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DUROLL PRO CBDR Series Manual

Electric pallet truck
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CBDR series
Electric Pallet Truck
 Operation Manual
 Parts Catalogue

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Summary of Contents for DUROLL PRO CBDR Series

  • Page 1 CBDR series Electric Pallet Truck  Operation Manual  Parts Catalogue...
  • Page 2 Welcome to choose CBDR series electric pallet truck! Hope our electric trucks would bring great convenience to your work ！ Please read the manual carefully before operation. ⚫ This manual is a universal manual. We reserve the right to modify technology of the electric ⚫...

  • Page 3: Table Of Contents

    CONTENT S SPECIFIED USE ............................1 ELECTRIC PALLET TRUCK INTRODUCTION ................1 1. S ......................... 1 COPE OF APPLICATION 2. A ......................1 LLOWED ENVIRONMENT FOR USING 3. T ........................2 ECHNICAL PARAMETERS III. OPERATION .......................... 9 1. S ........................... 9 AFETY NORMS 2.

  • Page 4: Specified Use

    1. Scope of application CBDR series electric pallet truck is powered by storage battery, and driven by a motor. It travels by gear transmission. There are electric steering and mechanical steering. The fork is lifted by the DC motor and the hydraulic actuation to push the cylinder up and down to lift the forks and the goods.

  • Page 5: Technical Parameters

    3. Technical parameters 3.1 Structure description Number CBDR Name ● Handle ● Emergency stop switch ● Instrument ● Electric lock Charging indicator (on-board charger) ○ Charging socket ( on-board charger) ○ ● Battery ● Hydraulic power unit Drive unit (floating mechanisms of mechanism steering and EPS are ●...
  • Page 6 (1) instrument: ① 808 instrument This instrument is a combination of battery capacity indicator and LCD hour meter, with the battery indicator of ten segments of colorful LED display (5 green segments, 3 yellow segments and 2 red LED).When the battery discharges by 70%, one red flicker lamp shows “energy storage”...
  • Page 7 The steering system is composed of operation handle, steering shaft, and floating support bearings. It is used to control directions of the truck. (3) Brake The brake of this truck is electromagnetic. When the accelerator pedal is released, the electromagnetic brake will be triggered.
  • Page 8 ⑤Turtle low speed button: When this button is pressed, the truck will travel at an extremely slow speed. This button is applicable for operation on especially narrow field or on the condition that the truck needs to be accurately located. (5) Electric lock It is used to control switching-on and switching-off of main power supply of the truck.
  • Page 9 3.2 Main technical parameters (CBDR electric pallet truck)
  • Page 10 Manufacturer(abbreviated) Model CBD20R-Ⅱ CBD25R-Ⅱ Driving mode Electric Electric Electric Drive mode Standing driving Standing driving Standing driving Rated load Q(kg) 2000 2500 3000 Load center distance (mm) Front overhang (mm) 914/964/1034 914/964/1034 914/964/1034 Tread (mm) 1211/1261/1331 1211/1261/1331 1286/1336/1406 Service weight(with battery) Axle load, front/rear, laden 1300/1410 1470/1770...

  • Page 11: Operation

    III. Operation 1. Safety norms Warning Please pay attention to the following items first before operating： This electric truck is only limited to utilization indoor with a hard flat floor. Operation in inflammable, explosive environment or corrosive environment such as acid or alkaline condition shall be strictly forbidden.
  • Page 12 Notice Never drive the truck when you are tired or un-concentrated, with an injection of drug, or after a liquor drinking. (4)Safety of working place： Notice This kind of electric truck is only limited to utilization indoor with a hard flat floor. Operation in inflammable, explosive environment or corrosive environment such as acid or alkaline condition shall be strictly forbidden.
  • Page 13 1.2 Safety Operation Specification (1)Check the safety condition around the truck A. Before starting up the truck, please ensure that there is no person around it.. B. If the driver’s view is shielded by the bulky goods carried, please drive backwards or drive under the guidance of other working personnel..
  • Page 14 2. Operation 2.1 Inspection before operation For the sake of safety operation and good situation of the electric truck, it is compulsory to check the truck completely before operation. Contact the sales department of our company when founding problems. Check point Check content When the operation handle is turned, with the Operation handle...
  • Page 15 gradually. The greater the accelerator knob is turned, the faster the truck travels. Warning When handling goods, never rotate the accelerator knob rapidly to speed up the truck abruptly (2) Slow-down The driving motor of the car is an AC motor, and the running speed of the motor is always controlled by the speed control controller.

  • Page 16: Usage, Maintenance And Charge Of The Storage Battery

    Notice When cleaning up the electrical system, use compressed air but not water. (3)Charge： Warning Open flame is forbidden to appear at the charge places, otherwise, explosion or fire disaster can be caused. (Make a record of charge. As for the charge method, refer to the part about storage battery operation) (4) After operation, the smudge on truck shall be wiped out.

  • Page 17: Initial Charging

    Step 1, Open up the over; Step 2, Insert one end of the charging lead which comes with the truck into the socket; Step 3, Put the other end into the two-phased AC power supply. Charge will start after several seconds. Warning When charging, there is hydrogen in the battery box.

  • Page 18: Use And Maintenance

    charging current shall be halved or the charging shall be suspended; the charging shall be continued after the liquid temperature drops below 35 ℃. However, the charging time shall be extended properly. (6) The basis of sufficient power: when the battery is charged to 31.2v (12 × 2.6V = 31.2v) in the second stage, the voltage change is not more than 0.005 (V);...

  • Page 19: Charger

    (4) It is not allowed to store with electrolyte. If it is necessary to store with electrolyte under special circumstances, the density and liquid level of the electrolyte shall be adjusted to the specified value with sufficient batteries. After one month of storage, the power supply shall be made up once according to the normal charging method.

  • Page 20: User Requirements For The Secondary On-Board Li-Ion Battery System

    Warning When lifting or carrying the battery, it must be handled with care, otherwise the battery may be damaged or personal injury may be caused V. User Requirements for the Secondary On-board Li-ion Battery System This URD is generally applied into the usage , maintenance and any other operations occur to the Li-ion batteries (Secondary On-board Li-ion Batteries System) on both electric storage and logistic trucks 。...
  • Page 21 Waterproof & Humidity proof Sign： It indicates to protect the products from rain, water and humidity. No Fire Sign： It indicates that fire is prohibited in this area when the product is on. Do Not Step Sign： It indicates the products must not be stepped on. (2) The use of Li-ion battery trucks shall be in accordance with the requirements of temperature, humidity and environment specified in the truck instructions, and the maintenance and disassembly of lithium battery shall be carried out when the battery case is clear without any foreign bodies,...

  • Page 22: Requirements On Charging The Li-Ion Batteries

    interface and voltage acquisition interface of lithium battery management system to prevent short-circuit damages to system components and even cause fire. Safety warning signs must be obeyed for safety ’s sake. (13) If operators find any of the following situations or have any concerns about the safety of the product, shut down the truck first, and take measures like disconnecting the power connection to ensure the safety of both the operators and the truck, then immediately contact the relevant personnel for further guidance.

  • Page 23: Requirements On The Storage

    6. Requirements on the storage (1) The storage of lithium batteries should be in clean and ventilated rooms with ambient temperature ranging from - 10 ~35 ℃ (recommended storage temperature ranging from 0 ~25℃). Long-term storage batteries (more than 3 months) should be placed in an environment with temperature of 25 ±...

  • Page 24: Inspection And Maintenance Before The New Truck Put Into Operation

    Notice No smoking. Arrange the self-protection Wipeout the effusive oil in time. Before adding lubricating oil, clean up the dirty oil or dust on the joint with brush or cloth. Except certain situation, turn off the key switch and pull off the power socket. Lower down the fork arms to the lowest point when carrying out maintenance.
  • Page 25 Clean Cover the lid, and flush with tap water. storage battery Inspect Burnish the coarse surface of contacts using sand paper. contactor after 200 hours(Monthly) Besides the weekly maintenance, the following maintenance should be carried out, and when the parts must be adjusted and replaced, please contact with maintenance personnel of our company.

  • Page 26: Recommended Working Medium

    1200 hours(every six months) During the maintenance for a half year, the maintenance process for three months shall be repeated. When the parts must be adjusted and replaced, please contact with maintenance personnel of our company. Burnish the coarse surface of contacts using sand paper. Contactor Replace according to the status when the function is not well.

  • Page 27: Structure Of Lifting Cylinder And Wearing Parts

    7. Structure of lifting cylinder and wearing parts： 1. Plunger 2. Dust ring DH35 3. O-rings 35.5X2.65 4. O-rings 42X2.65 5.Seal ring UHS35 6. Guide sleeve 7. Hydro-cylinder 8.Piston 9. Rider ring 10. Semi-ring 11.Pad 12. Circlip for shaft 20 8.
  • Page 28 pressure is low Contact maintenance personnel of our Oil pump is damaged company Contact maintenance personnel of our There is malfunction in valve block. company The pipeline is broken or leaking. Replace the pipeline or screw down the tie-in. The viscidity of oil is not suitable; the Change the oil.
  • Page 29 clockwise, the system pressure increases. While the screw is turned counter-clockwise, the system pressure decreases. After the adjustment, please screw down the locknuts. Hydraulic principle diagram...
  • Page 30 9.2 Controller error code a. 1230 controller...
  • Page 31 1311 Display Description Possible causes CODE The speed sensor signal 1 Incorrect or ineffective speed sensor wiring. motor speed encoder can’t be detected. 2 Controller defective. 1 Speed sensor malfunction. 2 The electromagnetic brake of motor is not loosened completely. The motor speed is not in the Motor Failsafe normal scope.
  • Page 32 has expired. Battery Over voltage Battery voltage is too high. Battery voltage is too high. 1 Battery voltage is too low. 4, 2 Battery Under voltage Battery voltage is too low. 2 Corroded battery terminal. 3 Storage battery is damaged. 1 The power of controller is small.
  • Page 33 b．1232 controller Mechanical steering + lead acid battery...
  • Page 34 Mechanical steering + lithium battery...
  • Page 35 EPS+Lead acid battery...
  • Page 36 EPS+ Lithium battery...
  • Page 37 EPS+ Lead acid battery (New EU standard)
  • Page 38 EPS+ Li-ion battery (New EU standard)
  • Page 39 1232/1234/1236/1238 Programmer Fault Diagnosis Menu and Status Display LED Fault Diagnosis Table There are red and yellow LED lights on the controller housing. Different flashing situations represent different failure situations. Seeing below： Lights Flashing Indication Controller is dead, for battery is out of power or a cable Both off fault occurs Yellow light flashes...
  • Page 40 VCL language fails to execute The function of cutback under high temp. takes effect Controller Overtemp Cutback: The controller works in a extreme temp. reduction of driving and braking overloaded torque, Improper installment of the monitor Check the controller temperature under the monitor menu Under normal operation, the battery needs to be charged, and the low-voltage limit function of the controller takes effect.
  • Page 41 Connected load open or short circuit Coil1 Driver Open/Short: Contaminated connection terminals. No output from Coil1 Driver 1. Wire harness damage or wiring error Main connector open or short circuit Main connector Open/Short: coil1 Contaminated connection terminals. driver, electromagnetic brake quit Wire harness damage or wiring error 1.
  • Page 42 Pot Low Over current 1. The combination of potentiometers connected to the low end of Speed governor quit, full braking potentiometers is too low input 2. Check the pot low under the monitor menu EEPROM Failure main contactor, motor Fail to write into EEPROM memory electromagnetic brake, speed...
  • Page 43 main contactor, motor electromagnetic brake, speed governor quit Encoder Characterization Fault: The description of encoder characteristics is wrong in the main contactor, motor encoder description step. electromagnetic brake, speed 2. Pulse frequency of motor encoder is not a standard governor quit value(32,48,64,80ppr) Motor Type Fault: main...
  • Page 44 1.Connecting failure of the battery or the battery wiring Severe 2. There are other large loads connected to Restart KSI Shut Stop Undervoltage the battery 3. The battery is dead or the model is inconsistent 1. In regen, the resistance of battery or Severe Overvoltage battery cable is too high Restart KSI...
  • Page 45 1. Analog command input 1 (J1-6) out of range Command Analog 1 Remain 2. Command low side (j1-14) out of range Restart KSI Stop Out Of Range then Shut (for resistance type) 3. Incorrect parameter setting 1. Analog command input 2 (j1-13) out of range Command Analog 2 Remain...
  • Page 46 1220E-2401 TRACTIO FLAS CLEAR STEER NAME POSSIBLE CAUSE CONDITIO FAULT FAULT CODE ACTION ACTION Controller 1. The steer motor wires shorted. Cycle KSI. Shutdown. 1 = Stop Overcurrent 2. Controller defective. Current Sense 1. Controller defective. Cycle KSI. Shutdown. 1 = Stop Fault Precharge Fault 1.
  • Page 47 Shutdown Bring 1. Excessive load on vehicle. Steering Warning Motor Temp Hot Controller operating Motor and Reduce 2 = Reduce Cutback extreme temperature Current Speed high temperature. backs Limit range. 1. Internal relay coil is broken. Warning Main Driver 2. Internal relay driver is open or Cycle KSI.
  • Page 48 Analog1 Out of range. Shutdown. Range 2. Incorrect parameter settings. 1. Position Analog Input 2 (J3-9) is of range. Feedback 2. The crosscheck on Position Hold then Analog2 Out of Analog Cycle KSI. 1 = Stop Shutdown. Range Input 1 (J3-2) and Position Analog Input 2 (J3-9) failed.
  • Page 49 1. Software defective. Software Fault Cycle KSI. Shutdown. 1 = Stop 2. Controller defective. 1. Communication between the Warning traction PDO1 Timeout Cycle KSI. then 1 = Stop controller and the 1220E has Shutdown. halted. 1. Incorrect parameter settings. Position feedback device Following Error...
  • Page 50 c. AC0 controller Mechanical steering + lead acid battery...
  • Page 51 EPS + lead acid battery...
  • Page 52 Mechanical steering + lithium battery...
  • Page 53 EPS+Lithum battery...

  • Page 54: Inspection Method

    AC0 failure and trouble shooting Display Description Failure Inspection method code wrong config Config failure Clean up EEPROM 1. Check whether the controller plug-in is plugged in properly. watchdog Watchdog failure 2. If the plug-in contacts well, please replace the control and check whether the fault is eliminated.
  • Page 55 error 1. Reset the accelerator; vacc not ok Accelerator failure 2. The accelerator is damaged. Check whether the power supply and ground of the accelerator are connected correctly. If they are Pedal wire ko Accelerator failure connected correctly, please change Change the controller.

  • Page 56: Check Method

    input error#2 Check whether A14 input is normal reset cutback 1 Power manager canbus ko bms communication Check can communication line failure BMS failure description Display Description Failure Check method battery high temp. warning Battery high temperature warning battery high temp. alarm Battery high temperature warning battery leakage warning Battery leakage warning...
  • Page 57 1. The motor is locked; check whether the brake is open and whether there is any foreign matter stuck in the driving mechanism. 2. The controller parameters are not set properly. See motor parameter adjustment for details. Wrong controller selection; or controller failure, contact the Over current of controller manufacturer.
  • Page 58 EEPROM reading and writing Controller fails, contact the manufacturer. parameter error Parameter overrun error If the parameter setting fails, contact the manufacturer. After reset, the key signal is not in the original position (throttle switch, direction switch, lifting / lowering, safety switch). The signal Operation timing error returns to its original position and the alarm is automatically eliminated.
  • Page 59 EPS+ Lead acid battery (New EU standard) EPS +Lithium battery (New EU standard)
  • Page 60 Table 17 AC F2-A Controller Troubleshooting Chart...
  • Page 61 FLAS FAULT NAME POSSIBLE SET/CLEAR (Curtis Integrated FAULT ACTIONS CAUSES CONDITIONS CODE Toolkit™) Controller Overcurrent Controller_Overcurrent_Activ 1. External short of phase U, V, or W 0x2510 Set: ShutdownMotor motor connections. Phase current Fault Type(s): ShutdownMainContact 2. Speed encoder exceeded 1 = Controller Over Current noise problems.
  • Page 62 1. Controller is operating in an extreme Set: environment. Heatsink Controller Severe ShutdownMotor 2. Excessive load temperature Overtemp ShutdownMainContact on vehicle. above +95 Controller_Severe_Overtemp Clear: 3. Improper Bring heatsink ShutdownEMBrake 0x16 mounting of temperature below Active ShutdownThrottle controller. C, and 0x2142 Reset FullBrake...
  • Page 63 menu » Battery » Keyswitch Voltage. 1. Battery parameters are Set: Capacitor bank misadjusted. voltage 2. Battery resistance exceeded the Severe too high for Overvoltage limit with ShutdownMotor Severe B+ Overvoltage given regen current. Severe_B_Plus_Overvoltage_ 3. Battery ShutdownMainContactor bridge enabled. Active ShutdownEMBrake disconnected while...
  • Page 64 ShutdownThrottle 0x2134 frequency and/or are above Fault Type(s): 1 phase current their Travel Control FullBrake detected exceeding Supervision the limit set by the settings when in the Travel Control stopped Supervision state. Clear: Reset Controller. parameter. 2. Misadjusted Travel Control Supervision parameters.
  • Page 65 4. Battery resistance UnderVoltageCutback too high. limit. 5. Battery disconnected while driving. 6. Blown B+ fuse or main contactor did not close. 7. See Programmer » System Monitor menu » Controller » Currents » UnderVoltageCutbac 8. See Programmer » System Monitor menu »...
  • Page 66 menu » Controller » Capacitor Voltage. Set: (1) The 5 V Supply (pin 16) is outside 5 V± 10 % 1. External load Ext 5V Supply Failure (2) The impedance on the Ext_5V_Supply_Failure_Active current is outside limits +5 V supply (pin 16) 0x2531 defined is too low.
  • Page 67 AC Motor Setup » Temperature Sensor. 1. Motor thermistor is not connected properly. 2. sensor polarity (between Pin 9 and Set: Motor thermistor Pin 12) is incorrect. MaxSpeed reduced Motor Temp Sensor input (pin 3. The motor (LOS, Limited Operating Motor_Temp_Sensor_Active 9) is at the voltage rail.
  • Page 68 Controller. Lower Driver See Driver 1 Fault Lower_Driver_Fault_Active 0x35 (page 145) 0x2440 Set: Motor encoder phase failure detected. 1. Motor encoder Clear: Reset Either Encoder Fault failure. Controller , or Encoder_Fault_Active 2. Bad crimps or if parameter LOS Upon 0x2230 faulty wiring.
  • Page 69 ShutdownMainContactor 0x39 Close 1. Main contactor did contactor Main_Contactor_Did_Not_ not close. commanded closed, ShutdownEMBrake Close_Active ShutdownThrottle 2. Main contactor tips FullBrake 0x2221 are oxidized, capacitor bank voltage Fault Type(s): burned, or not 1 = Main did not close when making good connection terminal) commanded contact.
  • Page 70 Controller 3. See Programmer » Controller Setup » Analog Inputs » Configure. Set: Controller ShutdownMotor operating ShutdownMainContactor system tried to read or NV Memory Failure ShutdownEMBrake write to NV_Memory_Failure_Active ShutdownThrottle 1. Failure to read or EEPROM memory and 0x2830 write to failed.
  • Page 71 Emer_Rev_Hpd_Active 0x47 Reverse operation ShutdownEMBrake 0x2331 Emergency Reverse, Fault Type(s): 1 concluded, but the the fault throttle, forward was set because and reverse inputs, various inputs and interlock were not returned to have not been neutral. Clear: returned to neutral. If EMR_Interlock = On, clear the interlock,...
  • Page 72 implemented in the application-specific VCL software. 2. See User/OEM documentation. 1. Runtime errors are defined using the VCL Error Module Set: VCL Run Time ShutdownMotor and VCL Error Error. See the ShutdownMainContactor detected ShutdownEMBrake System Information Clear: Edit VCL ShutdownThrottle file: application ShutdownInterlock...

  • Page 73: Internal Hardware

    » System Monitor Stall menu » AC Motor » Detected fault is Motor RPM. cleared and the Encoder LOS fault (flash code 9-3) is set, allowing limited motor control. ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle Supervision ShutdownInterlock Supervision_Active Set: Internal controller ShutdownDriver1 1.
  • Page 74 ShutdownEMBrake 0x2835 detected. Fault Type(s): Curtis hardware Clear: Reset Controller. ShutdownThrottle FullBrake code Motor Characterization Error Motor_Characterization_Active 0x2850 Fault Type(s): 71 Failure to write NV ram 72 Temp sensor fault 73 Motor hot 74 Controller temperature cutback 76 Undervoltage cutback 77 Overvoltage cutback 78 No encoder information 79 Current Regulator Tuning out...
  • Page 75 settings: AC Encoder Motor Setup » Steps parameter Quadrature Encoder matches » Encoder Steps. the actual encoder; Reset 3. Motor lost IFO Controller. control and accelerated without throttle command. Parameter Out of Range 1. Parameter value Set: Parameter Parameter_Out_Of_Range_ ShutdownMotor detected outside detected Active...
  • Page 76 type 1). Set: Encoder Fault (flash code 3-6) or Stall Detected (flash code 7-3) was activated, if parameter LOS Upon 1. Limited Operating Encoder Strategy (LOS) Fault = On and control mode has Interlock has been activated; been cycled, then the as a result of either Encoder an Encoder...
  • Page 77 2 = Motor Tech = SPMSM, enabled in torque Speed Mode Express or Feedback = Encoder mode. Speed 3 = Motor Tech = ACIM, 3. Dual drive enabled Mode; otherwise this Feedback = Sin/Cos on only one fault is controller. set.
  • Page 78 Reverse by the Emergency Supervision Reverse parameters. Supervision 2. See Programmer » parameters. Clear: Reset Controller. Application Setup » Emergency Reverse » Emergency Reverse Supervision. 1. Open or short on driver load. 2. Dirty connector Driver 1 Fault pins at controller Driver_1_Fault_Active Set: or contactor coil.
  • Page 79 Fault Type(s): pins at controller exceeded 1 = Driver Short or contactor coil. its overcurrent setting. Clear: 2 = Driver Overcurrent 3. Bad connector Correct open or 3 = Open/Short (High, should crimps or faulty short, Reset be Low) wiring. and then Controller.
  • Page 80 Driver 5 » Driver 5 Overcurrent. 1. A Driver Output is used for two or more functions. Set: 2. See Programmer » Driver assignment Driver Assignment Controller conflict Driver_Assignment_Active Clear: Setup » IO Resolve the ShutdownDriver{X} 10-8 0x2632 Assignments » Coil conflicted (Driver in 0xA8...

  • Page 81: Storage, Transportation And Loading Of The Truck

    ANALOG 6 OUT OF RANGE None, unless a fault 11-6 See Analog 1 Out of See Analog 1 Out of Analog_6_Out_Of_Range action 0xB6 Range. Range 0x2625 is programmed in VCL. VII. Storage, transportation and loading of the truck 1. Loading and unloading of the truck: Before loading the truck, check out the nameplate for the total weight of truck to choose appropriate hoisting handling equipment.
  • Page 82 Appendix I CBDR Electric Pallet Truck packing list Consignee： manufacturing number： contract number： date of production： Serial Cargo name Numb Net (kg) contour Remark numbe er of dimension(L× W× H) units Electric Pallet Truck Complete machine Technical documents, Accessory bag accessories and spare parts Note：1．The following documents are in the file bag...
  • Page 83 Fuse Electrical equipment Fuse Electrical equipment 180A seal ring UHS35 Hydro-cylinder 35X45X6 O-seal ring Hydro-cylinder 35.5× 2.65 O-seal ring Hydro-cylinder 45× 2.65 Dust ring DH35 Hydro-cylinder DH35 on-board Charging cable Charger charger AC0 controller Use part Specification Quantity Remark Designation Electric lock key Open the electric lock external...

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