to eliminate faults and hidden danger caused by long-distance transportation. Item Content Appearance of...
Page 77: Operator Controls And Instrument Panels
Operation Manual August 6, 2024 Operator Controls and Instrument Panels CPD40/45/50L/50 Operator Controls and Instrument Panels 10 11 1. Emergency button 7. Start switch 2. Parking brake lever 8. Switch assembly 3. Shift control lever 9. Accelerator pedal 4. Service brake pedal 10.
Page 78: Start Switch
Operation Manual August 6, 2024 Operator Controls and Instrument Panels CPD40/45/50L/50 Start Switch ON-- turn the start switch key to this position to turn on power for the machine. Then all of the electrical appliances are connected with power. Start switch (also called ignition switch) is located at the right side of the steering column which is used to turn on the power for the machine and has two positions progressing in a clockwise...
Page 79: Steering Wheel
Operation Manual August 6, 2024 Operator Controls and Instrument Panels CPD40/45/50L/50 Steering Wheel Shift Control Lever The shift control lever is located on the left side of steering column, which is used to control the travel direction of the forklift. There are three positions on the shift control lever: forward, neutral and reverse.
Page 80: Combination Switch
Operation Manual August 6, 2024 Operator Controls and Instrument Panels CPD40/45/50L/50 Working Implement Control Lever The sequence protection function is ensure the safety of the driver and prevent the mechanical injury caused by the loss of control of the vehicle due to the misoperation of the forklift.
Page 81: Startup Interface
Operation Manual August 6, 2024 Operator Controls and Instrument Panels CPD40/45/50L/50 Name Description Name Description Notes It will be on when the operator To numerically display the Seat light leaves the seat. current cumulative Service working time of the It will be on when the hour vehicle, with a maximum Seat belt light...
Page 82: Button Function
Operation Manual August 6, 2024 Operator Controls and Instrument Panels CPD40/45/50L/50 4. Button function (2) Other setting Item Description Note Langua Chinese by Chinese/English default. setting Range: 0~1 Reset The password is service required to reset the hour service hour meter. meter The mileage is reset at the same time.
Page 83 When the vehicle is traveling, if the operator In the following cases, park the vehicle in a safe leaves the seat or releases the seat belt for more place and contact LiuGong's dealers for than 3 seconds (if the vehicle is equipped with a inspection.
Page 84 Operation Manual August 6, 2024 Operator Controls and Instrument Panels CPD40/45/50L/50 Service Brake Pedal Lift Lever The brake pedal is located at the front of the The machine is not able to travel and operate if operator's seat. Depress any brake pedal and you don't sit on the seat correctly.
Page 85: Emergency Button
Operation Manual August 6, 2024 Operator Controls and Instrument Panels CPD40/45/50L/50 Emergency Button Fore-and-aft Adjustment Push the adjusting handle gently to the seat Before operating the machine, pull the center, move the seat body forward and emergency button backwards until a click is backward to reach a desired position, and heard Turn on the start switch, and then the release the handle and it will reset and...
Page 86 Operation Manual August 6, 2024 Operator Controls and Instrument Panels CPD40/45/50L/50 Backrest Angle Adjustment (Optional) Weight Adjustment and Suspension (Optional) Rotating the adjusting handle clockwise to increase the tilt angle and counterclockwise to Three positions are available for this weight decrease.
Page 87 Replace it when necessary. Contact your LiuGong dealer for seat belt replacements. Adjust length of the seat belt before use in order to ensure safety and comfortability. Length of the...
Page 88 Operation Manual August 6, 2024 Operator Controls and Instrument Panels CPD40/45/50L/50 Overhead Guard Overhead guard is an important safety part to avoid goods falling off from the machine and Before driving the machine, make sure that hurts the operator. Do not drill holes, welding on the steering wheel has been properly the overhead guard or reconstruct it, which will adjusted.
Page 89: Engine Hood
Operation Manual August 6, 2024 Operator Controls and Instrument Panels CPD40/45/50L/50 Battery 3. Rear combination light: with one set at each side. (reverse light, color in white; turn signal light, color in amber; taillight and position The battery is located in the middle of the frame, brake light, color in red.) under the engine hood.
Page 90 Operation Manual August 6, 2024 Operator Controls and Instrument Panels CPD40/45/50L/50 Fork Traction Pin Pull up and unscrew lock pins at both ends of the The traction pin is located behind the fork, and move the fork leftwards and rightwards. counterweight.
Page 91: Attachment Installation
7. It is prohibited to modify the attachment Nearly all of the attachment for medium and without the technical permission of LiuGong small ton forklift is installed with hook. In order to as the modification could cause safety ensure the installation safety, it's recommended problem and change the attachment function.
Page 92: Machine Starting
Operation Manual August 6, 2024 Machine Starting CPD40/45/50L/50 Machine Starting Battery sleep state enabled To reduce the power loss caused by battery self- discharge, if the continuous discharge current of the lithium battery is less than 5 A and the Before starting the machine, make sure that duration exceeds 1 hour, the BMS of the lithium nobody is working on or near the machine.
Page 93: Operation Techniques
Operation Manual August 6, 2024 Operation Techniques CPD40/45/50L/50 Operation Techniques 4. Check service brake performance.Run the forklift forwards. Release the accelerator pedal and then gently depress the service Traveling Operation brake pedal, the forklift will be able to slow down. After depressing the service brake pedal, if Before driving the machine onto roads, you can not feel any obvious slowdown in...
Page 94: Steering Operation
Operation Manual August 6, 2024 Operation Techniques CPD40/45/50L/50 Steering Operation Brake Operation The forklift adopts a full-hydraulic steering Service Brake system. Move the steering wheel slightly when Before engage brake, please first release the operating. accelerator pedal, and then slowly depress the 1.
Page 95: Downhill Operation
Operation Manual August 6, 2024 Operation Techniques CPD40/45/50L/50 Loading Operation Regenerative Brake When the accelerator pedal is released, the drive 1. Before loading, please confirm whether the motor will turn into an alternator to convert kinetic width of the loading board or the goods is energy into electric energy to charge the battery suitably matched with the opening degree of through a controller, which is called as...
Page 96: Cold Weather Operation
Operation Manual August 6, 2024 Operation Techniques CPD40/45/50L/50 7. When driving the forklift with a load down the When handling wide loads, the forklift must be hill, it is better to drive the machine reversely equipped with a fork carriage suitable for wide or at a slow speed.
Page 97: Hot Weather Operation
Operation Manual August 6, 2024 Operation Techniques CPD40/45/50L/50 Hot Weather Operation Stop the Engine 1. Turn the start switch to OFF position and take Pay attention to the following points when out the key. operating the machine under hot weather. 2.
Page 98: Transportation Information
Lift and fix the forklift during storage period to prevent the tires from deforming. Never Transportation Information cover the forklift with films because water vapor may accumulate. Contact with LiuGong dealer for further maintenance Transportation procedures if the forklift is parked over three months. In Storage Observe the national and local laws and The battery should be charged once a month.
Page 99: Fork Removal
4. Engage parking brake when parking the 8. For installing those parts removed before trailer on the ground. Chock the trailer wheels transportation, contact with LiuGong dealer with wedges. to install. 9. When it is necessary to remove the mast and counterweight before transportation, remove the mast first, then the counterweight.
Page 100 Operation Manual August 6, 2024 Transportation Information CPD40/45/50L/50 Mast--Assemble Figure 1 Part of the masts needs to be disassembled before machine transportation, such as high mast, which needs to be disassembled from machine and assembled to the machine again after being transported to the destination with the machine.
Page 101 Operation Manual August 6, 2024 Transportation Information CPD40/45/50L/50 6. Lifting of mast 7. Assembly of tilt cylinder and mast 1. Lift the mast by lifting crane and transport to 1. Insert pin into tilt cylinder and the hinge hole the front of the machine, align the of mast to connect the mast and tilt cylinder semicircular swing bearing support under the together.
Page 102 Operation Manual August 6, 2024 Transportation Information CPD40/45/50L/50 Fork Install 8. Connection of lift cylinder and sideshift pipes Move the fork and carriage so the top hook on Connect the lift cylinder with the lift connector A1 the fork can engage the upper carriage bar. of the multi-valve, and connect the sideshift pipe Raise the carriage to move the lower hook with the sideshift connectors A3 and B3 of the...
Page 103: Lifting Operation
Operation Manual August 6, 2024 Transportation Information CPD40/45/50L/50 1. Choose suitable crane and rope with maximum capacity according to the nameplate on the forklift to ensure safety when lifting. 3. Use moving equipment (such as a crane) to move a malfunctioning machine. Lifting Operation 2.
Page 104 Operation Manual August 6, 2024 Transportation Information CPD40/45/50L/50 5. This machine can be side lifted by a forklift. 2. Remove the fixed plate at the bottom of the Please choose a suitable forklift to lift this sideshifter. machine according to the nameplate. Lift the sideshifter by the lift eye.
Page 105 Operation Manual August 6, 2024 Transportation Information CPD40/45/50L/50 6. Lift the overhead guard and move to another location, then disassembly of the overhead guard was completed. 7. Assemble the overhead guard to the contrary of the above disassembly procedure. In the overhead guard disassembly process, place wedges in front of the front wheels and behind the rear wheels to stop the machine from moving.
Page 106: Maintenance Manual
Maintenance Manual August 6, 2024 Run-in CPD40/45/50L/50 Maintenance Manual 3. The signal switch of lift, tilt, sideshift and attachment is input in advance, then turn the start key to ON position. The instrument shows the fault code, oil pump lock. The Run-in correct operation: turn the start key to ON position then input the signal switch of lift, tilt,...
Page 107 Maintenance Manual August 6, 2024 Run-in CPD40/45/50L/50 2. Check the hydraulic system for leaks. Check oil level according to the relevant operation regulations. The following must be done after the break-in period of the new machine is completed 1. Check the fastening of all bolts and nuts. 2.
Page 108: Maintenance Interval Schedule
The maintenance intervals stated in this manual are determined according to the service hour meter or calendar intervals shown (daily, weekly, monthly, etc). Liugong recommends that maintenance should be performed according to whichever of the above-mentioned intervals occurs first.
Page 109 Maintenance Manual August 6, 2024 Maintenance Interval Schedule CPD40/45/50L/50 Every Every Three Half Year Every Year Items Description Tools Month Months (1200hours) (2400hours) (8hours) (200hours) (600hours) Clean the battery connector and check if the ○ ○ ○ ○ connector connects tightly Clean the ○...
Page 110 Maintenance Manual August 6, 2024 Maintenance Interval Schedule CPD40/45/50L/50 Power train system Every Every Three Half Year Every Year Items Description Tools Month Months (1200hours) (2400hours) (8hours) (200hours) (600hours) ○ ○ ○ ○ ○ Check for leakage Check for abnormal ○...
Page 111 Maintenance Manual August 6, 2024 Maintenance Interval Schedule CPD40/45/50L/50 Wheels Every Every Three Half Year Every Year Items Description Tools Month Months (1200hours) (2400hours) (8hours) (200hours) (600hours) Inflation pressure Pressur (only for ○ ○ ○ ○ ○ e gauge pneumatic tires) Check for cracks ○...
Page 112 Maintenance Manual August 6, 2024 Maintenance Interval Schedule CPD40/45/50L/50 Steering system Every Every Three Half Year Every Year Items Description Tools Month Months (1200hours) (2400hours) (8hours) (200hours) (600hours) Check the ○ ○ ○ ○ ○ clearance Check the axial ○ ○...
Page 113: Braking System
Maintenance Manual August 6, 2024 Maintenance Interval Schedule CPD40/45/50L/50 Braking system Every Every Three Half Year Every Year Items Description Tools Month Months (1200hours) (2400hours) (8hours) (200hours) (600hours) ○ ○ ○ ○ ○ Empty stroke Pedal stroke Scale ○ ○ ○...
Page 114 Maintenance Manual August 6, 2024 Maintenance Interval Schedule CPD40/45/50L/50 Every Every Three Half Year Every Year Items Description Tools Month Months (1200hours) (2400hours) (8hours) (200hours) (600hours) Check the primary Primary brake pump, brake piston leather cup pump, ○ and the check Secondary valve for wear brake...
Page 115: Lift System
Maintenance Manual August 6, 2024 Maintenance Interval Schedule CPD40/45/50L/50 Lift system Every Every Three Half Year Every Year Item Description Tools Month Months (1200hours) (2400hours) (8hours) (200hours) (600hours) Check the fork for damage, ○ ○ ○ ○ ○ deformation and wear condition Check the dowel pin for damage...
Page 116 Maintenance Manual August 6, 2024 Maintenance Interval Schedule CPD40/45/50L/50 Every Every Three Half Year Every Year Item Description Tools Month Months (1200hours) (2400hours) (8hours) (200hours) (600hours) Check the welding position among the inner ○ ○ ○ ○ mast, outer mast and the beam for cracks and damages...
Page 117 Maintenance Manual August 6, 2024 Maintenance Interval Schedule CPD40/45/50L/50 Every Every Three Half Year Every Year Item Description Tools Month Months (1200hours) (2400hours) (8hours) (200hours) (600hours) Check if the chain is tensioned and ○ ○ ○ ○ ○ deformed, damaged corroded Lubricate chain ○...
Page 118 Maintenance Manual August 6, 2024 Maintenance Interval Schedule CPD40/45/50L/50 Hydraulic system Every Every Three Half Year Every Year Item Description Tools Month Months (1200hours) (2400hours) (8hours) (200hours) (600hours) Check the hydraulic pump for ○ ○ ○ ○ ○ leakage and noise Hydraulic Check the drive pump...
Page 119 Maintenance Manual August 6, 2024 Maintenance Interval Schedule CPD40/45/50L/50 Safety device and accessories Every Every Three Half Year Every Year Item Description Tools Month Months (1200hours) (2400hours) (8hours) (200hours) (600hours) Check for good Test installation hammer Overhead guard and Check for load- deformation, ○...
Page 120 Maintenance Manual August 6, 2024 Maintenance Interval Schedule CPD40/45/50L/50 Every Every Three Half Year Every Year Item Description Tools Month Months (1200hours) (2400hours) (8hours) (200hours) (600hours) Check the frame and beam for ○ damages and cracks Check for loose Test ○...
Page 121: General Torque Specifications
Maintenance Manual August 6, 2024 General Torque Specifications CPD40/45/50L/50 General Torque Specifications Tighten the bolts used in the machine according to the torque requirements shown in the following table unless other specified: Metric system Standard Torque lb.ft (N.m) Thread Size 8.8 Grade Strength 10.9Grade Strength 7.7±1.1(10.5±1.5)
Page 122 Maintenance Manual August 6, 2024 General Torque Specifications CPD40/45/50L/50 Hexagon bolts with flange (metric system) Standard Torque lb.ft (N.m) Thread Size 8.8 Grade Strength 10.9Grade Strength 7±1 10±1 12±1.5 15±1.5 29±3 36±3 57±6 79±6 99±10 132±10 160±15 215±15 248±25 336±25 341±35 457±35 473±50...
Page 123: Lubrication Specifications
Maintenance Manual August 6, 2024 Lubrication Specifications CPD40/45/50L/50 Lubrication Specifications Oil Change Intervals and Approximate Volumes Always prepare a suitable container to collect any liquids before inspecting, servicing, testing, or adjusting the machine, or removing or disassembling any hydraulic parts or any liquid- containing components.
Page 124: Oil Specifications
★ 2# Molybdenum disulfide lithium-based grease Grease bearing, shaft of working implement, steering cylinder, For working implement ★ L-HM32 anti-wear L-HV46 low temperature LiuGong Hydraulic oil hydraulic system, steering anti-wear hydraulic oil hydraulic oil hydraulic system, brake system Gear oil ★...
Page 125: Tire Information
As for the tire inflation pressure under normal temperature, refer to the tire pressure decal on the machine. Tire Inflation Information Recommended inflation pressure: LiuGong recommends the use of dry nitrogen Front wheel inflation Rear wheel inflation gas for tire inflation and for tire pressure pressure (MPa) pressure (Mpa) adjustments.
Page 126 Maintenance Manual August 6, 2024 Tire Information CPD40/45/50L/50 Wheels--Change 3. Only tires of the same specification, structure, brand, size, ply rating, and tread pattern should be installed on the same axle. Front Wheels When possible, try to replace all the tires on the vehicle at the same time, or at least 1.
Page 127 Maintenance Manual August 6, 2024 Tire Information CPD40/45/50L/50 8. Remove the wheel nuts and replace the front wheels. 1. When removing the wheel nuts, do not remove the rim nuts by mistake. 2. Make sure the blocks are intact and strong enough.
Page 128: Working Implement System
Maintenance Manual August 6, 2024 Working Implement System CPD40/45/50L/50 Working Implement System 6. Remove the wheel nuts and replace the rear wheels. Mast--Lubricate 1. When removing the wheel nuts, do not Lubricate according to lubrication diagram. remove the rim nuts by mistake. 2. Make Clean the grease fitting thoroughly before sure the blocks are intact and strong lubricating.
Page 129 Drop-resistant measures of common two on that needs further safety measures, stage mast contact the LiuGong forklift dealer. When the inner mast rises, the chain wheel will rotate, and the fork arm carrier will rise with the inner mast at a speed ratio of 2:1. The static load Chain adjustment: Keep the mast straight, coefficient used for the lifting accessory is 1.33.
Page 130 Maintenance Manual August 6, 2024 Working Implement System CPD40/45/50L/50 Drop-resistant measures of full free two stage mast Even operated in a very low space, this kind of Choose suitable chain according to different mast can still raise freely. The middle lift cylinder height of the mast and do not exceed the raises the fork to a particular free height through maximum lift height.
Page 131: Important Maintenance Procedures
Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Important Maintenance Axle Oil--Replace Procedures Power Train System Care must be taken to ensure that fluids are contained during performance of inspection, Axle Oil Level--Check maintenance, testing, adjusting and repair of the product.
Page 132: Hydraulic System
Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Hydraulic System Hydraulic Oil--Replace Hydraulic Oil Level--Check Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component Park the machine on a flat ground before containing fluids during the operation of inspecting the hydraulic oil.
Page 133 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 4. Open the refilling port cap on the hydraulic 9. Turn the start switch to ON position, step on tank and then open the drain plug and drain the accelerator, and perform lifting, tilting, the oil into a suitable container.
Page 134: Brake System
Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Brake System 4. Fix the O-ring and leather cup to the head of slide valve, and secure the seal plate by tightening the bolt to a torque of 4.6~5.8N.m. Brake Oil--Check 5.
Page 135 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Turn the adjusting screw to adjust the brake Adjustment method: Remove the rubber plug on force. Turn the adjusting screw clockwise to the bottom plate and pull the clearance increase the brake force turn it counterclockwise adjustment pawl.
Page 136 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 (b) Remove the rivets with a hammer and a 4. Turn the parking brake lever backwards and chisel. release the service brake pedal slowly. Check to see if the machine stays at the Rivet the new friction lining: original position.
Page 137: Battery Maintenance
Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Exhaust of service brake system No smoking! Open flame, glowing metal wire and electric spark are not allowed to appear Keep a certain amount of brake fluid in the around the battery. Do not install any equipment reservoir during exhaust.
Page 138 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Battery--Maintain 7. Ensure that the battery is recharged once a month when the vehicle is not used for more than 3 months. Cautions for battery The following situations should be avoided during battery usage: undercharge, a long-term undercharge of battery would severely affect the Recharge the battery within 24 hours after...
Page 139 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Finishing charging Charge in time after using the battery. The ● battery should be charged fully once at least 1. Press the pause button of charger. every half month. Please charge the battery immediately after use and charge it fully 2.
Page 140: Electrical System
Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Electrical System 1. Fasteners of travel motor Schematic Diagrams for the Vehicle's Electrical Devices When motor is under repair and maintenance, turn the start switch to OFF, disconnect the battery connector to cut off Please refer to the “Schematic diagrams”...
Page 141 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Electronic control unit may generate heat during working which mainly cools through fan device and cooling system. Check electronic control unit every month routinely. Wipe out the dust When electronic control unit is under repair accumulated on the surface of the electronic and maintenance, turn the start switch to control unit and fan so as to let it cool down...
Page 142 2. Remove the cover of the fuse box, and take There may be a circuit failure if frequent fuse the broken fuse out with clamp. replacement occurs. Please contact LiuGong dealer if necessary. 3. Replace it with a new fuse with same specification.
Page 143: Other Maintenance
The backup alarm is installed at the lower end of blue spot light (optional), and LED rear floodlight the left rear column of the overhead guard. (optional), etc. Contact LiuGong dealer if anyone of above lights is damaged. In order to make it convenient for the users to replace broken bulbs, the following table lists the specification of the bulbs used in this machine.
Page 144 No matter how well the seat belt looks like, replace it every three years. Consult your LiuGong dealer for the replacement of the seat belt. Cleaning and inspection of cooling fan...
Page 145: Machine Troubleshooting
Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Machine Troubleshooting Features Possible reasons Solutions Battery exhausted. Check, charge or replace the battery. Tighten the battery terminal and smear a layer of Loose connection. non-acidic grease. Forklift is unable to start Fuse belowing out.
Page 146 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Steering System Troubleshooting Features Possible reasons Solutions Check valve failure inside valve body, the metering Clean or replace the pump is blocked with dirt metering pump Heavy steering Replace the piston sealing Interior leakage of steering cylinder ring Replace the shaft of steering...
Page 147 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Metering Pump Troubleshooting Failure Features Possible reasons Solutions Dirt on the joint surface. Clean the surface. Oil leakage from valve body, Seal ring damaged at shaft diameter Replace the seal ring Oil leakage plates, stator and the joint surface of rear cover...
Page 148 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Brake System Troubleshooting Feature Possible reasons Solutions Brake oil leakage in brake system Repair Improper clearance between shoe linings Adjust Insufficient Impurity adheres to shoe linings surface Repair or replace brake force Impurity mixed in brake oil Replace brake oil Improper adjustment of brake pedal...
Page 149 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Lift System Troubleshooting Feature Possible reasons Solutions Too much axial and radial clearance in oil pump Repair or replace the oil pump Use required oil and pay attention to weather Too high viscosity or temperature of hydraulic oil impact on oil temperature Weak lifting, Clean contamination and replace the oil...
Page 150: Electrical System Troubleshooting
Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Electrical System Troubleshooting Features Possible reasons Solutions 1) Check the battery connector, connect it correctly. 2) Check the fuse, replace if necessary. 1) Loose battery connector. No Instrument power 3) Check the emergency button for power. Turn it on if it 2) Fuse of control circuit is burnt.
Page 151: Battery Troubleshooting
Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Electrical Motor Troubleshooting Features Possible reasons Solutions 1) Check the fixed screw and connection for loosen, or replace 1) The controller can not check the coder. The motor vibrates the coder. 2) The coder damaged.
Page 152 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Drive Axle Troubleshooting Features Possible reasons Solutions Break oil leakage in brake system Repair Improper clearance between shoe linings Adjust the adjuster Break overheating Check if the machine slides Poor breaking Poor contact between drum break and shoe linings surface Readjust Impurity adherence to shoe linings surface...
Page 153 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Haitian Controller Troubleshooting Running SPN FMI Item Description Solution status code Controller short-circuit single 1. Restart the key switch overcurrent 2. Low battery voltage 1. Restart the key switch 2. Low battery voltage; Controller short-circuit contin- 3.
Page 154 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Running SPN FMI Item Description Solution status code Controller temperature too Controller Restart the key switch 1. Traction motor temperature sensor failure Motor temperature sensor Travel motor 2. Harness fails and the traction open-circuited motor temperature sensor cable is broken...
Page 155 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Running SPN FMI Item Description Solution status code 1. Motor speed encoder failure Motor Motor encoder failure 2. Harness fails and the motor speed encoder cable is broken 1. Motor speed encoder failure Phase A loss of motor Motor 2.
Page 156 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Running SPN FMI Item Description Solution status code Check whether the coil or con- Drive port 3 output overcur- necting wire at the output port 3 rent warning is short-circuited. Drive port input short-circuit Check whether the output har- overcurrent cutoff ness is short-circuited...
Page 157 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Running SPN FMI Item Description Solution status code 1. Please check whether the CAN bus is open-circuited, broken or short-circuited (con- CAN communication failure troller and instrument) 2. Check whether the resistance on CAN is 60 Ω...
Page 158 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Running SPN FMI Item Description Solution status code Internal power supply failure Controller Restart the key switch of controller Check the harness of motor Motor Motor encoder open-circuited encoder and temperature sensor Check the harness of motor Motor Motor encoder short-circuited...
Page 159 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Running SPN FMI Item Description Solution status code Traction energy limit/Second- Low battery and vehicle speed ary lock limit Low battery and oil pump speed Energy limit of oil pump limit Too low battery Low battery and lifting cutoff Too high voltage of BMS bat-...
Page 160 Maintenance Manual August 6, 2024 Important Maintenance Procedures CPD40/45/50L/50 Running SPN FMI Item Description Solution status code BMS current alarm BMS failure BMS voltage alarm BMS LV power supply failure BMS current acquisition cable falling off Check the wiring of lithium bat- BMS temperature cable fall- tery harness, and reconnect it if it ing off...
Page 161: Maintenance Note Table
Maintenance Manual August 6, 2024 Maintenance Note Table CPD40/45/50L/50 Maintenance Note Table...
Page 162: Revision Table
Revision Table August 6, 2024 Maintenance Note Table CPD40/45/50L/50 Revision Table Revision Version no. Date Note 202408000 2024.08.05. The first print...
Page 163: Index
INDEX August 6, 2024 CPD40/45/50L/50 INDEX Combination Switch ........74 Control Valve--Assemble ......127 Control Valve--Disassemble ......127 Accelerator Pedal ..........78 Crushing and Cutting Prevention ....23 Adjustment of brake clearance .....129 Applications .............41 Applications and Specifications ......41 Attachment--Remove and Lift ......98 Aux Lever (Optional) ........78 Depositing Loads ..........
Page 164 INDEX August 6, 2024 CPD40/45/50L/50 Main Structural Component ......6 Maintaining the Machine Safely ...... 36 Maintenance Beside the Mast and Fork ..123 Haitian Controller Troubleshooting ....147 Maintenance Interval Schedule ....102 Horn Button .............82 Maintenance Manual ........100 Hot Weather Operation ........91 Maintenance Note Table ......
Page 165 INDEX August 6, 2024 CPD40/45/50L/50 Safety Information ...........13 Safety Warning Labels ........13 Safety Warning Symbol ........13 Schematic Diagram ........161 Schematic Diagrams for the Vehicle's Electrical Devices ............134 Seat ..............79 Seat Belt ............81 Seat Belt--Inspect .........137 Serial Number of the Machine and Parts ..4 Service Brake Pedal ........78 Service Brake Performance--Inspect ....130 Shift Control Lever ..........73...
Page 166 INDEX August 6, 2024 CPD40/45/50L/50...
Page 167: Schematic Diagram
Schematic Diagram August 6, 2024 CPD40/45/50L/50 Brake Schematic Diagram Schematic Diagram Brake Schematic Diagram 50Y1497...
Page 168 Schematic Diagram August 6, 2024 CPD40/45/50L/50 Hydraulic Schematic Diagram Hydraulic Schematic Diagram 50Y2130...
Page 169 Schematic Diagram August 6, 2024 CPD40/45/50L/50 Electrical Schematic Diagram Electrical Schematic Diagram 50Y5148-1...
Page 170 Schematic Diagram August 6, 2024 CPD40/45/50L/50 Electrical Schematic Diagram 50Y5148-2...

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