1. Manuals
  2. Brands
  3. Noblelift Manuals
  4. Forklifts
  5. FE4P25-35Q Series
  6. Service manual

Noblelift FE4P25-35Q Series Service Manual

Battery balanced forklift
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
WARNING
Do not use the forklift before reading and
understanding the operating instructions
as well as the waring decals on the truck.
Keep for future reference.
FE4P25-35Q series-SM-003-2023-EN
Service Manual
FE4P25-35Q series battery balanced forklift
A

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the FE4P25-35Q Series and is the answer not in the manual?

Questions and answers

Related Manuals for Noblelift FE4P25-35Q Series

Summary of Contents for Noblelift FE4P25-35Q Series

  • Page 1 WARNING Do not use the forklift before reading and understanding the operating instructions as well as the waring decals on the truck. Keep for future reference. FE4P25-35Q series-SM-003-2023-EN Service Manual FE4P25-35Q series battery balanced forklift...

  • Page 2: Table Of Contents

    1.In General ..................................... 2 1-1 How to use this manual ............................... 2 1-2 Glossary ..................................3 1-3 Performance and Specifications ..........................6 1-4 Safety Notes ................................14 1-5 Maintenance ................................21 1-6 Lube ..................................24 1-7 Instructions of Disassembly/Assembly ........................25 1-8 Standard Torque ................................
  • Page 3 4-2. Drive motor ................................95 4-2-1 How to run it ..............................95 4-2-2 Test of drive motor ............................97 4-2-3 Removal / installation of drive wheel ......................98 4-3. Drive axle ................................. 99 4-3-1 Appearance and specifications ........................99 4-3-2 How to operate ............................. 101 4-3-3 Drive gear oil replacement ...........................
  • Page 4 5-5. Troubleshooting ..............................141 5-5-1 Pump motor ..............................141 5-5-2 Main hydraulic pump ........................... 142 6. Lifting/tilting/auxiliary system ............................143 6-1. Overview ................................143 6-2. How to operate ............................... 143 6-3. Fork service ................................145 6-4. Side-shifter service ..............................147 6-5.

  • Page 5: In General

    1.In General 1-1 How to use this manual 1-1-1 Composition of this manual This service manual mainly provides engineers and technicians service information for forklift repair and maintenance, which excludes vehicle operation instructions. The introduction section of this manual introduces the functions of the vehicle with attention to its different components.

  • Page 6: Glossary

    1-1-2 Definitions of Warning Signs The following three warning signs are applicable to this Manual: "Danger", "Warning" and "Caution". Each label is intended to indicate the severity and nature of the potential hazard, the consequences, as well as preventive measures against hazards. You will find these signs throughout this manual.
  • Page 7 the negative (-) side. This can be obtained with wires and electrical components. Connector A part of a wire assembly or harness wired to another wire assembly or harness to for an easier Disassembly and Assembly operation. Co-contactor A switch, relay, or part of a contactor that opens or closes a circuit. Components An electrical element consisting of an electromagnetic coil and a set of heavy Co-contactor...
  • Page 8 Fixture A fitting o secure an assembly consisting of two or more wires. Radiator A mounting frame for cooling semiconductors. Hydraulic System A hydraulic element circuit to convey oil pressure. Hydraulic Oil Tank A chamber for the oil storage in a hydraulic system. Mandatory Sign A symbol indicating the state of a vehicle when it is on or flashing.
  • Page 9 Service Brake A pair of brakes built into the drive shaft to enable the vehicle when the operator applies the pedal for stationary Short Circuit An unwanted electrical connection between two or more components. Side Shifter An accessory that moves the fork and its load to the left and right Socket The male contact of the connector which slides over the male contact of the other connector (pin).

  • Page 10: Performance And Specifications

    1-3 Performance and Specifications...
  • Page 11 a. FE4P25Q-Technical data (list 1-1) Item Unit Model Manufacturer's type designation FE4P25Q FE4P25QM FE4P25QH Drive: electric(battery or mains),diesel, Electric petrol gas, manual) Type of operation(hand, pedestrian, standing, Seated seated, order-picker) Load capacity/rated load Q(kg) 2500 2500 2500 Load centre distance C(mm) Load distance, centre of drive axle to fork x(mm)
  • Page 12 Max. Gradient performance, laden/unladen 15/15 20/25 20/28 Service brake Hydraulic Drive motor rating S 60 min Lift motor rating at S Battery standard Lion Lion Lion 76.8/277 76.8/206 Battery voltage, nominal capacity K V/Ah 76.8/412/554 76.8/277/412/554(option) (option) Battery weight Battery dimensions l/w/h 770/600/680 770/600/680 Type of drive control...
  • Page 13 4.10 Length to face of forks l2(mm) 2593 2593 2593 4.11 Overall width b1(mm) 1150 1150 1150 4.12 Fork dimensions s/e/l(mm) 45/125/1070 Fork carriage DIN15173 - ISO2328, class/type 4.13 ISO2328 3A 4.14 Fork carriage width b3(mm) 1100 1100 1100 4.15 Ground clearance ,laden, under mast m1(mm) 4.16...
  • Page 14 Type: solid rubber, superelastic, pneumatic, Pneumatic polyurethane Tyres size, front 28×9-15-14PR Tyres size, rear 6.50-10-10PR Wheels, number front/rear(×=driven wheels) 2×/2 2×/2 2×/2 Track width, front b10(mm) 1004 1004 1004 Track width, rear b11(mm) α/β(°) Mast/fork carriage tilt forward/backward 6/10 6/10 6/10 lowered mast height h1(mm)
  • Page 15 d. FE4P35Q-Technical data (list 1-4) Item Unit Model Manufacturer's type designation FE4P35Q FE4P35QM FE4P35QH Drive: electric(battery or mains),diesel, petrol gas, Electric manual) Type of operation(hand, pedestrian, standing, Seated seated, order-picker) Load capacity/rated load Q(kg) 3500 3500 3500 Load centre distance C(mm) Load distance, centre of drive axle to fork x(mm)
  • Page 16 ＜0.6 ＜0.6 ＜0.6 lowering speed, laden/unladen 13000/1400 Max. drawbar pull ,laden/unladen 17000/18000 17000/18000 Max. Gradient performance, laden/unladen 15/15 20/25 20/28 Service brake Hydraulic Hydraulic Hydraulic Drive motor rating S 60 min Lift motor rating at S Battery standard Lion Lion Lion 76.8/277 Battery voltage, nominal capacity K...

  • Page 17: Safety Notes

    1-4 Safety Notes The following safety sections contains the following subsections: general, personal safety, maintenance safety, compressed air hazards, hydraulic oil hazards, mechanical hazards, electrical hazards, and fire & burning hazards. Each heading is attached with the precautions you should take for your safety while working in your vehicle. Readers are advised with responsibility to read this manual thoroughly, and understand and follow all the following precautions.

  • Page 18: Personal Safety

    Personal Safety Do not operate or service a vehicle without authorization or training. Do not operate or service a vehicle after alcohol or drugs taking which will impair your judgement. If you have any disease or condition that restricts physical activity, please do not operate or service the vehicle.
  • Page 19 Make sure that the vehicle is empty and unoccupied, the cargo forks are lowered, all the hydraulic controls are in neutral position and the key is switched to OFF. Place a "do not operate" or similar warning signs to the start switch or the controller before repairing or servicing the forklift.
  • Page 20 Ensure all chains, hooks, slings and the like are in good condition and in correct capacity. Make sure the hook is positioned correctly. Lifting ring bolts should not be loaded laterally during lifting operation. Disassembly/Assembly Make sure that the assembly/disassembly site is kept clean and dry and that hand tools are kept clean.
  • Page 21 Hazard of Hydraulic Oil Please follow the following safety instructions for hydraulic system maintenance carefully. Oil removal under pressure, even if the pinhole size leaks, can penetrate the body elements and cause serious damage and possibly death. Please wear gloves, goggles, and make sure that your arms and legs are completely covered.
  • Page 22 Mechanical Hazards Keep all the objects away from the fan blades, or they will throw or cut any object or tool that falls or is pushed in. Do not operate the machine when any rotating parts are damaged and do not touch any other parts during the operation.
  • Page 23 Fire and Burning Hazards Attention shall be paid to the hot parts on the machine that has just stopped and to the hot oil in the pipes and compartments to avoid scalding. All hydraulic oils, many lubricants and some coolant mixtures are flammable. If the pipe is loose or damaged, there may be a fire.

  • Page 24: Maintenance

    1-5 Maintenance The following provides the key items and replaceable components to be checked during maintenance intervals. Note: all maintenance and repair should be carried out by a qualified authorized engineer except for the routine inspection of the vehicle driver. Note: careless disposal of waste oil is not only harmful to the environment, but also to human health.
  • Page 25 Check per 10 service hours or daily Item Inspection Standards and Methods Travel system Check for loose parts and fasteners. Check the dashboard indicator light for abnormalities. Check that the horn and other alarms are functioning properly. Check mast and hoist chains for wear and abnormal pins/rollers. Check the gear rack, forks and attachments for damage and abnormalities.
  • Page 26 Inspection per 500 service hours or 3 months Item Inspection Standards and Methods Tilt cylinder Lubricate chassis and mast pivot bolt fittings. Check the pins for loose retaining bolts or wear. Measure and adjust cylinder rod extension (max. 3.18 mm / 0.13 in) Standard bolt tightening torque: 95±...

  • Page 27: Lube

    1-6 Lube The following is a detailed description of the lubricant as required and the parts to be lubricated. Lubricating Oil Specification The following lubricants are recommended for chains and connecting rods: Item Specification DIN 51825 Standard Oil and Grease Hydraulic Oil（HYDO）...

  • Page 28: Instructions Of Disassembly/Assembly

    Note: Multi-stage oil mixing is not allowed for transmissions. Multi-stage oil with high molecular weight polymers as vi improvers lose their viscosity effectiveness due to the permanent and temporary shear of vi improvers and hence are not recommended for use in drives and compartments of drive system.
  • Page 29 Check and test before disassembly Be sure to record any problems before starting the disassembly, which can prevents unnecessary disassembly, loss of replacement parts, and repeated failures as caused by the same problem. To prevent failures, record failures and replace required parts are required. The following information shall be also checked and recorded: Vehicle model number, serial number and operation hours Reasons of the vehicle needs to be dismantled...
  • Page 30 Store bolts, nuts and other common parts in an orderly manner. Check and test in disassembly The cause of the fault is sometimes found in the process of disassembly. Therefore, it is important to carefully examine the condition of the friction surfaces and the contact parts. During disassembly, gaps, deformations, projections and other factors that may cause failures shall be measured and recorded.
  • Page 31 When using dangerous chemical cleaners, be careful to avoid a skin or eye contact. Used oil should be disposed of in designated containers at designated locations. Dust proof A dust cover is advised to keep cleaned parts free of dust and contaminants and to block up the ends of all pipes.
  • Page 32 Fix the bolts, nuts or other important fasteners that cannot be visually inspected with wires, cotter pins, lock washers or other components as shown in figure 1-20. Figure 1-19 Figure 1-20 Assembly Inspection At each step of the assembly process, each part's number shall be checked and recorded. Reassemble the gaskets Install the gasket and washer in the same position as before, and then check the gap for correctness.
  • Page 33 Assemble keys and keyways Check if the keyway and key are loose and in contact with the key head. If the key head touches the keyway, then the rest of the key head shall be removed. Handling the general part Handling the packaging Packing, as well as gaskets &copper packing should be replaced as instructed.
  • Page 34 The O-rings shall be lubricated to avoid surface scratching during installation. Silicone rubber O rings are prone to damage hence attention is required to avoid overstretch. Handling the oil seal Oil seals shall be prevented from dust sedimentation, especially on the lips, and there shall be no rust or scratch.
  • Page 35 Do not over-turn the bearing to remove the purifier by compressed air. The oil seal ring shall be installed in the correct direction. Please note the following when installing the bearing. Neither hit the outer ring with a hammer for installation, nor hit the inner ring to insert the outer ring.
  • Page 36 8. Inspect the hose during tool movement. Make sure that the hoses do not contact any machines or other hose. 9. Shut off the motor 10. If necessary, place the hose in a new position so that it will not touch the position when moving the tool.
  • Page 37 Tighten accessories of other types Pipe fittings (shear sleeve) of high load: please turn the nut with a wrench until a slight reduction in torque is felt after the pipe passes through the nut and touches the shoulder in the fitting body, which indicates that the sleeve has been removed from the nut High seal fittings: place the nut and sleeve on the pipes with the short end of the sleeve toward the end of the pipes.

  • Page 38: Standard Torque

    1-8 Standard Torque 1-8-1. Standard torque of bolts and nuts Be careful that the metric and British size fasteners shall not be mixed in used. Mismatched or incorrect fasteners may cause damages or malfunctions to the vehicle or personal injuries. Exceptions to these torques may be provided in the service manual if required.
  • Page 39 For metric fasten...

  • Page 40: Standard Torques For Fastening Fittings

    1-8-2. Standard torques for fastening fittings Standard torques for O-ring surface seal fittings Fig 1-32 Fig 1-33...
  • Page 42 Thread fittings for conical pipes...

  • Page 43: Electric Control System

    2.Electric control system 2-1. Overview The electric system of the FE4P25-35Q series electric forklift truck is powered by a 76.8V lithium battery pack. The traction power of the vehicle is provided by an AC motor. The lifting power of goods is driven by AC motor oil pump to produce oil pressure, and then by hydraulic pipeline through the hydraulic cylinder on both sides of the door frame to achieve the lifting, tilt and side movement of cargo fork.

  • Page 44: Emergency Stop Button

    2-2. Emergency Stop Button 2-2-1. Appearance and Specifications Item Specification Emergency Stop Switch CE4T-10R-01 2-2-2. Function The emergency switch is used to shut off the current in the electrical system in case of emergency, and thereby stopping the operation of the vehicle. When pressed the key, all DC and AC circuits are open except the speaker circuit.

  • Page 45: Controller And Related Equipment

    2-3. Controller and Related Equipment 2-3-1. Appearance and Specifications Controller assembly Inmotion controller Technical specifications Description Specification Serial Description Specification Number PWM Working frequency 10KHZ Accelerator control 2 lines of 0-5KΩ/5KΩ-0, 3 lines of signal potentiometer, 0-5V, current source, electron accelerator Insulation strength with radiator >500Vac Speed control type...

  • Page 46: Circuit, Functions And Circuit Diagram

    2-3-2. Circuit, Functions and Circuit Diagram Circuit Diagram of Inmotion Controller...
  • Page 47 Critical Power Supply of controller This model is equipped with a drive motor and a pump motor, which are controlled by different controllers. The forklift is powered by the controllers through key switches and then turned on. Current to the contactor of the line Power supply of controller. Once the controller is energized, a magnetic coil built into the line contactor will receive power from the driven motor controller.
  • Page 48 These devices provide DC power and interact with controllers that activate or receive data based on a number of parameter settings to control the motor. The two motor controllers are identical to hardware, but each controller is programmed with different types of firmware to achieve different functions. The safety &...
  • Page 49 4.Slope anti-backward slip function. The electric forklift with AC traction motor has the excellent function of staying non-slip on the slope. 5.The maximum driving speed is adjustable. Reasonable setting on maximum driving speed of electric forklift can prevent any overloading of traction motor due to high speed. 6.Static reply switch off.

  • Page 50: Test

    2-3-3. Test A. Controller The diode voltage of AC MOSFET circuit inside the controller shall be tested and checked for any burn out damage. According to the table below, each test item shall be tested repeatedly for more than 3 times. Item Multi-meter terminals Range of normal value...
  • Page 51 B. Line contactor and fuse Figure 2-22 Line contactors Circuit fuse Figure 2-23 For circuit contactor and fuses, an ohmmeter shall be connected at the point shown in the figure and shall be tested for the specified value.

  • Page 52: Disassembly And Installation

    2-3-4. Disassembly and Installation Access to control panel 1. Disconnect the battery connector. 2. Keep the key switch open to discharge the power module. Twice for 30 seconds. 3. Close the key switch 4. Remove the top cover (1) to enter the drive motor controller and the pump motor controller.
  • Page 53 Disassembly/installation of pump motor controller 1．Disconnect the control harness from the controller connectors 2．Disconnect U, V and W cables. Tightening torque：9.5± 1 N· m（7.0± 0.7 lb· ft） 3．Remove B+ and B- wires from the pump motor controller 4．Loosen and remove the pump motor controller 5．Perform the above steps in reverse order to install the pump motor controller Disassembly/installation of circuit contactor 1．Disconnect the cable from both terminals.

  • Page 54: Miscellaneous Load

    2-4. Miscellaneous Load 2-4-1. Fuse holder A. Function and composition To protect DC load from overcurrent, equipped with the fuse box as the following shown. B. Disassembly and Installation Preliminary steps 1.Close the key switch 2.Disconnect the battery connector. 3.Remove the cover. Steps 1.Disconnect the two harness connections from the fuse box.

  • Page 55: Dc-Dc Convertor

    2-4-2. DC-DC Convertor A. Appearance and Specifications Item Specification Maximum power IN 300W Input voltage DC 80V Output voltage DC 24V B. Circuits and Functions The DC-DC converter power supply (80V/) into a 24V power supply, which is suitable for various loads.

  • Page 56: Lamp Bank

    The functions of each terminal are as follows: 1.The INPUT terminal receives power from the battery to activate the DC-DC converter. 2.Collect the OUPUT terminal with green（24V+), which overrides the load supplied from the converter and then passes the fuse box to the load. The terminal overrides the load supplied from the converter and then passes the fuse box to the load.

  • Page 57: Display Panel

    2-5. Display panel 2-5-1. Display introduction A new type of combination display is adopted to realize auxiliary control function and provide driver's vehicle condition display interface. It consists of control circuit, accumulated time counter (LCD), battery power meter, fault code display and other display circuits. According to the current demand of electric vehicles, this display has made a new design in the control circuit and display form, which can provide intuitive vehicle status information for drivers, with compact structure, beautiful appearance, high degree of automation and reliable quality.
  • Page 58 Key functions Icon Name Function Move the cursor up or add 1 to the selected number; Up key Switch S mode (tortoise speed mode) on the main interface; When entering a password, it represents 1; Move the cursor to the left; Switch P mode on the main interface; When Left shift key entering a password, it represents 3 Move the cursor to the right;...
  • Page 59 Display content of startup interface Interface display Function description Battery power and value Display battery power range 0-100%; The icon is red when the battery level is 0-9, yellow when the battery level is 10-19, green when the battery level is 20-100 in lead acid mode, and blue when the battery level is in li-battery mode (the battery level alarm value is 20 in lead acid mode, and 21 in lithium mode).

  • Page 60: Menu Functions

    2-5-3. Menu functions a. Switch monitoring display content SW MONITOR Function Description Seat SW Displays the status of the seat switch, with 0 representing open and 1 representing closed Forward SW Displays the forward gear switch status, with 0 representing open and 1 representing closed Reverse SW Displays the status of the reverse gear switch, with 0 representing open and 1 representing closed...
  • Page 61 b. Operation monitoring display content OPERATE MONITOR Function Description Key On Hour Display the startup and operation time of the traction controller T. Enable Hour Display the running time of the traction controller P. Enable Hour Display the operating time of the oil pump controller Steer Pot Val Display the steering analog AD sampling value, which can be used to check whether the steering potentiometer signal is normal...
  • Page 62 c. Temperature monitoring display content TEMP MONITOR Function Description T.M. Temp Display the current traction motor temperature T.ACS. Temp Display the current traction drive temperature P.M. Temp Display the current pump motor temperature P.ACS. Temp Displays the current pump driver temperature Left M.
  • Page 63 e. Traction setting display content T.M. SET Function Description T.E. Max Speed Traction max speed for E running mode. T.E. Acc Traction max acceleration for E running mode T.REDU. Brake The braking rate when the accelerator is not released. The higher the value, the stronger the braking effect T.NEU.
  • Page 64 f. Pump setting display content P.M. SET Function Description P. Max Speed Pump drive max speed P. Lift Accel Pump drive max acceleration，The higher the value, the stronger the acceleration effect P. Lift Speed Set the maximum rotational speed for lifting. The higher the value, the faster the lifting speed P.
  • Page 65 g. Battery settings display content BDI SET Function Description The BDI value. Bat. Voltage Displays the battery voltage detected by the controller BDI.Reset SW not used BDI.Reset Vol When the battery voltage exceeds the reset voltage value and the battery power is lower than 70%, the battery power is reset to 100% Bat.Full SW not used...
  • Page 66 h. Steering setting display content STEER SET Function Description Steer Lim Speed On Activate the turn speed limit function Steer Min Lim Scale Speed ratio during cornering Steer Pot Active High Maximum effective value of steering analog quantity, used for steering potentiometer calibration Steer Pot Active Low Steering analog minimum effective value, used for steering potentiometer...
  • Page 67 i. Other settings display content Other set Function Description Language Set Chinese and English language selection Store Para Write a value of 1 to save the modified parameters Restore Para Write a value of 1 and restore to the factory default value Version Display instrument software version information T.C.

  • Page 68: Jiachen Hdu 1296

    2-6. Jiachen HDU 1296 2-6-1. Function introduction The Handheld Unit is a powerful and intuitive programming and diagnostic tool that can monitor and modify controller parameters online, allows users to save parameter files online, saves the parameter files to the Handheld Unit or an external USB storage device, and sends the edited parameter files to the motor controller when online.
  • Page 69 The schematic diagram of the interface pin number: The interface pin definition: Pin number Description Pin number Description CAN_L CAN_H The Handheld Unit uses silicone buttons, a total of 13 buttons, which are up, down, left, right, increase, decrease, F1~F3 function buttons, power button, favorites button, home button, and help button. Function buttons: F1~F3 function buttons, Correspond to the content at the bottom of the screen, this button is invalid when there is no content;...

  • Page 70: Function Description

    Under AA battery power supply: 1) When the Handheld Unit is running, press the power button on any interface for 3s, the Handheld Unit will shut down; 2) After the Handheld Unit is turned off, press the power button for 1 second, and it will restart to run. Favorites button: This button is another way to quickly start the application.

  • Page 71: System Information

    Description of the main interface content Parameter name Description Battery level When the battery level is low, an empty battery icon appears; Connection status Display CAN communication status. When the device receives CAN data, it displays CAN ; when the device does not receive CAN data for 1 s over time, it displays CAN ;...

  • Page 72: Parameter Setting

    Parameter setting Select the "Parameters" function icon in the main interface and press the "F3" key to enter the parameter setting sub -interface; the parameter setting sub -interface is divided into Tract Set and Pump Set, which are allocated according to the index address and sub -index of the CAN open protocol; total Tract Set parameters 292 items, a total of 220 items for Pump Set parameters;...

  • Page 73: Parameter Monitoring

    2-6-4. Parameter monitoring Select the "Monitor" function icon on the main interface. The sub -interfaces are divided into Traction Monitor and Pump Monitor, which are allocated according to the index address and sub -index of the CANopen protocol; there are a total of 97 entries for Traction Monitor parameters, and a total of 51 entries for Pump Monitor parameters;...
  • Page 74 Programming Select the "Program" function icon in the main interface, you can save the parameters of the electronic control as a “para” file, or restore the parameters in the “para” file to the electronic control. (Note: The “original. para” file stored in the device is a parameter export protocol file, please do not delete it.) Programming -parameter export interface Programming -parameter import interface...

  • Page 75: System Settings

    System Settings Select the "System Set" function icon in the main interface to set the current backlight brightness, communication mode (RS232 or CAN), USB mode and system language and other local settings. a) Backlight brightness: adjust between 10~100, press the corresponding "+" and " -" keys, the value will increase or decrease correspondingly;...

  • Page 76: Connection Port

    2-6-6. Connection port The connection port to the handheld unit is shown in the figures as below.

  • Page 77: Controller Fault Table Diagnostics And Troubleshooting

    2-7. Controller fault table diagnostics and troubleshooting Inmotion system Code display on Troubleshoot Fault cause instrument Incorrect start Accelerator pedal switch Release pedal switch active before key on Incorrect start Forward switch or reverse Turn off the direction switch switch active before key on Forward switch and reverse switch active Direction switch fault at the same time...
  • Page 78 Traction controller temperature is high Traction controller temperature is high alarm Traction controller temperature sensor Traction controller temperature sensor fault fault 1. Traction motor temperature is low Traction motor temperature is low 2. Traction motor temperature sensor is fault 1. Traction motor temperature is high Traction motor temperature is high 2.
  • Page 79 Traction motor temperature sensor or Internal power supply error speed sensor connection wire is open Pump controller temperature is low Pump controller temperature is low alarm Pump controller temperature is high Pump controller temperature is high Pump controller temperature sensor fault Pump controller temperature sensor fault 1.
  • Page 80 BMS CAN bus Off The BMS CAN communicate incorrectly BMS over temperature protection BMS over temperature protection BMS CAN Error BMS CAN Error HPG CONTROLLER INCORRECT HPG controller incorrect start START Check display and controller CAN DISPLAY CAN FAULT connection...

  • Page 81: Battery

    3.Battery 3-1. Appearance and Specifications Item Battery system parameters Remark Cell model LiFePO4 Rated voltage 76.8V Operating voltage N=24 2.5V*N～3.65V*N Standard charging current 0.5C Standard discharging current 200A Maximum discharging current 400A/5s ≤0℃ Start heating, > 5℃ stop heating Heating Option Natural cooling Cooling mode...

  • Page 82: Battery Internal Parts

    3-2. Battery internal parts The parts of lithium battery Name QTY Remark DCDC Antenna LED metal indicator Buzzer The software varies according to the capacity BMS(A555-G) Gold resistor Current divider Relay(400A)(discharge) Vehicle communication socket High voltage discharge socket Discharge cable assembly -30G lifting Charging communication socket High voltage charging socket Relay(300A)(recharge)

  • Page 83: Introduction Of Lithium Battery Port

    3.3. Introduction of lithium battery port The charging and discharging port description...

  • Page 84: Lithium Battery Fault Analysis And Description

    3-4. Lithium battery fault analysis and description Fault repair list of battery pack system Fault type Preliminary Test method Failure confirmation Countermeasure estimate 1. If the resistance is measured to be infinite, the the CAN communication wire harness is indicated as disconnected.
  • Page 85 Before replacing the fuse, check whether there is a short circuit 1. Remove the battery box cover and between the high pressure box cover, check positive and whether the fuse is normal (in the case negative discharge of shutdown, select the lead file of the of the locomotive multi-meter and use the meter pen to Broken fuse...
  • Page 86 indicator System 2. Check if the 12V charging socket Replace the cable Wire harness is not light of the internal harness , and GND harness are harness of the working properly battery pack components normal charging socket is not on are damaged 3.

  • Page 87: Disassembly And Installation

    3-5. Disassembly and Installation When installing and replacing lithium batteries, they shall be fixed reliably and shall not be overturned; It is forbidden to knock the pole post and lead clamp; Strong impact shall be avoided during handling. 1. Open side panels on both sides 2.

  • Page 88: Drive / Brake System

    4.Drive / Brake System 4-1. Overview 4-1-1 Drive system Name QTY Remark Drive axle(AQ) 30-35 Drive axle(AQ) 25-28 Seal washer Gear box (ZN) FE4P25-35Q Gear box (ZN) FE4P25-35QM/H Dowel pin GB119.2-10x24 Washer GB97.1-12-200HV Washer GB93-12 Bolt GB5786-M12x1.5x45-8.8 Nut GB6178-M20-8 Washer GB97.1-14-200HV Washer GB93-14 Bolt GB5785-M14x1.5x160-8.8 Split pin GB91-4x40...

  • Page 89: Drive Motor

    The drive/brake system consists of the followings: 1 The drive motor regulated by the respective controller transmits the rotating force to the drive shaft (electric mechanical power). 2 The drive shaft converts the rotational force transmitted from the drive motor into torque and speed suitable for driving through its gear set and sends them to the corresponding wheels (mechanical power).

  • Page 90: Test Of Drive Motor

    The cycle occurs again and the magnetic flux has a waveform that generates a voltage pulse. The controller analyzes the amplitude of the pulse to calculate the speed of the motor. The smaller the amplitude, the higher the speed of the motor. Like other sensors, the encoder generates a main signal (signal A) and a reference signal (signal B) through two hole sensors.

  • Page 91: Removal / Installation Of Drive Wheel

    Removal / installation of drive wheel 4-2-3 1.Place a jack or block of wood under the forklift to empty the wheel and loosen the nuts. 2.Remove the nuts and the drive tire. 3.Perform the above steps in reverse order to install the drive wheels. Wheel nut tightening torque (FE4P25-35Q) Front wheel：...

  • Page 92: Drive Axle

    4-3. Drive axle 4-3-1 Appearance and specifications Name QTY. Remark 25-28 Cone nut - 24354-32311B 25-28 Column bolt - 24353-72001B 25-28 Bearing 33012 25-28 Hub-A20A3-02011JXX 25-28 Bearing 30214 25-28 Oil seal retaining ring - 24453-02121G 25-28 Oil seal 100X1125X12-Z6351-01004 25-28 Brake hub - 22673-02031 25-28 Nut M20X1.5-B4223-00020B...
  • Page 93 Name QTY. Remark Half-shaft bolt - 24453-02061B 30-35 Half shaft - A22J3-02011 30-35 Gasket - A22A3-02031 30-35 Round nut M58X2-25555-00004 30-35 Stop washer 58-25555-00006 30-35 Bushing 60X75X10-24453-02121G 30-35 O-ring 59.6X2.4-2555-00008 30-35 Brake bolt - 25953-72001 30-35 Brake bolt - A22A3-02051 30-35 Right brake assembly - AXQ-Q03E5-1520R 30-35...

  • Page 94: How To Operate

    The drive axle has the advantages of reasonable design structure, reliable performance and long service life. The axle housing is made of cast steel with good rigidity and large bearing capacity. See the table below. Main Technical Parameters Type of truck FE4P25-28Q FE4P30-35Q Drive axle structure type...

  • Page 95: Braking Function

    Braking function Once the brake pedal is pressed, brake oil is injected into the drive shaft through the master cylinder to push the piston. Then, the pushed piston compresses the friction disc and the steel disc overlapped with each other; There is friction between them. Thus, the friction disc loses its rotating power.

  • Page 96: Accelerator

    4-4. Accelerator 4-4-1 Appearance and specifications Plug-in definition Color Power supply + 12V - + 80V Signal output, 0-10V Green Ground wire 1 Black COM (common) White Idle switch signal Blue None 4-4-2 How does it work Electric vehicle is powered by a drive motor. As a result, the accelerator that determines the vehicle's travel speed is connected to the drive motor controller.

  • Page 97: Disassembly And Installation

    4-4-3 Disassembly and installation Preliminary steps 1.Turn off the key switch. 2.Remove floor covering mat Process 1.Lift the base plate slightly and perform the following steps: 2.Remove the accelerator pedal connector from the main harness. 3.Loosen the three sets of bolts and nuts and remove the accelerator. 4.Perform the above steps in reverse order to reinstall the accelerator pedal.

  • Page 98: How Does It Work

    4-5-2 How does it work The combination switch is a combination of direction switch, turn light switch and large and small light switch. 1. F/R direction switch 2. Turn light switch 3. Large and small light switch The direction switch controls the driving direction of the vehicle and transmits the signal to the display for display.
  • Page 99 Rear headlamp switch The rear headlamp switch is a single gear switch, which controls the lighting and extinguishing of the rear headlamp. Pull up and light up the rear headlamp, and push down to extinguish the rear headlamp. The F/ R direction switch (forward/ reverse) is used to enable the operator to use the connection to the F/R combination switch to select the driving direction of the vehicle.

  • Page 100: Brake System

    4-6. Brake system 4-6-1 Overview The brake system is composed of brake pedal, brake master cylinder and wheel brake, which is the internal expansion oil pressure type of the front two wheels braking. 4-6-2 Brake pedal The structure of the brake pedal is as shown in the figure. The pedal converts the pedal force acting on the pedal into the brake oil pressure through the push rod of the brake master cylinder.

  • Page 101: Brake Master Cylinder

    4-6-3 Brake master cylinder The master cylinder consists of a valve seat, a check valve, a return spring, a main cup, a piston and an auxiliary cup. The end is fixed with stop washer and stop steel wire, and the outside is protected by rubber dust cover.

  • Page 102: Brake

    1.Lock nut 2.Push rod 3.Dust cover. 4.Lock wire 5.Lock washer 6.Auxiliary seal cup 7.Piston. 8.Main seal cup 9.Spring. 10.Check valve 11.Seat. 12.Pump body Figure Brake master cylinder 4-6-4 Brake The brake is a double shoe brake, which is installed on both sides of the drive axle. The brake consists of two sets of brake shoes, brake cylinder and regulator.
  • Page 103 Brake(25-28) Name Remark Brake base plate assembly 23653-73011 Bilateral symmetry Brake backing plate assembly (right) Spring tension rod 23653-72101 Spring washer GB93-6 Bolt GB5782-M8x16 Brake wheel cylinder assembly 22373-72041 Brake cable assembly OC11246-14603 Bilateral symmetry Brake cable assembly right OC11246-24603 Clearance adjuster 23653-72041 Spring 23653-72051 Friction plate assembly 23653-73021...
  • Page 104 Brake(30-35) Name QTY. Remark Rubber plug 24433-70040G Spring tension rod 24433-70010G Bolt M8 × one point two five × 20GB/T5783-2000 Spring washer GB93-6 Brake base plate assembly (left) 24433-7200G Bilateral symmetry Brake backing plate assembly (right) Hand brake rod (left) 24433-70140G Bilateral symmetry Hand brake rod (right) Pin 2 24433-70150G...
  • Page 105 Guide block 24433-70080G Torsion spring (left) 24433-70090G Bilateral symmetry Torsion spring (right) Guide plate 24433-70060G Return spring (II) 24433-70070G Pawl (left) 24433-70100G Bilateral symmetry Pawl (right) Return spring (I) 24433-70010G Push rod (left) 24433-70120G Bilateral symmetry Push rod (right) Push spring 24433-70130G Clearance adjusting rod 24433-74040G Clearance adjusting screw (left) 24433-74020G Bilateral symmetry...
  • Page 106 (2) Parking brake The parking brake device is assembled in the wheel brake and consists of a pull rod and a push rod. The pull rod is installed on the side of the main brake shoe by the pin and pulled The action of is transmitted to one side of the auxiliary brake shoe through the push rod.

  • Page 107: Parking Brake Control

    4-6-5 Parking brake control The parking brake handle is cam type, and the brake force can be adjusted by the adjuster located at the end of the brake handle. Adjustment of braking force: turn the adjuster clockwise to increase the braking force; turn the adjuster anticlockwise to reduce the braking force.
  • Page 108 (2) Remove the shoe return spring. (3) Remove the fixed spring from the main brake shoe. (4) Remove the main brake shoe and auxiliary brake shoe. Remove the adjuster and adjuster spring at the same time. (5) Remove the brake pipe from the brake cylinder. Then remove the mounting bolts of the brake cylinder and remove the brake cylinder from the brake base plate.
  • Page 109 (7) Disassemble the brake cylinder: remove the dust ring. Press one side of the piston to push out the other side of the piston, and then press this side of the piston with your fingers. 2. Brake inspection Inspection of all parts, repair or replacement of damaged parts. (1) Check whether there is rust on the inner surface of the cylinder and the outer circumference of the piston;...
  • Page 110 3.Brake assembly (1) Apply brake fluid on the cup and piston of the brake cylinder, and assemble the spring, piston cup, piston and anti-ring in sequence. (2) Install the brake cylinder on the brake base plate. (3) Install the brake base plate on the drive axle. (4) Apply heat-resistant grease all over as shown in the figure.
  • Page 111 (a) The thread direction of the adjuster and its installation direction; (b) Adjuster spring direction (the adjuster teeth are not allowed to contact with the spring); (c) The direction of the return spring of the ejector pin (the spring hook at the end of the support pin shall be fixed on the opposite side of the ejector pin);...

  • Page 112: Brake Pedal Adjustment

    (2) If the adjuster fails to do the above actions when pulling the adjusting lever, the following inspection shall be carried out: (a) Install the adjustment lever, top bar, top bar spring and compression spring seat firmly; (b) Check whether the ejector return spring and adjuster spring are damaged, and then check whether the rotation of adjuster gear and its engagement part are excessively worn or damaged.
  • Page 113 Stop bolt Push rod Brake bolt Freepath Free stroke (5) Adjustment of brake switch Brake switch (a) After the height of the brake pedal is adjusted, loosen the lock nut of the brake switch; Fastening (b) Pull off the plug to separate the wire; (c) Turn the switch so that the clearance A = 1mm;...

  • Page 114: Fault Analysis And Troubleshooting

    4-6-8 Fault analysis and troubleshooting Problem Cause analysis Exclusion method 1 Brake system oil leakage repair 2 Brake shoe clearance not adjusted Regulator 3 Brake overheating Check for slipping 4 Poor contact between brake drum and friction plate Resetting 5 Impurities attached to friction plate Repair or replace 6 Impurities mixed into brake fluid Check brake fluid...

  • Page 115: Maintenance And Service

    4-6-9 Maintenance and service ① Before running in test, the new drive axle shall be filled with gear oil (the selection of gear oil shall be strictly in accordance with the specification, and the specific model shall refer to table 2-1). Oil shall be injected from the oil filling hole on the upper part of the axle housing until oil overflows from the oil level hole in the middle of the axle housing.
  • Page 116 ⑦ Requirements for inspection and commissioning items during installation: When reinstalling the drive axle hub, pay attention to adjusting the brake clearance adjuster so that the clearance between the brake drum and the friction plate is between 0.3mm and 0.5mm. The tapered roller bearing on the hub shall be filled with about 100ml of 3 × lithium grease.

  • Page 117: Parking Brake

    4-7. Parking brake 4-7-1 Appearance and specifications Name Bolt GB5783-M10x20-8.8 Spring washer GB93-10 Flat washer GB97.1-10-200HV Backing plate (hand brake) Hand brake assembly Flat washer GB97.1-6-200HV Spring washer GB93-6 Bolt GB5783-M6x16-8.8...

  • Page 118: How Does It Work

    4-7-2 How does it work For this model, the parking brake is built into each drive shaft. Once the operator pulls the lever, the cable assembly pulls the brake lever, which in turn presses the brake piston and the resilient disc. This causes the compression discs to produce friction braking forces in the drive shaft.

  • Page 119: Troubleshooting

    4-8. Troubleshooting 4-8-1 Driving motor Problem Possible causes Drive motor does not Switch not off (battery connector, key switch, seat switch, F/R switch or parking brake work switch): Turn off the switch. If it still fails to operate, use a voltmeter to test the power supply of the control panel and the current of each switch.

  • Page 120: Drive Axle

    Replace with a smaller hydraulic pump. Check the mast for restrictions during operation. After a work shift, the forklift's working capacity exceeds its designed capacity without available power: Battery positive (-) or The battery is dirty and the electrolyte is on the top of the battery and in contact with the negative direct frame.
  • Page 121 Damaged mounting surface: After removal, readjust or replace the components. O-ring damage: Replace the O-ring. Hub leakage Damaged oil seal: Oil seal replacement O-ring damage: Replace the O-ring. Input shaft leakage Damaged oil seal: Replace the oil seal. Motor O-ring damaged: Replace the motor O-ring.

  • Page 122: Service Brake

    4-8-3 Service brake Problem Possible causes Pedal resistance is not firm (spongy) Leakage or low level Air in the brake hydraulic system. Master cylinder loosening Too much pressure of pedal when braking Mechanical resistance on the brake pedal. Limit the brake lines. Bad master cylinder Pedal towards the floor Leakage or low level.

  • Page 123: Hydraulic System

    5. Hydraulic system 5-1. Overview 5-1-1 Component Name Remark Hydraulic Tube Assembly (Extraordinary)8-L3000-1SC-60° Hydraulic Tube Assembly (Extraordinary)8-L2500-1SC-60° Hydraulic Tube Assembly (90° )6-L750-1SC-60° Connector (straight)6-G1/4 M14X1.5-60 ° O-ring - inside 11.2x2.65 Hydraulic Tube Assembly (90° )6-L700-1SC-60° Rubber hose (return oil) Hose hoops QC/T390 - - 38 (34) Return oil hose 23X5 2560 (mm) Unit is mm...
  • Page 124 Joint (to bend) 25 - G1 - Φ 32 Joint (to bend) 15-M27x2-M22x1.5-60° Connector (straight) 12-2XM22X1.5 -60° Connector (lock bend) 6-M12X1.5 - M14X1.5 -60° Connector (lock bend)12-M20x1.5-M22x1.5-60° Connector (straight) 8-M20X1.5 - M16X1.5 -60° Hydraulic Tube Assembly (90° )13-L2600-2SC-60° The hydraulic system operates multiple brakes with pressurized oil from the main hydraulic pump and draws oil from these actuators.

  • Page 125: Pump Motor

    5-2. Pump motor 5-1-2 hydraulic schematic diagram 1. Hydraulic oil tank 2. Oil suction filter 3. Pump motor 4. Gear pump 5. Steering gear 6. Multi way valve 7. Steering cylinder 8. Speed limiting valve 9. Shut off valve 10. Lifting cylinder 11.
  • Page 126 One of the hydraulic control switches, the F/ R switch or the accelerator switch signals the controller. Turning the F/ R switch to forward or reverse will trigger the pump motor to run at idle for 6 seconds. It then goes into PP mode to stop unless it's in six seconds The clock signals from the accelerator.

  • Page 127: Pump Motor And Main Hydraulic Pump Removal / Installation

    5-2-2 Pump motor and main hydraulic pump removal / installation 1. Remove the counterweights first 2. After the counterweight is removed, remove the pump motor U V W cables 3. Remove the hydraulic tubing 4 Remove the fixing screw , the motor can be removed...

  • Page 128: Main Hydraulic Pump

    5-3. Main hydraulic pump 5-3-1 How does this work Figure 4-13 This model uses internal gear pump as its main hydraulic pump. The internal gear pump includes a driven gear (2) [external gear] and a driving gear (1) [internal gear], as shown in the figure. The volume of the meshing area between the driving gear and the driven gear increases as they rotate and draw oil.

  • Page 129: Disassembly And Assembly

    5-3-2 Disassembly and assembly Disassemble 1. Loosen and remove the 4 screws (pos.22) on the cover plate (pos.19). 2. Carefully remove the cover plate (pos. 9) from the housing (pos. 18). 3. Remove the shaft plate II (2), pinion shaft (17), rod spring (16), segment (11,12), segment spring (14,15) and sealing roller (13).
  • Page 130 6. Place the section spring II (15) so that the 2 bows are pressed on the sealing roller, as shown in the figure. 7.Install in the same way as the bow against the inner gear segment (12 8. Install shaft plate II (2) close to the housing or damage to the bearing bush (6) hydraulic system in the cover plate (19 9.

  • Page 131: Multi-Way And Priority Valves

    5-4. Multi-way and priority valves 5-4-1 Appearance and specifications The multi-way valve adopts two-piece four body type. The hydraulic oil from the working oil pump is controlled by the multi-way valve stem to distribute the high-pressure oil to the lifting cylinder or tilt cylinder. There are safety valve and self-locking valve inside the multi-way valve.
  • Page 132 The priority valve measures the hydraulic oil to the control valve and steering unit after receiving the oil from the main hydraulic pump, in order to always give priority to the steering system when steering is required. Priority valve is mainly composed of steering safety valve, spring, valve core and valve body as shown in the figure.

  • Page 133: Disassembly And Assembly Of Multi Way Valve

    5-4-3 disassembly and assembly of multi way valve 1. Remove the connection between the control lever and the multi-way valve 2. Remove the connector and micro-switch 3. Remove the fixing bolts...

  • Page 134: Troubleshooting

    5-5. Troubleshooting 5-5-1 Pump motor Fault phenomenon Possible causes Poor connection or blown fuse. Check the battery connections. Check the key fuse. Check whether the hydraulic pump motor may cause the fuse to blow. Key switch, seat switch or line contactor not closed. Turn off the seat and key switch.

  • Page 135: Main Hydraulic Pump

    Hydraulic pump motor overheated. If the motor temperature reaches 155° C (311° f) The controller does warn of overheating and reduce performance. Pump motor control circuit overheated. The hydraulic speed of If the temperature of the power unit reaches 100° C (212° f), the controller will display overheat forklift is very slow warning and reduce performance.

  • Page 136: Lifting/Tilting/Auxiliary System

    6. Lifting/tilting/auxiliary system 6-1. Overview The lifting system is a two-stage roller type vertical lifting and shrinking system, which is composed of inner and outer door frames and fork frames 6-2. How to operate A. Mast tilt Mast tilt operation is performed by two double acting cylinders. In the case of each cylinder, one end is connected to the chassis of the vehicle and the other end to the side of the Mast.
  • Page 137 B. Standard Mast lifting The standard (STD) Mast assembly uses two Mast and two single acting cylinder cylinders to lift the load. Rollers mounted on the inside and outside of the carriage and Mast respectively facilitate these up / down movements.

  • Page 138: Fork Service

    6-3. Fork service A. fork inspection The forks shall be checked at least every 12 months. If the forklift is used in multi shift or heavy work, it shall be checked every six months. 1. Check the fork carefully for cracks. Pay special attention to the heel (A), all welding areas and mounting brackets (B).
  • Page 139 In some cases, a load backrest can be used extension instead of stops. The shaft mounting fork can use any collar or gasket on the shaft to the fork one side. They can also use U-bolts, pins or similar devices, it engages the fork through the top structure of the bracket.

  • Page 140: Side-Shifter Service

    6-4. Side-shifter service A Standard side-shifter and cylinder removal / installation Initial steps 1. Lift the bracket and place a wooden block under it. 2. Lower the bracket onto the wood block and secure the crane to the load backrest. 3.

  • Page 141: Tilt Cylinder Service

    Process 1. Mark the hose and port of the side-shift cylinder as reference for assembly. 2. Disconnect the hose from the side-shift cylinder and plug and cap the hose and port. Prepare the oil pan to catch any oil that is coming out of the hose and the cylinder port. 3.
  • Page 142 Initial steps 1. Prepare a hoist and tie the straps to both sides above the Mast. 2. Remove residual pressure in the hydraulic system by moving the lever back and forth several times by closing the key 3. Prepare the oil pan. 4.
  • Page 143 Disassembly / assembly of tilt cylinder Tools needed: claw spanner 1. Place the tilt cylinder in a vise and use a dog wrench to remove the rod assembly. Installation torque: 270± 30 Nm (200± 22 lb ft) 2. Loosen the nut (2) and bolt (3) and remove the eye (1). Installation torque: 95±...

  • Page 144: Mast Side Cylinder

    6-6. Mast side cylinder A. Overall removal / installation of main lift cylinder 1. Remove the chain. 2. Remove the upper and lower fixing bolts and hoops of the oil cylinder 3 Remove the lifting oil pipe and lift the middle gantry to remove the oil cylinder B.

  • Page 145: Initial Steps

    Initial steps Remove the main lift cylinder (see Section 5-3-7). Process 1. Using a claw wrench, remove the rod cap (10). 2. Remove the O-ring (7) and support ring (8) from the outer diameter of the rod cover (3), the dust wiper (4), the plug (4) and the U-ring seal (6) from the inside.

  • Page 146: Steering System

    7. Steering system 7-1. Overview The steering system is a set of devices that turn the vehicle left or right. In this model, the steering system is hydraulically operated and consists of a control group and an actuator group: 1. The control group determines the speed and direction of steering and supplies hydraulic oil to the operation group accordingly.

  • Page 147: Steering Axle

    7-2. Steering axle 7-2-1 Appearance and specifications Name Remark 30Q steering axle-AQ Hub cap (1218-10200) Gasket G27Z4-30711 Bearing 30207 Gasket G27Z4-30711 Bearing 30211 Straight through nozzle M6(Q700B06) Bolt M6X12 Spring washer 6 Sensor linkage bracket AQ-Z03N3-20201 Oil seal 264973 Left knuckle assembly AQ-Z03N3-22311 Bearing 33206 Spacer sleeve Z03M2-33051 Sealing gasket KOMV4-30231...
  • Page 148 Right steering knuckle assembly G27Z4-33301QT Steering cylinder Z03M2-10400 Bolt M14X50 Spring washer 14 Radial joint bearing GE16ES Bolt M8x16 Spring washer 8 Baffle A21B4-32081B Connecting rod A21B4-32081B Bush H24C4-12003 Radial joint bearing Z-GE16ES-K27 Connecting rod pin A21B4-32261AB Slotted nut 249289 Pin 3.2x40(15225) Bush G27Z4-33071 Oil seal G27Z4-33201...

  • Page 149: Disassembly And Assembly Method Of Steering Axle

    7-2-2 Disassembly and assembly method of steering axle 1) Assemble special spillage at the counter weight lifting indication, remove the fixing screws, and then use the line crane to slowly lift, lower the center of gravity to the designated maintenance storage area.

  • Page 150: Disassembly And Assembly Of Steering Gear

    7-2-3 Disassembly and assembly of steering gear 1 Open the casing and remove the oil pipe 2 Remove the fixing bolts...

  • Page 151: Troubleshooting

    7-3. Troubleshooting Problem Possible causes It takes too much force to turn the Priority valve (if equipped) releases pressure oil at a low setting steering wheel The pump oil pressure is low and the pump is worn. Steering gear cover too tight The steering column is not aligned with the steering gear.

  • Page 152: Battery Charger

    8. Battery charger The safety precautions, product features, technical performance, operation steps, installation and debugging, fault treatment, equipment maintenance of SKC-N lithium intelligent charger are expounded and explained. Please read this manual carefully after opening the box, and keep it properly for later inspection.
  • Page 153 Safety tips To ensure personal and equipment safety, the personnel operating this equipment must abide by the following principles and regulations: Before the equipment is powered on, please make sure that the equipment is well grounded; Before the equipment is powered on, please make sure that the input voltage, frequency, circuit breaker or fuse of the device and other conditions meet the specifications;...

  • Page 154: Product Overview

    Product overview SKC-N lithium intelligent charger is a new intelligent charger. The product has high input power factor, low input current harmonic, high efficiency, good EMC performance, simple process, high standardization degree, high reliability, beautiful appearance, simple use, operation, maintenance, far better than the same application types of products, can be widely used in transportation, industry, logistics and other industries.
  • Page 155 Input protection Input under-voltage, input overvoltage Output protection Output overvoltage, output short circuit, battery reverse connection Over-temperature Over-temperature inside the module protects shutdown. protection Abnormal protection Abnormal power device protection shutdown When an uncontrollable abnormality occurs, the shutdown can be forced through the Emergency stop protection emergency stop button...

  • Page 156: Installation And Commissioning

    8-3. Installation and commissioning 1. Installation precautions The operating voltage and current of some components in the power supply system are very large, and to ensure personal safety, the following regulations shall always be observed: 1). Only those who have received training in power system and have full knowledge of power system can install the system of power system.
  • Page 157 2) Yida plug input line Industrial pin wiring diagram Wiring definition: The Yida interface is a three-phase 5-wire. R1 S2 T3 =L1 L2 L3=A B C =U V W （The four logos are all national logos）are connected to three live wires, PE or ground wire identifies the ground wire, and N connects to the neutral wire.

  • Page 158: Output Wiring Instructions

    3. Output wiring instructions （The concrete object shall prevail.） 1). Output Wall DC charging gun Output Wall DC charging gun Wiring definition The charging gun is designed according to GB/T 20234.3-2015. DC power line: DC+, DC-. Equipment ground wire: PE. Charging communication line: S+, S-.
  • Page 159 4. Commissioning operation instructions Precautions before powering on the machine Before the charger is turned on, check whether the battery box wiring is correct, whether a short circuit occurs or the positive and negative terminals are reversed. Avoid the charger from burning components or wiring due to overload.

  • Page 160: Charger Display And Simple Troubleshooting

    8-4. Charger display and simple troubleshooting 8-4-1 Charger display Click on the icon: , enter the help description interface. Click on the icon: switch alarm sound , to turn on the alarm sound state, to turn off the alarm sound state. The control operation requires password permission.
  • Page 161 Click on the icon: , back to main interface. Click the reservation icon to set the time of the reservation mode. The password is 123456. Reservation function setting instructions: Click on the icon: , enter the password input interface and enter the factory parameter setting interface after the password is entered correctly.
  • Page 162 Parameter setting Parameter setting information: The rated voltage, rated current and shunt range are related to the machine hardware and must not be modified at will after shipment. If the above parameters need to be modified, please consult the manufacturer. The charger number is convenient for the user to distinguish, and the user can set it at will.
  • Page 163 Charging steps (1) Select "On" charging control mode. The “CAN” and “485” indicators light green. (2) The DC charging gun is connected to the battery normally. (3) The “remaining capacity” is less than the “permissible charging SOC limit” to start charging. (4) The “Battery”...
  • Page 164 The Divan screen display interface Main page The main screen contains charging information and power, etc. The background color blue indicates standby, suspended or full state, green indicates charging state, and red indicates fault state. Click the battery icon （ ）...

  • Page 165: Troubleshooting For Charger

    Troubleshooting for charger 8-4-2 Troubleshooting instructions When the charger works abnormally, find the charging status display area on the right side of the charger touch screen, pass the status indicator above to determine the cause of the failure, and then carry out troubleshooting.
  • Page 166 2. Troubleshooting instructions for Segment code screen charger Failure phenomenon Cause of failure Solution 1. Charge the replacement car. If normal, the 1. The BMS of the vehicle The charger cannot be battery BMS is damaged. If the same problem charged after being battery is damaged.
  • Page 167 It does not charge after Working state: standby 1. Click the "Battery Information" interface: starting up, the touch Charging connection: normal Whether you have received the charger screen is bright, and Fault information: normal message: "Yes". Received BMS message: "No". the background color is Battery capacity: 0.0% blue...

  • Page 168: About After-Sales Warranty

    8-5. About after-sales warranty 1. Warranty conditions Due to transportation reasons, the user found that the product or accessories were damaged during the unpacking inspection; The user fully complies with the installation, storage and use rules specified in this specification. 2.

Table of Contents