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CPD10-30 DC CPD10J

1. Model CPD20 CPD25 D Power type Battery Rated capacity kg 2000 2500 Load center mm 500 Lift height H mm 3000 Free lift height H4 mm 140 Fork size LxWxT mm 1070x120x40 1070x120x45 Fork outside spread Min Max B4 mm 240 1040 Mast tilt angle forward backward a i 6 12 6 Front overhang X mm 479 484 dp 5 Length to fork face L1 mm 2349 2381 O Overall width B1 mm 1152 Overall l Mast lowered height H1 mm 2060 dimension Mast extended height H3 mm 4040 Overhead guard height H2 mm 2159 Min turning radius R mm 2050 2100 Min right angle stacking aisle width RAXA mm 3715 3755 No load Travel speed km h 12 5 11 12 5 10 5 full load Lifting speed mm sec 400 260 390 250 Max grade ability 10 Service weight kg 4160 4360 Max pull force full load KN 8 Front mm 7 00 12 12PR Tyre Rear mm 18x7 8 14PR o Front B2 mm 960 o Tread E Rear B3 mm 950 O Wheelbase Y Y 1500 Ground Mast mm 120 100 clearance Frame F mm 120 100 5 Voltage V 48 Battery S Capacity Ah 630 700 o Drive motor KW rpm 7 0 1400 gt Motor 3 Hydraulic motor KW rpm 8 6 1600 u Controller GE separate excitation controller SPECIFICATION CPD20J CPD25J Model CPD20J CPD25J D Power type Battery Rated capacity
2. gir a r EINE a oiea TT 22 el Ry Y ty AE ee N 7 NN po t P z 7 7 7 a FESTE eh Pr Le P eo pi e I lic an D Jo ear E DER Lact mr 7 7 7 7 LA 4 4 P ae a PE Por REN 7 i RASA R X a b RASA Right Angle Store Aisle a Clearance b Length of load External view of electric forklift truck SPECIFICATION CPD10 CPD15 Model CPD10 CPD15 D Power type Battery Rated capacity kg 1000 1500 Load center mm 500 Lift height H mm 3000 Free lift height H4 mm 162 Fork size LxW mm 920x100x40 Fork outside spread Min Max B4 mm 200 968 Mast tilt angle 6 12 a o forward backward P 6 12 o Front overhang X mm 429 E Length to fork face L1 mm 2056 e Overall width B1 mm 1090 Overall Mast lowered height H1 mm 1995 dimension Mast extended height H3 mm 4042 Overhead guard height H2 mm 2162 Min turning radius H mm 1820 Min right angle stacking aisle width RAX mm 3370 n No load Travel speed km h 13 5 11 5 13 11 full load Lifting speed mm sec 400 300 390 285 E Max grade ability 15 Service weight kg 2900 3120 Max pull force full load KN 6 6 5 Front mm 6 50 10 10PR Tyre Rear mm 5 00 8 8PR o Front B2 mm 890 Tread Rear B3 mm 920 C O Wheelbase Y mm 1250 Ground clearance Mast M mm 110 95 No load full load Frame F mm 105
3. Pump body Driving gear Driven gear Front cover Rear cover Lining plate Seal ring Ring Oil seal O 0 ON ODO KR WO I Snap ring Bolt Washer Ll MD Fig 7 9 Gear pump 104 1 Disassembly Before disassembly the pump make it clean and put the removed parts on the paper or cloth Don t damage the parts a Hold the pump in a vice by lightly clamping the flange section b Remove bolt 11 pump cover 5 pump body 1 Fig 7 9 c Remove lining plate 6 driving gear Zand driven gear 3 d Remove seal ring Zand ring 8from the front and rear covers Caution If the seal ring needn t be replaced don t remove it from the front cover 2 Inspection The disassembled parts except rubber parts should be washed with gasoline a Pump body inspection Fig 7 10 If the scraping trace is up to 1 2 long of the inner periphery it indicates that the bearing and gear shaft are subject to excessive wear replace the pump body b Lining plate inspection Fig 7 11 Inspect the contact surface of the lining plate If the surface is worn or its thickness is smaller than the specified value replace the lining plate Bushing Outlet Fig 7 10 Fig 7 11 c Front and rear cover Fig 7 12 If the inner surface of bushings discolored replace d Inspect the driving gear and the driven gear If they are worn replace them Fig 7 13 e Replace seal rings bus
4. Piston Primary cup 00000 0o Spring oO c N O o A C N Check valve Fig 2 2 Master cylinder 2 1 3 Wheel brake Mounted on each side of the drive axle the wheel brake is the internal expansion hydraulic type consisting of two brake shoes operating cylinder and adjuster The brake shoe one end of it being connected to the anchor pin and the other to the adjuster is stressed on parking brake plate by the spring and spring pull rod The primary shoe is provided with the parking pull rod while the secondary shoe with the adjuster lever of the clearance self adjuster See Fig2 3 2 4 2 5 33 1 The operation of wheel brake is as follows The primary and secondary shoes are respectively forced by a force equaled in value and contrary in direction by operation of the operating cylinder to bring that the friction piece being in contact with the brake drum The primary shoe forces the adjuster with the aid of friction force between the friction piece and the drum Due to this the adjuster pushes the secondary shoe by larger force than that offered by operation of the operating cylinder The secondary shoe upper end is forced strongly against the anchor pin providing large braking force See Fig 2 3 On the other hand the braking operation in the truck s reverse travel is performed in reverse order but the braking force is the same as that being in the case of the truck s forward travel See Fig 2 4 2 Parking b
5. O ef f 17 Back buzzer O 18 Separately excited controller i 9 PO 13 19 Foot horn switch He 20 Travel motor l T a 2 we 21 Lift motor fmt 1 3 A e Fig 4 1 Construction of electric system DC 51 i 93N ev amp 10700 dund 13945 Iv you TMs C 9j amp 19 920y 62 ItAd Suorjo9uuoo p 19 Olid Ed 9d e an d d c a 2 81 i181 AAN eld MBA Q 211AS 27 TMs M i P ody 2 pim Yo TMs I 471 9SAJ9AO9 I MS en pie premioy WT u ol t z Q931IAS oyeig YO LAS Koy tna Fig 4 2 Principle of electric system DC CPD10 25 32 t a 4o30u dund urey EL soyow uorjoa eisia 08 U N om Sax 04300 U01791 uoiins dung are e npou JeMod E IV SOd 2 s Me LA D 6l Z uoirus ld Old jo3uoo dund Und Ad jo1uoo vonoen j g dund YOLIMS SuoI199uu09 1In94l Md Suonoeuuoo iIno4n m dung Old 6d Zid Zd Id Ed 9d Zd Bld Zld Id as wp IS AS 08 Mci ogg zu A O MO Wy if 90 30 AZI MA A08 Qoyrws uorjoerrq jj yms oyeg i at e AOS rasche Fig 4 3 Principle of electric system DC CPD30 53 18 x Head lamp Front combination lamp Inching switch Lift potentiometer Meter assy Steering switch Direction switch Hand brake Horn Horn absorber Foot horn switch DC convertor Microrelay Back up buzzer Foot brake switch Seat switch Warning lamp Rear combinati
6. Ring Snap ring Cut off valve Spring lock ring Cotter pin Nut lock Nut adjustment Joint Chain Chain wheel A Action of cut off valve There is a cut off valve that operates when the high pressure hose bursts for any reason to prevent the load from dropping down abruptly at the bottom of the lift cylinder Fig 7 5 The oil from the lift cylinder flows through small holes in the circumference of the cut off valve spool and produce a pressure difference between two chambers As the pressure difference is smaller than the spring force as result of passing the holes so that the cut off valve spool won t move If the high pressure hose bursts the pressure difference will be big enough to overcome the spring force causing the spool to move until the holes on the circumference of the spool are blocked up and allowing only a small amount of oil to flow through the holes at the spool end to let the forks descend at low speed Normal Cut off Fig 7 5 Action of cut off valve 101 7 1 3 Flow regulator valve The flow regulator valve located in the lift cylinder circuit is to limit the descending speed of loaded forks and support when there are accidents such as bursting because of high pressure its construction is referred to Fig 7 6 Ta A Operation of flow regulator valve Fig 7 7 When the lift spool is placed in the lift position the oil from the control valve flows thr
7. The steering motor is controlled by direction switch it will run only when the direction switch is on forward or backward position and pressing the accelerator pedal When exhausting start the steering motor by lightly turning the hand wheel If occurs abnormal performance turn off the power source and find out the trouble to remedy it The hand wheel must be convenient and flexible and the steering wheel can be deflected Do the steering left and right several times and then the air in the steering system can be exhausted 50 4 Electric system 4 1 General description The electric system is composed of battery drive motor lift motor multifunctional controller system control switch LCD combined instrument and lamps etc The construction and principle of electric system is referred to Electric forklift truck with DC motor Fig 4 1 Fig 4 2 Fig 4 3 Electric forklift truck with AC motor Fig 4 4 Fig 4 5 Controller and contactors 18 Fuse box Horn Head lamp Front combination lamp Harness front overhead guard Dashboard assy Hand brake switch Flasher unit Direction switch co NO C1 WD co Batttery O Turn lamp switch E AI I be woes dea S ai T 11 Brake lamp switch HA i T ai oe f 12 Harness dashboard 20 13 Harness meter Accelerator 9 14 Battery Socket assy j 10 11 15 Rear combination lamp Lift switch SD pu L4 LN
8. A Pull force adjustment of lever Fig 2 10 Parking brake A Adjustment of switch Fig 2 11 1 Loose two mounted bolts 2 Pull the parking brake lever 3 Mount the roller on the bracket of control lever after hearing the sound of motion press for 1mm and tighten it 4 Release the parking brake and pull the SERE control lever again make sure the switch is ON Fig 2 11 Parking brake lever 38 2 2 Disassembly assembly and adjustment of wheel brake This paragraph covers the disassembly assembly and adjustment of the wheel brake the adjusting method of brake pedal when the wheel and wheel hub is disassembled The description here is mainly for the brake of 3t forklift truck the other forklift trucks are similar in maintenance in general except the structure of adjuster 2 2 1 Disassembly of wheel brake 1 Remove the hold down spring of secondary shoe Remove the anchor pin adjust lever adjusting device and spring See Fig 2 12 2 Remove return springs of two shoes See Fig 2 13 3 Remove three hold down springs of primary brake shoe See Fig 2 14 4 Remove the primary and secondary shoes At the same time remove the adjuster and adjuster spring See Fig 2 15 5 Remove the brake line from the operating cylinder then remove the mounting bolts of operating cylinder and detach the operating cylinder from the backing plate of wheel brake See Fig 2 16 6 Remove the E retainer
9. Lamp switch amp electric key electric key not indicated in the diagram Pull the lamp switch to the first shift the front and rear clearance lamps light Pull the switch to the second shift the headlamps light while the front lamps and rear lamps keep on Turn the key switch clockwise to connect electric controller the instrument circuit and the electric circuit are ready for work 3 Error code display When the electric controller is in trouble a specific code displays it can afford serviceman fault information To make a detailed diagnosis please refer to the list of alarm code At the moment when the start switch is cut off the alarm code on the left of meter will show the working hours and disappear after several seconds 4 Signal of normal battery voltage When turn off the key switch this lamp lights meaning working state is normal 5 Warning of under voltage battery The lamp lights when the battery is in a state of under voltage in the meantime the controlling power of lift switch negative pole is cut the lifting is prohibited The under voltage value of the battery 48V is set on 40V It means if the voltage is below 40V the value will be held for several seconds the under voltage protecting circuit comes into play 6 Right turning signal 8 Width indication 7 Brake signal l 10 Backward state signal l l 9 Forward state signal 11 Short signal 0 12 Headlamp signal 13 Left turning signal
10. driving to suit for the working environment or errors will be shown in electric system including meter 2 As the power of the vehicle battery is different from traditional energy its actual capacity is related to working state and aging different from rated capacity According to the common performance when capacity drops to 2096 one cell charge the battery to prolong the life of battery 3 Using PC machine or hand hold device connecting with control device the users can enter into software setting interface with powerful functions within certain limits You can measure and know the working condition of truck more intuitively for example as follows working current and rotating speed of AC drive motor working current rotating speed working hours and trouble list of lift motor and other system parameters 2 7 Caution plates The caution plates attached on the vehicle indicates the operating method and instructions Before driving it please be sure to read them thoroughly If the caution plate drops stick it again When maintaining check if the caution plate is complete and the writing is legible if necessary please replace them 1 Safety mark People are forbidden to stand on or down the fork 20 2 General information when operating GENERAL INFORMATION WHEN OPERATING WAS Parsons who have not been property trained must not operate this torki truck range ols a ae netions before operation Do from
11. 11 13 Motor current offset alarm 17 Main breaker 20 Power inverter Watchdog timer alarm 22 over temperature Alarm on 5V encoder voltage Alarm on 12V output voltage 62 64 77 78 3 Pump motor commands Motor blocking over temperature active on start Motor thermal sensor alarm mmal a Emu Inverter temperature alarm CRC fault alarm Bank CRC restored 0 Steering sensor alarm Brake pedal switch alarm P Capacitors pre charge too slow Capacitors pre charge Encoder alarm timeout 71 4 8 Harness LL 6 9 10LPQ 12 8 9 160LP0 eec riga el LGD tsp ld en 2 Ka 1 8 9 100100 qQo3TAS 3jTT 9 120100 I TA L 9 190100 HN 90 GO ssoure xoq Send LED QU u piena peeuieAo Te9I YIM F99UUON gt 11 68 0100 691 INEO KO H E 9 1POLPO oxuoo or zoope UDIO E 11 8 9 1H0LrQ TM ie vv d eg Sun pe pesyteao YIM 39euuo FOO p 9 LO IMOR S s ssi 6 9 1001f0 KOO RU Rum nn Mel Sp pas UIN ost KOJO UpyTas ZULIBENS ssourey preng peouloAo U1IA 198uuo D IA EDIC CIC UTM 309uuo Too EI ER ae fe KOLGI T un e gt 11 6 9 1601f0 2 t 9 180LP0 i e 9 1g0 ra PIUS E a a MERC mp 9 LMS OkYeI L Co 60 COGO en lore W ane a cor GO LG moie Mens a Ba M feme GR m IE ae e LI Oe c fu d 12 8 9 190100 EDICY GD GD amp 9 L21L70 Sr 1l ES astu S NOTUM DREI L TOO TEU Jojou p urquo 12 8 9 180101 O WAS oea iz t 9 1201r0 OLEN ay 122r Jey Ij Udo i einn L E 9 1
12. 21 King goar Differential shaft Torque Shim 970 1450kg cm x PIE Differential gear H him AL Im E ie T La VA La 450 550kg cm A a P yO Half shaft IN eut Jm gear Gear Transmission housing O ring Torque 350 450kg cm LN Module pe aas o ee ar Traction motor Fig 1 2 Gear box and differential 2 3t 28 Gear shaft Bearing seat Left half of differeniai case Half shaft gear Gear shaft Planet gear Ring gear Right half of differenial case Fig 1 3 Differential 29 The hub s torque 2100 2300kg cm 1 Housing 5 2 Half shaft 2 s 3 Wheel brake A m 4 Brake drum E 5 Oil seal j 6 Taper bearing e cdi Ra y 7 Wheel hub Se 8 Taper bearing C Se TS a 9 Oil seal S e 10 Tyre A ze X 11 Rim 2 jJ Lock nut Fig 1 4 Drive axle 30 1 2 Assembly of wheel hub 1 Fill the chamber of wheel hub with lithium base grease about 100 cc then fit the hub on the shaft 2 Screw down the adjusting nut with a torque for about 1kg m and then loosen it for 1 2 turn 3 Put the spring balance up on the bolt to measure the hubs starting torque When the starting torque arrives to the specified value lock the nuts slowly otarting torque 5 to 15 kg m 4 Install the lock plates and lock nuts after that pull the lock plates up to lock the bolts 5 Wheel assembl
13. 95 Ss Voltage V 48 Battery Capacity Ah 400 440 480 O Drive motor KW rpm 5 3 1700 5 Motor Hydraulic motor KW rpm 8 2 1600 Controller GE separate excitation controller SPECIFICATION CPD10J CPD15J Model CPD15J D Power type Battery rs Rated capacity kg 1500 Load center mm 500 Lift height H mm 3000 Free lift height H4 mm 162 Fork size LxWxT mm 920x100x40 Fork outside spread Min Max B4 mm 200 968 Mast tilt angle forward backward a 6 12 6 Front overhang X mm 429 ep z Length to fork face L1 mm 2056 e Overall width B1 mm 1090 Overall Mast lowered height H1 mm 1995 dimension Mast extended height H3 mm 4042 Overhead guard height H2 mm 2162 Min turning radius H mm 1820 Min right angle stacking aisle width RAXA mm 3370 o No load Travel speed km h 15 13 full load Lifting speed mm sec 400 300 Max grade ability 15 Service weight kg 3120 Max pull force full load KN 6 5 Front mm 6 50 10 10PR Tyre Rear mm 5 00 8 8PR o Front B2 mm 890 o Tread E Rear B3 mm 920 a Wheelbase Y mm 1250 Ground Mast mm 110 95 clearance Frame F mm 105 95 S Voltage V 48 Battery S Capacity Ah 400 440 480 O o Drive motor KW rpm 8 1600 T Motor 3 Hydraulic motor KW rpm 10 2450 Controller Italian SME AC Controller SPECIFICATION CPD20 CPD25
14. Clearance self adjuster 35 D D Q AMK lt 8 A O Expansion direction A A 9 9 B B Fig 2 8 Wheel brake 1 1 5t 1 Parking pull rod 8 Pressure spring 15 Dust ring 2 Primary brake shoe 9 Secondary brake shoe 16 Cylinder body 3 E retainer 10 Spring 17 Piston 4 Operating cylinder 11 Ratchet pawl 18 Spring 5 Return spring 12 Clearance self adjuster 19 Cup 6 Parking push rod 13 Spring 7 Spring 14 Push rod 36 o A C N Operating cylinder Spring Push rod Secondary brake shoe Backing plate Fig 2 9 Wheel brake 2 3t 6 7 8 9 0 Parking push rod Pressure spring Spring Ratchet pawl Clearance self adjuster 37 11 12 13 14 Spring Parking pull rod Primary brake shoe Return spring 2 1 4 Parking brake control device The parking brake lever is of a cam type The brake force can be adjusted with the adjuster on the end of the brake lever Brake force adjustment When you turn the adjuster clockwise the force increases otherwise when you turn the adjuster counterclockwise the force decreases See Fig 2 10 Pull force 15 to 30 kg A Pull force adjustment of control lever Fig 2 10 1 Position of releasing the brake 2 Pull the lever point B with 15 30Kg force it can be pulled to diagrammatic position When the force is great the point A turns to right on the contrary turns to left Parking braker lever Brake lever Right cable Left cable
15. Dust ring Fig 3 5 Steering cylinder 12 Bushing 13 Clip ring CON DOOF WD gt 48 3 Wheel hub The rear wheel hubs are fitted to the knuckle shafts through two tapered roller bearings the wheels with rims are bolted on the hubs There are oil seals keeping the grease in the hubs and the chambers of the knuckles between the inside of the two tapered roller bearings The degree of the bearing tightness is adjusted by the nut 3 2 Adjustment and maintenance 3 2 1 Rear wheel bearing pre load adjustment 1 As shown in Fig 3 6 fill up the chamber formed by wheel hubs wheel hub bearing and wheel hub covers with lubricating grease Coat the lips of the oil seal with lubricating grease 2 Press the hub bearing into the hub and fit the hub on the knuckle shaft 3 Fit a flat washer and tighten a castle nut with torque of 206 235N m 21 24kg m and loosen it and then tighten it again with torque of 9 8N m 1kg m 4 To ensure firm installation of the hub slightly knock at it with a wooden hammer and in the meantime rotate the hub for 3 4 turns 5 Tighten the castle nut and align one of its notches with a cotter pin hole drilled in the steering knuckle 6 Again slightly knock at the hub with a wooden hammer and in this time rotate manually the hub for 3 4 turns to ensure its smooth rotation with a specified torque of 2 94 7 8N m 0 3 0 8kg m 7 If the torque value necessary to rotate the hub is more than the specifi
16. Open all lids of the battery and keep ventilation when charging Keep alllids close to avoid electrolyte splashing while using battery While changing battery keep the battery box verticaly and lower it slowly to avoid electrolyte overflowing Clean the battery bracket regularly to avoid that the bracket is corrupted by electrolyte 24 17 Routine battery maintenance ROUTINE BATTERY MAINTENANCE Be sure the battery voltage not less than 85 of the rated voltage while using The battery should be recharged within 24 hours Never overcharge the battery during charging it Replenishing distilled water regularly to keep the electrolyte level normal If the battery is not in use for along time Please remember to recharge it once a month The battery temperature exceeding 55 C is strictly prohibited keep away from flame to avoid explosion Keep the battery surface dry and clean 18 Faulty starting decal electric forklift truck witch DC motor STARTING POINTS FOR ATTENTION 1 According to the operating order of electric forklift truck ad just the sitting positin make sure the seat electric lock closed turn on the key switch for several seconds after the main contactor is attracted then turn on the direction switch and press the accelerator pedal slowly 2 f the operating order is wrong the meter will indicate the corresponding error code such as 01 02 03 06 11 91 etc Generally you c
17. Rap e Tu bra E rh trei tt dtirend uo duet 62 a f SME compact meter AC asses duc dnee ente Edad cie einer 66 ZO FIOI SS an an ee ae b t DO Ns ett Punt en pai ran oe aedi deo dd ou AME E d 12 MOTON ae E A O N T I N 75 5 1 General description or DG BI nase ee a a Le 15 5 2 9ME three phase AC MOlor 2e He 17 5 3 Inspection and maintenance of DC motor cccc ccc eee cence ee eeee ee eenaeeeees 78 5 4 Failure diagnosis of DC motor 0 0 ccc nennen nsn nennen nnn 84 6 Battery and charger ioi Ex xE ER EIRMOD EDU ee ee 85 6 1 Structure OF battery ana en teste ase Hae Ud ve Os eee ene 85 6 2 Specification of battery and charger ssseessssesssee mmm 85 6 3 Usage and maintenance of battery sss nens 86 6 4 Troubleshooting guide ccccc cece eee cce eee cceeeeeseeeeeseeeeesueeeeesaeentsuaeeeesages 90 8 9 Charger 22 52 25 2 Bee een ibi es Eee ee eee 91 7 Hydraulic system oe deze das ed sh Shae o rra EE vu een 94 rex Ee reed 94 7 2 Maintenance and adjustment of hydraulic system sseeesseueessse 104 9 Lif ing SVSIGeI u ee ec euiro bre pieta put 109 Oo Geheral descripH ol essen 109 8 2 Maintenance and adjustment of lifting system sssseeeeesseeeeeseeee 112 Charging record card of electric forklift truck ssusuesuueueuueuuee 115 NOTE T a ee Een 116 I External view and specification
18. The density of electrolyte is 1 280 1 290g cm 25 C A Temperature conversion of density The density of electrolyte is changed with temperature the relation is counted as follow formula D 25 D t4 0 0007 t 25 D25 the density of electrolyte g cm at standard temperature 25 0 D t The real density g cm when the temperature is t 0 0007 Exchange factor of temperature t Ihe temperature of electrolyte when measuring density 2 Compound the electrolyte with ceramics cylinder which is anti acid anti heat without iron or other anti acid containers When compounding the electrolyte first put measured distilled water or deionizer water in clean container then put measured thick sulphuric acid into water at last mix them with vitriol stick Note Don t put water into thick sulphuric acid against spattering and causing injury 6 3 3 Perfusing electrolyte 1 After assembling the battery twist pore plug and pour the electrolyte cooled down to 30 Cinto the battery which will be absorbed by pole plates add electrolyte to 15 20mm upper the plate in time 2 After perfusing the electrolyte the temperature of the battery will raise Charge the battery after the fluid cooling down to 35 C about 4 8 hours later Note Normally the electrolyte in the battery has been compounded so it s not necessary to add again The electrolyte only can be added and compounded according to the need when the professional repairs the
19. Use the plate with enough length width and strength 2 Pull the parking brake and use jacks to stop the wheel 3 Fasten the plate on the center of the cabin there must be no grease on the plate 4 The left and right height of the plate must be equal to make the loading and unloading smooth 5 Don t change the direction on the plate to prevent the danger 6 Reverse the truck slowly when loading the forklift on the freight car 2 1 3 Sling the forklift truck 1 Only the specially trained personnel can sling the truck 2 Sling points should be always at the positions specified in sling index plate nn 3 The slinging cable must be enough to hang the forklift truck 4 Disassembled parts of forklift truck must be slinged in appointed position Weight kg Dimension mm Weight kg 530 1890x1040x470 750 1135x365x936 5 860 1890x1040x470 750 1135x397x936 5 1030 1935x1100x470 860 1135x397x936 5 1200 Notice Dismantling and slinging the component shall not be performed without the approval of our company Under special circumstances the appointed sling position should be used The balance weight fork and mast of the truck all have their appointed hang up position The above mentioned weight is only for a reference which may be adjusted because of configuration difference or technology optimization 2 2 Storage of forklift truck 1 Lower the mast to the lowest position 2 Turn off the key switch
20. Y 9 Hub cap 2 9 O 10 Steering hub 11 Lock pin 12 Adjust shim 13 Needle bearing 14 Oil seal 15 King pin 16 Knuckle 17 Steering cylinder 18 Steering axle body 19 Pin shaft Fig 3 3 Steering axle 20 Pin shaft 47 1 Steering knuckle Both steering knuckles are fitted between the upper and the lower axle body through two king pins tapered bearing dust cover and O ring The king pin is locked on the steering axle body with upper being with backing pin and lower being with cotter pin Both ends of the king pin are supported by tapered bearing which are pressed into the axle body See Fig 3 4 Thrust bearing Knuckle Lock pin Shim King pin Needle bearing Bushing Support seat ONOaR WD Fig 3 4 Knuckle 2 Steering cylinder The steering cylinder is of double action piston type Both end of the piston rod are connected with steering knuckles through connection rod Left or right steering of the truck is achieved with the help of the left or right travel of the piston rod driven by the pressure oil from the powered steering unit The piston seal adopts combination seal of support ring and O ring The Yx ring seal is adopted on cylinder cap and piston rod The cylinder is fixed on the steering axle through cylinder caps of both sides See Fig 3 5 Thrust bearing Cylinder cover Cylinder body O ring Support ring Sleeve O ring Sleeve 9 Yx ring 10 Gasket 11
21. after initial key switch closure 15 Battery voltage is too low or control card is miss adjusted 47 41 Open thermal protector TP or transistor over temperature 16 Battery voltage is too high or control card is miss adjusted 23 24 2 28 46 Look Ahead test for A2 volts is less than 12 of battery voltage 42 43 44 45 77 _ Motor current is detected during regenerative braking i If the armature motor current is greater than 450 amps for longer than 3 5 seconds the armature motoring current will be turned off 65 The field current exceeds the current limit of field transistor 49 51 57 64 65 67 76 71 82 4 7 SME compact meter AC 4 7 1 General description Four wheel AC electric forklift truck adopts Italy SME newly LCD meter displaying in real time on high definition LCD The CAN wire of meter is connected with control main board according to RS232 communication standard The EYE software obtains allowable landing and upgrade panel with functions of detailed upgrade diagnosis and adjustment The control circuit adopts SCM technology sampling displaying and controlling in real time The intense and feeble circuit in the instrument adopts light electricity separating with control relay 4 7 2 Structure of meter 1 Panel body 2 Wick 3 Key switch 4 Lamp switch 5 Meter panel 6 Meter gasket 7 Meter hood 8 SME meter 66 SME meter connector CONNECTOR AMP ECONOSE
22. battery 6 3 4 Measure density of electrolyte The density of electrolyte is changed with the temperature When measuring the 87 density of electrolyte put the sucker of the densimeter into the electrolyte vertically extruding the rubber tube with finger then the electrolyte will be absorbed into the glass tube at last the buoy of densimeter will float Read the number of densimeter Note The densimeter must be floated vertically not lean to the glass tube Pipette type densimeter Electrolyte aca A Antitetnd nime nn ETET a nte M bi o ee see m o omo oA oo P Visualize the mark 1 J 6 3 5 Adding distilled water 1 Get a certain amount of distilled water with a graduated container 2 Open all pouring caps of battery units 3 Absorb distilled water with ball type injector to charge the battery When electrolyte is over 15 20mm upper the plate stop charging 4 After charging tighten the pouring cap 5 Clean the surface of battery unit with a wet cloth Graduated cylinder Ball type injector Note 1 Wear eyes protect glasses rubber overshoes and rubber gloves 2 When adding the distilled water never exceed the appointed amount Adding too much will lead the leakage of electrolyte then the truck will be damaged when charging or discharging 3 When adding too much draw out water with ball type injector 88 6 3 6 C
23. drive motor and three phase AC lifting motor It s with function of speed sensor temperature sensor simple construction reliable performance free of maintenance Fig 5 3 Fig 5 3 Structure of AC motor 1 Front cover 2 Bearing 3 Temperature sensor 4 Support cap 5 Stator 6 Rotor 7 Rear cover 8 Gear sensor 9 Speed sensor 5 2 1 Operating environment Operate normally under the following conditions 1 Elevation is lower than 1200 meters 2 Air temperature ranges between 25 C and 40 C 3 Relative humidity is 100 5 2 2 Daily inspection and maintenance 1 Always keep clean and no water oil pollution or dust in the motor 2 Check the bearing for heat or leakage 3 The load current of the motor can t be over rated current 4 If there is friction scream or other noise stop working at once after removing the failure the motor will keep on working 77 5 3 Inspection and maintenance of DC motor 5 3 1 Maintenance and service when driving Visualization Clean the dust Motor Compare with the normal Environment Foreign u u frame driving conditions and judge if Return to matter n the temperature is normal normal liquid Compare with normal Motor High temperature frame Bearing temperature Return to Motor frame 80 C normal Bearing 55 C E Motor Compare with normal Check and Vibration er frame vibration troubleshoot bearing board Ear measurement compare u Check
24. for securing the parking brake cable to the backing plate Remove the backing plate mounting bolts and detach the backing plate from the drive axle See Fig 2 17 7 Disassembly of operating cylinder Remove the dust ring and push the piston 39 assembly out of the operating cylinder See Fig 2 18 2 2 2 Inspection of wheel brake Inspect all parts to make sure if there s any worn or damaged part If necessary repair or replace with new one 1 Check the inner surface of operating cylinder and the periphery surface of the piston for rusting Then measure the clearance between the piston and pump body Fig 2 19 Specified clearance 0 03 0 10mm Maximum clearance 0 15mm si C KS CI 2 Visually check the piston cup for damage or deformation If unsatisfactory replace with new one 3 Check the free length of the spring of operating cylinder If unsatisfactory replace it 4 Check the friction piece for thickness to see if it is excessive worn If necessary replace it See Fig 2 20 Fig 2 20 40 Unit mm DD 1015 202 at 4 5 0 5 Check the condition of the brake drum s inner surface If any damage or excessive wear is found repair by machining or replace it See Fig 2 21 Unit mm dn c NN 1 0 1 5t 2 0t 2 5t 256 Max thickness 256 312 312 2 2 3 Reassembly of wheel brake 1 Apply brake fluid to the piston and the piston cup and reinstall the spring the pi
25. it lights up as follows Normally operating When the system key is on or off the lamp lights up Meter is not connected to the controller The lamp is on after this state remains for 3sec Meter is not working lamp lights No alarm code and the alarm indication lights off when the truck works normally 3 Move the turning switch forward and backward the left and right turning signals flash When turn on the headlamp lamp indication lights up 4 Brake indication Operating the hand brake indication as P lights up pull the hand brake the signal turns off Note When the electric quantity is below normal that is to say the position of the hand on the meter is down one form please charge up the battery 4 7 5 Working circumstance 1 Elevation is lower than 1200 meters 2 Working temperature 25 C 40 C 3 Relative humidity is not larger than 95 4 7 6 Cautions 1 Forbid wetting the meter When washing the truck don t let water into the meter if it happens clean it with dry cloth 2 Don t pull the plug of the meter and harness for the connection 3 Forbid impacting or scratching the meter strongly 4 When the meter works abnormally contact with our company for maintenance 70 4 7 7 Troubleshooting of AC electric forklift truck Alarm description Alarm description Maximum battery voltage Minimum battery voltage EN um EN ee ee al os 8 w Ya wish eee EM 20 uu 2 5 25
26. kg 2000 2500 Load center mm 500 Lift height H mm 3000 Free lift height H4 mm 140 Fork size LxWxT mm 1070x120x40 1070x120x45 Fork outside spread Min Max B4 mm 240 1040 Mast tilt angle forward backward a i 6 10 6 Front overhang X mm 459 464 Ww z Length to fork face L1 mm 2349 2381 O Overall width B1 mm 1265 Overall l Mast lowered height H1 mm 2040 dimension Mast extended height H3 mm 4240 Overhead guard height H2 mm 2125 Min turning radius R mm 2050 2100 Min right angle stacking aisle width RAXA mm 3715 3755 gt No load Travel speed km h 14 12 full load Lifting speed mm sec 420 310 420 300 z Max grade ability 10 Service weight kg 4160 4360 Max pull force full load KN 8 Front mm 23x9 10 16PR Tyre Rear mm 18x7 8 14PR 7 Front B2 mm 1040 o read E Rear B3 mm 950 Wheelbase Y mm 1500 Ground Mast mm 105 85 clearance Frame F mm 140 120 Voltage V 48 Battery l S Capacity Ah 630 700 o Drive motor KW rpm 8 1300 5 Motor 3 Hydraulic motor KW rpm 15 2200 u Controller Italian SME AC Controller SPECIFICATION CPD30 Manufacturer KION Baoli S Model CPD30 Power type Battery Rated capacity kg 3000 Load center mm 500 Lift height H mm 3000 Free lift height H4 mm 145 Fork size LxWxT mm 1070x125x45 Fork outside spread Min Max B4 mm 250 1100 Mast tilt angle forward ba
27. o i traction motor Battery BE El Fig 4 7 Controller assy DC CPD30 Red Start switch Orange Start switch Blue Potentiometer Brown Potentiometer Blue Potentiometer Brown Potentiometer Fig 4 8 Accelerator 57 4 3 SME AC electric controller assy 1 General description Four wheel AC controller assy is composed of two power inverters which separately drives traveling and lifting motor main control box DC contactor control aluminum sheet Main control box is connected with power source module separately controlling two power modules 2 Structure of controller CONTROL BOARD BATT CONNEC TOR NOTICE The electric control device contains capacitance which is discharged by procedure through hydraulic motor when cutting off the key switch then cut off the main contactor to turn off the circuit power Before doing the service maintenance and inspection for the forklift firstly cut off the key switch for one minute then discharge the capacitance completely by process control 4 4 Distribution and setting of sensor AC 4 4 1 General description The electric forklift truck embodies many superior features such as infinitely variable lifting speed steering speed adjuster and pedal setting which can be adjusted and set in real time by EYE software These functions have been initialized before delivery and needn t to be changed except the conditions as follows 1 Aft
28. pole of the meter with motor bedplate positive pole with either of the two terminals the measured value should be more than 0 5 MO If the measured value below 0 5 MO clean the baked carbon in the motor with compressed air if necessary dry the motor with airer then measure it again If the measured value is still abnormal replace the motor T Inspection of rectifier Rectifier is the most important part of the motor If oil or foreign matter adhered on it it will cause electric brush excessive roughness and weaken the efficiency of the rectifier Clean it with compressed air or dry cloth Polish up the roughness of the rectifier surface with 500 or 600 sand paper and clean carefully If appearing excessive roughness maintain the rectifier with cutting tools After the cutting correct the thickness of mica lamination Maintaining rectifier needs special mechanical tool so you d better call qualified serviceman 83 5 4 Failure diagnosis of DC motor Failure Reason All copper pieces are E black The pressure of electric brush is incorrect ac Commutator pieces are short circuit The commutator pieces Br n Armature coil is short circuit are black with the regular 4 The commutator pieces and armature coil are faulty order welding or break in the circuit The commutator pieces The middle line of commutator is out of position are black but nothing The surface of commutator is not plat or round
29. push rod by operation of the brake pedal As the brake pedal is pressed the push rod pushes the piston forwards The brake fluid in the cylinder flows 32 back to the reserve tank through the return port until primary cup blocks up the return port After the primary cup passes through the return port the brake fluid in the cylinder is pressurized and opens the check valve flowing through the brake pipeline to the operating cylinder Thus each operating cylinder piston is forced outwards This brings the friction pieces on the brake shoes come into contact with the brake drum and slows or stops the truck Meanwhile the back cavity of the piston is filled with brake fluid led through the return port and inlet port When the brake pedal is released the piston is forced back by the return spring At the same time the brake fluid in each operating cylinder is pressurized by the return spring returning into the master cylinder through the check valve With the piston in its original position the brake fluid in the master cylinder flows into the reserve tank through the return port The brake fluid in the brake pipelines and operating master has a residual pressure proportioned to the set pressure of the check valve which makes each operating cylinder piston cup securely seated to prevent oil leakage and eliminates a possibility of air locking when the truck is sharply braked 1 Link rod Push rod Dust cover Snap ring Secondary cup
30. regular The motor vibrates The clearance between the electric brush and the brush box is too large The electric brush is The distance between brush box and commutator damaged discolored or surface is too large urst The mica between commutator sheets sticks out The electric brush materials isn t fitting The trademark of electric brush is not correct The motor is over capacity The commutator is not clean The commutator is not plat or round Mica sheets or some commutator pieces stick out The electric brush is badly grinded Spark is great The pressure of electric brush is not large enough The trademark of electric brush is not correct The electric brush is blocked in the brush box The brush holder is loose or vibrated The magnetic polarity and order is improper The spark of the electric brush is too great Electric brush and brush The electric brush and soft wire are contacted poorly wire gets very hot The area of the soft wire coil is too small The electric brush makes l The surface of commutator is not plat abnormal noise 84 6 Battery and charger 6 1 Structure of battery The battery is composed of lower pole plate negative plate clapboard capping and electrolyte 1 1 5t 2 2 5t 3t forklift truck forklift truck forklift truck Capacity Name Battery Voltage Density of electrolyte Weight Appropriate 570AH 1000AH 600AH batte
31. truck during fuelling or battery charging WIS a g S dt beck whan raveliin ng me GIISSTB uuo re ruck Jower forks to the Ailt the mast upright apply the A varese aras 9 Never aslope 3 Nameplate of forklift truck 4 Lubrication system Lubrication system diagram Every 1200h Every 600h Every 300h Every 100h Daily Q Grease C Gear oil C Grease gt Hydraulic oil OOD sy SEO A Rec AA Brake fluid ELECTRIC COUNTERBALANCED FORKLIFT C Model CPD Type Rated capacity kg Service weight Load center mm fwithout battery Max Lift Height i imm Battery weight Max Rated voltage V Battery weight Min Rated Driving power kw Serial No Manufacturing License No Year of manufacture 5 Capacity chart The capacity in the chart should be reduced 200kg when the forklift with side shifter CAPACITY CHART 2t FORKLIFT TRUCK LIFT HEIGHT mm BA 4250 se IN m SINGLE TYRE DOUBLE TYRES 23 8 L m TAA T LA N amp L E x LOAD CENTER mm 6 Inspections before starting Inspections before starting Do inspections before starting the truck 1 Hydraulic oil level The liquid level should be in the middle position of up and down marks of oil level indicator 2 Check the pipes joints and pump valves for leakage and damage 3 Check the driving brake 1 The virtual travel of brake pedal should be between 20 30mm 2 The clearance between front backin
32. trucks It adopts imported motors and electric controllers improving the reliability of trucks and making the performance more superior The combination meter based on User Interface makes the operation more easily and conveniently This manual states the forklift truck s specifications operation maintenance main assemblies constructions and working principles so as to help operators to use the trucks correctly and attain the highest functions It is necessary to read over the manual before operating or maintaining the forklift trucks The rules and notices in this manual should be abided seriously by all of relative personnel to enable these trucks in optimized working state for long period and bring the highest efficiency The partial content in this manual might not correspond with the actual condition because of technical improvement Our products are subject to improvements and changes without notice CONTENTS I External view and specification lsssesssssssssssssse 1 II Safety instruction operation amp maintenance of electric forklift truck 8 2 1 Shipping loading unloading and slinging of electric forklift truck 8 22 SIOrage Ol TOME IFOe Koo ee 9 2 3 Precautions before operation sess seen ess 9 2 4 Information of safety operation cece cece cece eee cece enna eee eee eee eeaeeeeeaaeeeeaaes 9 2 5 Periodic servicing and maintenance
33. 4 3 14 Electric controller hour meter 15 Working hour meter 4 6 2 Lighting signal Include all kinds of illuminating lamps signal lamps horn and buzzer etc Headlamp 55W Front combination lamp turning clearance 10W 5W Hear combination lamp turning clearance backward braking 10W red 5W red 21W white 21W red Warning lamp 21W optional 63 4 6 3 Meter connector to body harness to electric key B2 U O Al A2 43 to dual switch A hpupoweri2V FR Dual switch shift I width indication Dual switch shift II head lamp Hand brake signal 48V A8 A10 B1 12V key switch B2 Output 12V key switch Red B4 Output 48V Output 80V Voltage measuring pump output Backing buzzer output 12V e NUM m m m ms 86 9 64 4 6 4 Troubleshooting instructions If misoperation of the vehicle or trouble of electronic control occurs a state code will be displayed on the instrument With the status code number follow the procedures outlined in the status code instruction sheets to determine the problem Status code 01 02 03 05 otart switch or brake switch fails to close Accelerator depressed with no direction selected Too high input voltage of accelerator Accelerator input voltage too low when power up after initial key switch closure Both the forward and reverse directional switches are closed at the 11 Start switch closed when power up
34. 90100 ssourey piens peou1oAOo Teer YIM ouuo Fig 4 10 Harness DC CPD10 30 2 eje d 3n punoy 1 i162 eee jou J jJ el e 8 Fr Do pettan e a pi 2s miwp fener reese teste efor E e Crane A ll 3 uN CES por eto 9 mamnun od en nr T one C n er ii IZ e Z AMOL tg E o popen Iri ur E m rati ra a je 3i Eh a Us pu P ma amp ow m wo ON 33 TAPAA as re qos XAV yous XAV rS JIN z n Ci M c he il te De ao7omorjuajod 33r 10332400 90 01 HT TON aeusep4 IZ e Z AIEOL eitapunoi II papas aut ina NU Bururey i dul s HL mS g T yar as Zurupu E Pu ssaurey pens peoulow yun usep4 E Pi ni ine z id gen gx 6 06 poy Sz ve 12 2 190 Fe fer ye x8 Y Em d gI uoa1y xoq 99TH ge xoe g poy You TMs Oc enpgg G MOT A 1ojBIeTe00R Jo INN Jo oo ay 0 Surpuodse ioo Jequmu ssoureu aul Fig 4 11 Harness AC CPD10J 15J 73 aerd Am punoy Asp T DD E m emea oy T To T T ieee OL LE er iv eter Lil SiySe rats cei ie Obes GBR rez yop ML E g acc 0194000 QQ OI EIOS iz aigo WORD POY gt we PN umouonumod qoiras BupyouySuprya vouno Dv ar GAE ve i Kong WA 199000 E D N g Ej iz 2 A160L au al DU Be Ev ry WO LOW N09 ON Woo ON Fig 4 12 Harness AC CPD20J 30J 74 5 Motor 5 1 DC motor 5 1 1 Main paramete
35. AL 174984 2 Illustration for SME meter connector Connections lin bus 1 Input 67 4 7 3 Outline and instructions of meter Compact meter engineered by SME Pny F EBEN i hi mpr que rm P 158539 LA iS A Traveling speed km h Hand brake switch lamp lights when pulling the hand brake With safety seat switch open meter indicates seat symbol main contactor can t be connected and truck can t travel until seat switch closes IBBEBH Time meter Odometer Turning angle indicating the position of rear wheel Maintenance time indication Remind the users to maintain and service the forklift truck olow speed operating With the lamp on the traveling speed and lifting speed will be reduced in slow speed mode Traveling speed Indicated by 0 9 forms Overheated motor temperature warning 68 Battery level indicated by 9 segments Display signals with alarm code 12 when battery is completely discharged Charge the battery when indicating on 1 segment Press E S H button you can set operating mode for system E economic mode S midrange mode H high mode H High mode High acceleration decelerate rate max grade ability suitable for loading large quantity goods in short time and climbing abrupt slope this mode wastes electricity only used when necessary S Midrange mode The parameter lower than High mode E Economic mode The parameter has been optimized Working on this mode in ge
36. Baoli Original instructions OPERATION amp SERVIGE MANUAL Balance Weight Type 1 3T Electric Forklift Truck CPD10 30 DC CPD10J 30J AC KION Baoli Jiangsu Forklift Co Ltd Baoli CPD10 30 DC CPD10J 30J AC Balanceweight Type Electric Forklift Truck OPERATION amp SERVICE MANUAL 1 3T KION Baoli Jiangsu Forklift Co Ltd PREFACE Balance weight type electric forklift trucks are designed on the base of the advanced features available from both local and foreign designs These trucks are suitable to handle transport and stack goods in factories mines stations ports freight yards warehouses and used widely in food processing textiles and other light industries The use of forklift trucks fitted with kinds of attachments will become extensive These forklift trucks feature a wide vision mast system full powered steering unit self boost brake stepless speed control open type overhead guard and high quality motor battery multifunction integration electric controller and large screen combination meter so they have a lot of advantages such as good performance easy operation wide vision flexible steering reliable braking powerful and smooth power low noise no pollution and beautiful appearance Newly designed AC system can control the torque intelligently the standard soft provides a complete toolkit to meet the demands of users and it optimizes the operation and reduces the producing cost of
37. E Please pay more regard to safety when adjusting the lift cylinder at an elevated height Upper beam Shim of inner mast Lift cylinder WM c Fig 8 5 Agjust lift cylinder 8 2 2 Adjust the height of lift bracket 1 The truck should be stopped on horizontal ground And ensure the mast vertical 2 Lower the forks on the ground adjust the set nut on the upper of chains to assure the distance A between main rollers and the lift bracket Fig 8 6 Type of fork 1 1 5t 36 41 24 29 112 3 Make the mast tilt backward when forks are descended to the ground adjust the top joint of lift chains and let the tightness of two lift chains be equal Fig 8 7 Chains os lir a Top nipple Set nut LE Lok nut Fig 8 6 Fig 8 7 8 2 3 Replacing rollers of the lift bracket 1 Place a salver on the forks and make the forklift stop on the flat ground 2 Make the forks and salver descend to the ground 3 4 Take down the top joint of the chains And take out chains from sheave Lift the inner and outer mast Fig 8 8 1 n A A 5 The forklift will be reversed when the lift bracket is disengaged from the outer mast Fig 8 8 2 6 Replace main rollers Take apart all the snap rings from the lift bracket and take out main rollers except the adjust shims Make the new main roller the same type as the old one fit on the lift bracket and fastened with snap ring 113 8 2 4 Repl
38. Fig 7 8 When the tilt lever is pushed forward the high pressure oil enters into the cylinder body from the cylinder tail moving the piston forward and causing the mast assembly to tilt forward until 6 degrees When the tilt lever is pulled backward high pressure oil enters into the cylinder body from the guider sleeve and moves the piston backward tilting the mast assembly backward until 12 degrees DR ANHE a Se Lu AE AQ MAS iy ar DS NNY LIN Lig A 4 o dit 4 ee i n Ty Dem Y Kd Jd Ms Fig 7 8 Tilt cylinder 1 Ear ring 6 Guide sleeve 11 Yx ring 2 Dust ring 7 Bushing 12 Wear ring 3 Snap ring 8 O ring 13 Piston 4 Yx ring 9 Piston rod 14 Yx ring 5 O ring 10 Cylinder body 103 7 1 5 Oil tank The oil tank is located on the right side of the frame There is an inlet filter in the oil tank and a return filter in the return oil pipe in order to supply cleanly oil A Replace oil filter 1 Loose the drain plug and discharge oil 2 Clean the oil tank board and disassemble the screw Remove the inlet pipe and return pipe JRemove the oil tank board 5 Remove the return filter replace new filter 6 Remove the inlet filter replace new filter 7 Remove the old gasket replace new one and smear sealant Three Bood 400 or equivalence 8 Install the oil tank board connect the inlet pipe and the return pipe 7 2 Maintenance and adjustment of hydraulic system 7 2 1 Maintenance of gear pump
39. Travel speed km h 14 5 12 full load Lifting speed mm sec 420 280 Max grade ability 10 Self weight kg 4850 Max pull force full load KN 10 Front mm 23x9 10 Tyre Rear mm 18x7 8 o Front B2 mm 1040 o read E Rear B3 mm 980 2 Wheelbase Y mm 1630 Ground Mast mm 105 85 clearance Frame F mm 140 120 Voltage V 80 E Battery S Capacity Ah 500 600 o Drive motor KW rpm 13 1500 5 Motor 3 Hydraulic motor KW rpm 22 2100 Controller Italian SME AC Controller II Safety instruction operation amp maintenance of electric forklift truck It is important for drivers and managers to remember the principle of first safety and ensure the safety operation as the description of Operation amp Service Manual Please read this manual thoroughly This will give you a complete understanding of Baoli forklifts and permit you to operate them correctly and safely 2 1 Shipping loading unloading and slinging of forklift truck 2 1 1 Ship the forklift truck 1 Apply the parking brake when shipping the forklift trucks by container or freight Car 2 Fix the mast and the balance weight with steel wire and use jacks to prevent the forklift trucks from moving in the cabin 3 Pay attention to the overall length width height when loading unloading and shipping and conforming the regulations is necessary 4 Single transporting if necessary after disassembling the mast and balance weight 2 1 2 Load and unload the forklift truck 1
40. When turning on the key switch meter shows error code 50 it expresses that the lift is in the state of start up If the voltage of the battery is too low the error code 12 will indicate When meter shows code 40 the lift sensor is wrong The common error code as 90 it shows failure steering sensor or the damaged or loosen sensor 2 Lamp switch Pull shift I front and rear clearance lamps light pull shift II the head lamps light while the clearance lamps light too 3 Steering signal Pull the steering lamp switch backward the front and rear 18 combination turning signals on the left side of the truck light pull the steering lamp switch forward the front and rear combination turning signals on the right light 4 Brake signal When braking press down the brake pedal to turn on the rear combination brake lamps red b Reverse signal When reversing pull the direction switch backward then the travel motor reverses rear combination reversing lamps white light and the back up buzzers sound 6 Press E S H or tortoise key on the right of the meter the operating mode and speed will be adjusted too 2 6 4 Maintenance of the control system During using the electric forklift truck its necessary to maintain the control system periodically 1 Check the contact terminal for wear status and contactor if works freely Check the contact point every three months 2 Check foot pedal or micro switch of levers Measure the v
41. ace rollers 1 Take apart the fork bracket from the inner mast then replace the main roller following the way as 8 2 3 2 Park the truck on the flat ground and lift up the front wheel 250 300 mm away from the ground Fig 8 9 3 Pull parking brake lever fully and use a wedge to make back wheel stationary 4 Take apart bolts which fastened lift cylinders and the inner mast Hang up the inner mast without losing shims of the piston rod heads carefully 5 Take apart bolts which jointed lift cylinders and the bottom of outer mast and take apart the oil pipe between two lift cylinders without loosing the nipple 6 Main rollers on the upper outer mast will be showed on the top of the inner mast as soon as main rollers were taken apart from bottom of the inner mast after laying down the inner mast 7 Replace main rollers Take apart the upper rollers without losing shims Fit the new main roller and shims together on the outer mast 8 Hang up the inner mast and let all rollers in the inner mast 9 Assemble the lift cylinder and the lift bracket as the procedures contrary to disassembly 114 Appendix The charging record card of electric forklift truck Model of truck Identification No Date of purchasing Model of battery Battery No Date of first using Charged Distilled electricity Fluid level of Density of electrolyte Charging electrolyte g cm before charge hours normal lower after charge beg
42. age warning of the battery displays on the liquid crystal displayer please charge in time according to the following essentials a Park the truck at appointed place Turn the key switch on OFF position and connect the battery When replace the battery sling it from the truck as rules b Confirm the input voltage and frequency of the charger select appropriate the switch socket matched with the battery c The minimum quantity of electrolyte should be kept the level of the electrolyte must be higher than guide plate for 15 20mm or be in the scale range ruled by vent plug d Correctly connect the plug of the battery with relevant charger e Turn on the switch the charger displays system s version the voltage of battery and the maximum charging current of charging The charger begins to give an automatic test f After testing the charger enters formal charging procedure scroll displaying as follows voltage U current A charging time H indicating hour minute and ampere hours charged AH 92 g When the full indicator flashes the battery capacity is full The charger has entered automatically floating state at the same time the floating current of the charger is 1 3A h After having charged turn off the switch disconnect the battery plug from the charger i Before using the forklift truck make sure the specific gravity of battery electrolyte has achieved the value as follows Te
43. an replace the faulty operation f error code 51 indicates on the meter turn off the key for several seconds and then restart or turn off the seat switch for several seconds then it will return to normal 19 Overturn caution decal Z N WARNING Truck can TIP OVER Cause serious INJURY or DEATH Slow down before turning Nr OEIL Fasten Seatbelt If truck tips over Da Not Jump Lean Forward m Hold On Tight Brace feet f Lean away from impact 25 IL Construction principle adjustment and maintenance of electric forklift truck 1 Transmission system 1 1 General description The transmission system consists of a gear box assembly differential assembly and drive axle With direct connection of the drive gear and the drive motor the travel speed of the truck can be changed with rotating speed of the motor and the travel direction can be changed with the rotation direction of the motor 1 Gear box and differential Gear box is located between the drive axle and drive motor This device is utilized to reduce rotating speed of output shaft of drive motor increase the torque transmitted from output shaft and then transmit the torque to the differential Refer to Fig1 1 1 5t Fig1 2 2 3t The differential is fitted on the front portion of reducer housing with two end bearing seats the front end of the differential is connected with the axle housing The differential case is of splitting type with
44. and HOMME MISS or others troubleshoot normal noise 5 3 2 Maintenance and service when stopping Assembly Assembly Visualization Tighten clean part Screws etc Looseness dust or rust and spray paint Visualization Connected Terminal pai Looseness or insulation Tighten and check process i Inlets and Visualization Professional Connection outlets wire abnormal damage repair 78 5 3 3 Periodic inspection of motor 1 Inspecting judgment Inspection frequency of the motor is related with operation time every day But at thick dust or high humidity place it is necessary to add inspection frequency Operation time More than 12 hours everyday Less than 12 hours everyday Check frequency Once every two years Periodic inspection must be done according to the following list Judgment Roller Bearing Visualization hearing grease Clean replace bearing sealed leakage noise and dust Visualization high roughness Surface Clean correct Connection because of damage rustiness part Visualization looseness Tighten Screw rustiness and dust antirust replace Visualization high roughness Surface Clean correct because of damage rustiness Visualization connection Connection Tighten replace Terminal looseness insulating treatment Visualization damage of Wire l l Professional repair covering protection 0 00630 5 20 C Professional repair Visualization dust Insul
45. ating resistance higher than Rotor Clean heat Coil 1MQ measured with 500V l treat with varnish ohmmeter Visualization damage discolor Antirust Damage Spray paint peeling and rustiness and repaint S Foreign Visualization dirty dust and Clean antirust ean matter dust rustiness and paint 79 2 Inspecting essential During periodic inspections please abide by the following essentials 1 Select a clean and dry place 2 When disassembling taking notes of the order of disassembled parts is necessary Put the screws and washers into a prepared empty box 3 When disassembling or assembling parts such as bracket strike at it slightly with a wood hammer If striking with a metal hammer the bracket may be broken 4 Don t damage the parts during operation Make the stator coil and bearing far away from water dust or sand especially from being damaged 5 It s necessary to clean and check after finishing disassembling If find parts lack or damaged replenish or replace at once 6 Wipe the coil with dry cloth or soft brush instead of hard material or gasoline petroleum and other solvent 7 Dry the coil when the insulating resistance is too low Heat the coil to 80 C90 C until the resistance is more than 1MO 8 Check if the bolts are loose and tighten them 9 Please refer to the fifth item Inspection and maintenance of bearing 10 When the paint has discolored or peeled off antirust treatment or r
46. ckward a 6 10 6 Front overhang X mm 454 5 Length to fork face L1 mm 2481 C versi Overall width B1 mm 1265 Mast lowered height H1 mm 2040 un Mast extended height H3 mm 4273 Overhead guard H2 mm 2125 Min turning radius R mm 2230 Min right angle stacking aisle width RAXA mm 3915 No load Travel speed km h 13 12 full load Lifting speed mm sec 380 250 Max grade ability 10 E Service weight kg 4850 Max pull force full load KN 10 Front mm 23x9 10 Tyre Rear mm 18x7 8 5 Front B2 mm 1040 o Tread E Rear B3 mm 980 O Wheelbase Y mm 1630 Ground Mast M mm 105 85 clearance Frame F mm 140 120 E SS ee m pen o Drive motor KW rpm 10 2 1500 5 Motor Hydraulic motor KW rpm 10 2000 i Controller GE separate excitation SPECIFICATION CPD30J Model CPD30J D Power type Battery Rated capacity kg 3000 Load center mm 500 Lift height H mm 3000 Free lift height H4 mm 145 Fork size LxWxT mm 1070x125x45 Fork outside spread Min Max B4 mm 250 1100 Mast tilt angle forward backward a i 6 10 6 Front overhang X mm 454 u z Length to fork face L1 mm 2481 e Overall width B1 mm 1265 Overall Mast lowered height H1 mm 2040 dimension Mast extended height H3 mm 4273 Overhead guard height H2 mm 2125 Min turning radius H mm 2230 Min right angle stacking aisle width RAXA mm 3915 P No load
47. der lever 2 Adjust the pedal height with the stopper bolt shown as Fig 2 28 3 With the brake pedal pressed and pull the rod out until its front end comes into contact with the master cylinder piston 4 Tighten the push rod lockina nut Brake switch Stroke of brake switch 5 10mm Height of pedal 115 135mm A Brake switch adjustment 1 After you adjust the height of the brake pedal loose the lock nut of the brake switch 2 Pull the plug out to let the lead separate 3 Turn the switch to make the clearance about 1mm Brake switch 4 When you press the brake pedal make sure that the brake lamps light at the same time 2 2 6 Wheel brake troubleshooting ed 1 Hardened friction piece surface or foreign matter adhered there Noisy brake Repair or replace Uneven 3 Malfunction of operating cylinder Repair or replace braking 4 Shoe return spring deteriorated 5 Deflected drum Repair or replace 1 Oil leaks from brake system Seat 2 Maladjustment of brake shoe clearance Adjust the adjuster spon 3 Air mixed in brake system brake 4 Maladjustment of brake pedal Readjust 44 3 Steering system 3 1 General description The steering system consists of steering hand wheel steering shaft steering oil pump and steering axle The steering shaft is connected with steering unit by knuckle which connects the connection shaft and hand wheel The steering column can be tilt forward and backward t
48. e battery is lower than 1 80V and over charging for it will effect the usual life and performance of battery 5 When charging open the cap for pouring liquid After finishing charging close the cap Keep the vent clear for prevent exploding and damage of battery 6 After using the battery charge it in time If not charging in time undercharge usually standing idle without charging for long time or over discharging the pole plates of the battery will be sulfatization which effect a decline in performance of the battery or cause failure if seriously 7 There is ox hydrogen separated out when charging its necessary to keep good ventilation condition and avoid burning to keep off the explosion 8 During using and charging the level of the electrolyte will decrease and the density will increase Usually add distilled water to keep normal capacity and density of electrolyte Notice Electrolyte can t be added directly 9 Keep the surface of the battery clean maintain and service the pole terminals bolts and connectors loose connections or poor contact must be removed in time 10 During using the battery if the voltage of the single battery is uneven or the 86 battery is not often used a balanced charging an amount over charge every month is necessary 6 3 2 Compound electrolyte 1 The electrolyte of battery must be compounded with sulphuric acid and distilled water or deionizer water according to GB4554 standard
49. e battery in dry clean proper ventilation warehouse 5 C 40 C 2 Let the battery far away from the direct sunshine insolating and drenching and the heat source over 2 meters 3 Avoid the battery being upside down tailed flat knocked or pressed 4 Far from any poisonous or mordant things Forbid any metals and foreign matters dropping into the battery 5 Don t store the battery with electrolyte Under special conditions charge the battery and adjust the fluid level and density of electrolyte In the process of storage charge the battery according to the common way every month 89 6 3 8 Handle waste battery Waste battery should be handled properly in line with relevant laws and regulations 6 4 Troubleshooting guide There are lots of reasons for the troubles besides production quality or transportation and storage unsuitable maintenance will lead to many troubles After the failure launch its necessary to analyze and take effective measures to remedy as soon as possible The features reasons and troubleshooting of the common troubles are as follow 1 Rated capacity not being reached or not enough Capacity drops 2 Capacity drops gradually 3 Capacity drops suddenly 1 The voltage is too high when charging drops quickly when Voltage is discharging abnormal 2 Opening voltage reduces markedly Balanced charging improve the operating Way Not enough charge Density of elec
50. e forklift truck during the test of lifting traveling and idling but the noise of the forklift truck may fluctuate due to different operation and the influence of the external environment 44 The driver feels the vibration of the forklift truck when operating and traveling the forklift truck According to ISO3691 and based on EN 13059 standard The vibration of the forklift truck fluctuates according to environment condition In normal working condition the vertical direction acceleration mean value from the seat to the operator is referred to the following table But the vibration frequency felt by the driver depends on the working condition etc road operation method so the actual vibration frequency must be determined according to environment condition when nee Model the HEN DC Ou S position value from the seat to the a NEN EN12053 12053 EN1809 13059 CPD10 15 69 1dB A 1 10 m s CPD20 25 pe 1 08 m s CPD30 63 9dB A 1 11 m s 45 Users select Lengthening fork in order to carry widening loads Pay much attention not to overload and observe the allowable load and the capacity chart on the truck Careful driving should be taken when traveling and turning 46 When operating the machine observe and follow all markings on the machine The marking plates must be replaced if lost or damaged 47 The forklift truck must be used under the following environment below an elevation of 1000 meters and temperatu
51. e lever can control the speed of the lifting or descending of the goods When the goods are lifted or descended the initial speed shouldn t be too fast in either case 20 It is necessary to brake before tilting the mast forward or backward It s also necessary to tilt forward slowly so as to prevent the goods from slipping off the rack 21 Tilt the mast of the high lift forklift truck as backward as possible when the truck works Use minimum forward and backward tilt when loading and unloading It is dangerous to travel or turn at high levels 22 On the high lift forklift truck with lifting height more than 3m it is noted that the goods on it will fall down take the protection measures if necessary 23 The overhead guard is main part which is strong enough to meet safety standard and protect the operator from falling materials It s very dangerous to dismantle or rebuild the overhead guard because these conditions could lead to an accident 24 A load backrest shall be used as protection against back falling objects on the fork It s very dangerous to dismantle or rebuild the load backrest because these conditions could lead to an accident 25 Load should be contacting with a load backrest Do not handle the load which exceeds height of a backrest When loads go over the load backrest there is a danger of load s falling against operator 26 The stability of the truck is influenced by the wind force during outside operation you
52. ed above mentioned screw out the castle nut for 1 6 turn and then measure the torque value 8 When the torque value measured is up to the specified one lock the castle nut with a cotter pin Fig 3 6 Pre load adjustment 49 3 2 2 Inspection after reassembling the steering system 1 Turning the steering hand wheel right and left to the bottom inspect whether strength of left and right steering is uniform the steering power is smooth 2 Inspect whether connection of the hydraulic pipeline and left and right steering is correct 3 Lift up the rear wheels and slowly turn the steering hand wheel right and left several times to exhaust air from the hydraulic pipeline and the steering cylinder 3 2 3 Troubleshooting of steering system Analysis of trouble Pump damaged or broke down Hose or joint damaged or pipeline blocked Air in steering oil circuit Exhaust air oteering unit fail to reposition due to spring piece damaged or elasticity Replace spring piece insufficient Fail to turn hand wheel Clean or replace Difficult to turn hand wheel Inspect the seal of the Oil leakage in the steering cylinder Truck s snaking or moving with Spring damaged or elasticity insufficient Replace oscillation l Too low oil level in the oil tank Refill oil Excessive noise na m Suction pipeline or oil filter blocked Clean or replace oeals of guide sleeve pipeline or joint Oil leak en damaged Replace Note
53. epaint is necessary 11 Tighten the terminals securely The pontes must be insulated completely with insulating rubberized fabric 12 After assembling check carefully for any residual parts and if the screws are loosen Before trial operation rotate the shaft with hands check for any abnormality 13 Select a place away from moisture dust alkaline or other harmful gas for storing motor Smear anticorrosive oil on the ends of the shaft and wrap with oil paper or membrane etc 3 Usage and maintenance of commutator Commutator has four check windows for checking maintaining commutator and replacing electric brush The seat has four equi spaced magnetic poles with coil made of F copper wire soaked with Grade F insulating paint The stator parts and the neutral position of electric brush have been adjusted the users can t disassemble or adjust it unauthorized 1 Check the armature rotation for flexibility 80 2 Check the terminals and outlets for correctness and tightness 3 The electric brush must slide smoothly in brush box 4 Check if commutator pieces are clean if necessary clean the carbon powder on gaps between commutator pieces and on the commutator surface with soft down less cloth If there is oil on the surface clean it with white cloth with alcohol Do it when stopping the truck 5 Check the fasteners for tightness 6 The brush holder must be firm When turning or disassembling first make a sign and the
54. er long term operation the loose parts will be indicated with alarm codes 2 The damaged electronic components are indicated with alarm code replace them 3 When replacing or disassembling other parts after disassembling steering lifting potentiometers it s necessary to reset the value 58 4 4 2 Steering potentiometer 1 Specification of steering potentiometer Resistance limitation OKO 5KO Steering angle 0 360 Voltage 12V 2 Adjustment a Install the potentiometer on truck body make steering wheels on zero degree straight traveling direction adjust potentiometer to make output resistance value be about 2 5 KO if there is deviation the output resistance must be between 0 KO and 5 KO when locating on 90 90 position b Connect PC machine with controller connector C If electric potentiometer installs correctly the output voltage value will be changed with hand wheel s turning d Enter STEERING SENSOR CALIBRATION menu STEERING SENSOR VALUE 10 Parameter ANTICLOCK w l al Default Steering middle B Bo bo Min Max 1 mv 10300 500 11500 TURN STEERING ANTICLOCKWISE 1200 mv 1200 j500 11500 11500 e Select ANTICLOCK parameter turn hand wheel left until minimum steering value displays save it f Enter CLOCK menu g Turn hand wheel right until maximum steering value displays save it h Enter MIDDLE menu i Turn the steering wheel left and right until zero value dis
55. f industrial trucks Self propelled trucks up to and including 10000 kg capacity and industrial tractors with a drawbar pull up to and including 20000 N Annex of Machinery Essential health and safety requirements relating to the design and Directive 2006 42 EC construction of machinery EN 1726 1 1998 Done at Jingjiang Jiangsu China Name of the signatory gang g d Wx ChenBin On Title Director of Quality Assurance oignature 117 Baoli Y KION Baol Jiangsu Forklift Co Ltd Service Hotline 400 828 2789 Tel 86 523 8461 6148 Fax 86 523 8461 6126 P C 214500 Add No 8 Xinzhou Road Economic Development Zone Jingjiang Jiangsu China www baoli mh com We reserve the right to make any changes or modifications of pictures and specifications in this manual without giving previous notice and without incurring any obligation Edition MEO7 03 2010 Baoli KION Baoli Jiangsu Forklift Co Ltd Tel 86 523 8461 6148 Fax 86 523 8461 6126 P C 214500 Add No 8 Xinzhou Road Economic Development Zone Jingjiang Jiangsu China www baoli mh com Edition MEO7 02 2009
56. g plate and pedal should be larger than 20mm 4 Check the parking brake frequently and make sure that the truck with full load can stoponthe ramp with 15 slope when pulling the lever to the bottom 5 Check if meters lamps switches and electronic wirings are working normally 7 Adjust parking brake HAND BRAKE ADJUSTMENT reduce E increase C gt F Standard Operation Force 8 Add hydraulic oil 22 9 Tyre safety decal charging tyre WARNING Tyres have high air pressure and can be very dangerous to lake apart Only qualified personnel should remove tyres When removing a wheel from the truck First deflate the tyre then loosen nuts A When splitting the rim again check that the tyre is deflated and the air valve is removed Never loosen nuts B if air is still in the tube Wheels should be firmly on the truck or placed in a safety cage during inflation Never over inflate a tyre Split rim Cage protector 10 Sling decal 11 Sling point indication 12 Forbid entering into the rear space of the mast NO ENTER INTO THE SPACE BEHIND THE MAST 23 13 Tyre pressure decal charging tyre 14 Hand caution decal WARNING 15 Forbid conveying person 16 Routine battery use ROUTINE BATTERY USE 1 Limiting appropriate distilled water or diluted vitriol slowly while replenishing electrolyte The electrolyte level must be proper The level exceeding is prohibited
57. gulator jo valve 7 me ateering unit R Tilt e linder a Ex i aa Hultiplax reversing valve Tl a a rate Stearing cylinder Bear Mu cs TT Oil tank Principle diagram of hydraulic system CPD10 CPD20 Pri h li rimary pressure hydraulic Mpa 145 175 17 5 system P1 5 Steering pressure P2 EN 9 3 Hydraulic oil circuit 96 7 1 1 Control valve The control valve consists of four valve housings two spools and one relief valve The control valve lever distributes the hydraulic oil from oil pump to lift cylinder or tilt cylinder In the control valve there is relief valve and self locking valve The relief valve installed upon control valve inlet can control the pressure of system and the self locking valve set on the tilting valve pieces is used for preventing serious results happening of tilting cylinder because of misoperation when there is no pressure source The retaining valve is separately installed between inlet and lift valve inlet port and between lift valve inlet port and tilt valve inlet port The diagram of control valve is referred to Fig 7 1 Lift plunger piston Tilt plunger piston Measure point G PT 1 4 Fig 1 Diagram of control valve 97 1 Operation of the control valve The control valve is operated by the levers All control levers are mounted on a linking shaft fitted on the cabinet through a bracket The control levers operate the spo
58. harge the battery 1 Precaution when charging a Each time after the battery is discharged it should be charged in time Don t place the discharged battery more than a day If it is left idle for long time without charging sulphatized pole plates will make the battery reduce performance b When the forklift truck is seldom used it is necessary to charge the battery full before laying aside and then charge it once a month c Measure the density when the discharging quantity is thought very weak when the density is below 1 160 it is necessary to charge the battery d Balanced charging is necessary when the density difference is over 0 020 usually give the battery a balanced charging every two months e When the time of balanced charging is too more that is over charging battery s life will be shorten f If the temperature of electrolyte is above 55 C before charging it is necessary to leave the battery idle for a period of time not until the temperature come down can it be charged g Overcharging or over discharging could make the temperature of electrolyte go up When charging the battery open the battery cover to radiate heat and ventilate 2 Characteristics of full charging battery a The battery voltage of is about 52V 1 2 5t forklift truck with 24 groups batteries or 86 8V St forklift truck with 40 groups batteries b The density of electrolyte is about 1 280g cm 6 3 7 Storage of battery 1 Store th
59. he accelerator pedal on initial state b Connect PC machine with controller connector c If accelerator connects correctly the output voltage will change with the stroke of the pedal d Enter ACCELERATION PEDAL CALIBRATION menu 61 e Press the pedal slowly until START lamp lights save it f Select MINIMUM menu press the pedal slowly until output value is larger than start value save it g Select MAXIMUM menu press the pedal slowly until the max output value occurs save it h Get out of menu uc sena PEDAL SENSOR VALUE 0 mV Forward Reverse Start P Value Default Min Max MII vi mv fr000 4500 SLOWLY PRESS PEDAL UNTIL START SWITCH TURIS ON fu fw feson soo remo 4 6 LED instrument DC The electric forklift truck adopts newly displaying with combination of LED and LCD Control circuit adopts micro computer technology sampling displaying and controlling in real time The intense and feeble circuit in the instrument adopts light electricity separating with control relay It has under voltage warning and high automatic supporting function Refer to Fig4 9 4 6 1 Outline and instructions of instrument Fig4 9 LED instrument 62 1 Voltmeter It indicates voltage of the battery The single cell voltage must greater than 1 80V that is to say when the forklift truck with load the voltage of 48V battery can t be lower than 43 2V the voltage of 80V battery can t be lower than 72V 2
60. he horn TAC NONI SO NOS When DIESSING the button Operating lever Indicate turning Dm turning lights Pull operating lever when turning Operating lever Mast lifts when pulling backward lift cylinder a NINE descends when pushing forward Operating lever Tilt backward when pulling n tilt cylinder SPARIS trey Inder backward it s forward oppositely Accelerator pedal Control output voltage Press and accelerate Seat adjust handle Adjust seat position sg hock battery cover Press the rear button of battery cover to open the lock Lock the battery cover 2 6 2 Electric forklift truck with DC motor 1 Start Before starting put the hand brake switch on the brake position turn on the urgent power down switch pull the shift direction switch to neutral If not the safe circuit plays its part then the forklift truck can t start Turn the start switch electric lock clockwise to shift Ito turn on the power meter indicator and electric control circuit release the hand brake switch Push the shift direction switch forward press down the accelerator pedal then the truck goes forward if pull the direction switch backward the reverse lamps light and the back up buzzers sound If having an operational error the meter will show relevant error code then reset the key switch to restart the forklift truck 17 2 Lamp switch Pull shift I front and rear clearance lamps light Pull shift IL the head lamps light while the clea
61. hing seals snap rings oil seals and spring snap rings as require 105 Fig 7 12 Fig 7 13 3 Assembly a Install a new seal ring and a new ring on the front cover of pump b Install the lining plate on the groove of the front cover don t confuse the inlet oil port and the outlet oil port c Install the driving gear and the driven gear on the front cover d Install the lining plate on the side of the gear with groove aiming gear point don t confuse the inlet oil port and the outlet oil port Fig 7 14 e Install a new seal ring and a new ring on the groove of the rear cover Fig 7 15 f Install the rear cover on the pump body don t confuse the inlet oil port and the outlet oil port g Tighten up the connecting bolts with a specified torque of 9 to 10 kg m after all Groove Snap ring Root section Bottom of the pump body inner surface Outlet oil port Fig 7 14 Lining plate Fig 7 15 Seal Notice The maintenance data of oil pump parts may be different because of the difference of manufacturers 106 4 Trial run After installing the gear pump in the truck check it reassembled for specified performance and do the trial run for it If the pump s gears are seized or internal parts worn excessively you should renew the hydraulic oil and filters or clean them The trial run procedures are as follows a Install the gear pump in the truck Then install a pressure gauge in pressure inspect
62. in over Voltage V ge D Q gt gt gt gt TE gt gt Tu P gt gt gt gt gt gt gt gt E O D e e Density of electrolyte St It must be charged when the density of electrolyte is lower than 1 160g cm S25 St 0 0007 t 25 S25 The density when the temperature is 25 C St The density when the temperature is t C measured value t The temperature of liquid measured value Final voltage about 52V 1 2 5t about 86 8V 3t Charged electricity 130 150 of battery ration Liquid level Higher than the shield for 15 20mm Abnormal condition Note Please copy and fill in this list strictly it will provide basis for maintenance and service of battery 115 NOTE 116 EC DECLARATION OF CONFORMITY MANUFACTURE Name KION Baoli Jiangsu Forklift CO LTD Address No 8 Xinzhou Road Economic Development Zone Jingjiang Jiangsu China Post 214500 Jiangsu China THE TECHNICAL DOCUMENTATION WAS COMPILED BY Name Wu Yun Cheng Address Hoppengarten 19 Germany Post 40489 Duesseldorf Germany HEREBY DECLARES THAT THE PRODUCT DESCRIBED BELOW Description Industrial truck Counterbalanced Lift truck Model Serial number Manufacturing year COMPLIES WITH THE PROVISIONS OF THE FOLLOWING EUROPEAN DIRECTIVES 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 2006 95 EC LVD Directive COMPLIES WITH THE PROVISIONS OF THE FOLLOWING HARMONIZED STANDARDS Safety o
63. ion port of the control valve b Loose the adjustment screw of the relief valve and run the pump at 500 to 1000 rpm for ten minutes The oil pressure should be lower than 10 kg cm c Increase the speed of the pump to 1500 to 2000 rpm for ten minutes d Without the change of the speed in step increase the pressure to 20 to 30 kg cm at a time and run the pump for five minutes Then increase the pressure to 175 kg cm Each circuit works for five minutes and then renews the return filter During the increase of the pressure observe the change of oil temperature and pump body surface temperature and working voice If the oil temperature or pump body surface temperature is excessively high decrease the load to reduce the oil temperature then go on doing the test e After the trial run measure the flow amount through lift speed with the pressure of 175 kg cm of the relief valve 7 2 2 Troubleshoot If the hydraulic system has a fault find out the possible cause according to the following tables and repair it 1 Control valve Lower oil pressure of the lifting oil Spool is held up Disassembly and clean circuit Oil hole is blocked Disassembly and clean Vibrate and the oil pressure rising Spool is held up Disassembly and clean slowly Exhaust not fully Exhaust fully The oil pressure of the steering oil Spool is held up Disassembly and clean 107 circuit is more than the specified Oil hole is blocked Disassembly and c
64. ket with bolts The moving along inner mast wind plate can be adjusted by shim To prevent the clearance when moving make two immovable side rollers move along the outside of inner mast wind plate Main rollers sustain the longitudinal loads And side roller sustains the transverse loads When forks reach the maximum height the upper pair of main rollers will come out from the top of the inner mast Fig 8 3 Fig 8 4 Backrest Main roller Spring amp Stopper pin Fork Fig 8 3 Lift bracket 1 1 5t 8 1 3 Fork pin Backrest i I stopper pin Fig 8 4 Lift bracket 2 3t The fork pin fastens the fork on the definite position When adjusting the clearance of the fork pull the fork pin turn 1 4 circle the fork clearance must be adjusted according to the loaded goods 111 8 2 Maintenance and adjustment of lifting system 8 2 1 Adjust lift cylinder Fig 8 5 Readjust the stroke of the lift cylinder when replacing the lift cylinder the inner mast or the outer mast as following 1 Place piston rod heads without shims into the upper beam of the inner mast 2 Ensure that two lift cylinders are lifted at the same time when the mast ascended at its height 3 If they not lifted synchronously add shims between the upper beam of the inner mast and the piston rod head which reaches to its height firstly The shims thickness is 0 2mm or 0 5mm 4 Adjust the tightness of lift chains NOTIC
65. l the brake line on the operating cylinder 11 Measure the inner and outer diameter of brake drum Adjust the adjuster to obtain the difference needed between the drum inner diameter and the friction piece outer diameter 2 2 4 Operation test of clearance self adjuster 1 Make the brake shoe diameter approach the specified mounting size and pull the adjusting level with your finger along the arrow marks as shown in Fig 2 27 to turn the adjuster gear When removing off your finger the adjusting lever should return to its original position without rotation of the adjuster gear Note Even if the adjuster gear turns back along the adjusting lever motion when removing your finger the adjuster will still operate normally after it is fit in the truck 42 MSS nd m f MIO m N CEA 7 At EZ F SS i SEZ EFT Fig 2 27 2 If the adjuster fails to do the above operation when the adjusting lever is pulled proceed with the following inspection a Make sure that the adjusting lever push rod rod spring and the return spring for push rod are securely installed b Check the push rod return spring and adjuster spring for damage and also check the adjuster gear for rotating condition and meshing section for undue wear or damage Check if lever and gear is contacted If above mentioned condition occurs replace the damage parts with new ones 2 2 5 Brake pedal adjustment see Fig 2 28 1 Push the master cylin
66. lean Misadjusted relief Adjust Misadjusted relief Adjust Noisy control valve Slide surface worn Replace relief valve Oil leakage outside i i Replace O ring seal Replace spring Lower setting pressure Valve seat surface Adjust or replace relief is worsen valve FR Valve seat surface Correct valve seat Oil leakage inside IS worsen surface Higher setting pressure Valve is held up Disassembly and clean 2 Gear pump Lower oil level of oil tank Add oil up to specified level Less exhausting oil Blocked pipe line or oil filter Clean or replace oil Lining plate seal ring bushing seals or snap ring broken down Replace Adjust the pressure of surplus Lower pressure of Misadjusted surplus valve valve to specified value with gear pump pressure gauge Retighten loose connections for Air entering into the pump suction pipe Add oil into oil tank Replace oil seal Worn suction pipe or Check pipe or repair filter Air entering in resulting from Retighten the connection Too high oil stickiness Use oil with proper stickiness Air bubble in oil Find out cause and correct Oil leakage in Oil seal or seal ring broken 108 8 Lifting system 8 1 General description The lifting system is the type of lifting and descending vertically with rollers of the two stage It consists of the inner mast the outer mast and the lift bracket The fork is fastened on the bracket upper beam groove with pin the fork cleara
67. mage or fault is found the matter should be reported to the manager Only trained and authorized serviceman shall be permitted to service the truck Do not operate the truck until the truck has been repaired completely 4 Maintain the motor electric controller and battery according to their manuals 5 Check all plugs once a month 6 Don t wash the truck with a water syringe Outdoor using the truck in rainy day is forbidden 7 Clean the dust of photoelectric coupler of the hydraulic motor switch 8 Clean and dry the surface of the battery usually 9 Periodic maintenance must be done according to the following list after using the forklift truck Bearing steering wheel Replace grease 3000 3 Bearing dvewhee Replace grease 1000 3 Steering ink lever Replace grease 1000 Ca Parking brake lever Addgeme LS Pin footbrake Adigeme 6 Drive axle body Replace gero 240 Dems e Emm e Pin itingoyinder AddWbrcaiggesse 40 9 Kingpin otknucke Replace grease 1000 L1 Fyorauic tank and ter cen rir Hysrauico Repas wo 14 Switch hyarauic motor Clean photoelectric coupler 300 15 Brush tractonmotor Check wo 16 Bush hydraulic motor Check wo 17 Brush PS motor check wo 15 Notice When serving and checking the truck do not
68. mperature of opecific gravity of Temperature of opecific gravity of L EN NEN pm NE NE RC 0 1 42944 1 4280 1 287 1 273 2 Balanced charging After the battery fully discharging measure the specific gravity when charged distilled water and that of all batteries then converse the values setting the temperature 25 C come out the difference When the difference is over 0 02 and other performance ruled balanced charging is necessary Charging equally according to these procedures After operating by the way the same with daily operating press balance charging function button the balance indicator flushes and JH appears When the battery is fully charged press the balance button to release The charger returns to normal condition Notice If charged more frequently it may lead overcharge and shorten the useful life of battery 93 7 Hydraulic system 7 1 General description The hydraulic system consists of gear pump control valve lift cylinder tilt cylinder and hydraulic lines Oil pump directly connected with motor supplies hydraulic oil which distributed to each cylinder by control valve 1 Performance of components Forklift model 1 1 5t 2 2 5t 3t Type Gear pump Control Type Single action piston type with cut off valve otroke 1495mm lifting height is 3000mm Type Dual action piston type 94 pump 2 Diagram of hydraulic system Lift evlinder mi Flow ra
69. must notice specially 27 Be careful and slowly driving over a dock board or bridge plate 28 When travel with load don t tilt mast forward don t do handling Don t brake abruptly to prevent the bulk from slipping off the forks 29 Drive the forklift truck to the stacked goods at a low speed at the same time pay much attention to sharp and hard objects near the goods otherwise the tyres will be pricked 30 Pay attention to pedestrian obstacle and bumpy road when driving Pay attention to the clearance over the forklift truck 31 Keep your head hands arms feet and legs within the confines of the operator s compartment Never allow other persons on the forklift truck 32 Crossing turning and tilting shall not be taken on a slope It could cause turning sideways of the truck it is very dangerous On a slope drive the truck with load forward to ascend and backward to descend When the truck goes down on a slope drive slowly with the brakes on Make sure that the engine should not be shut down when traveling on a slope 33 The starting turning driving braking and stopping of the truck should be done smoothly When steering on the humid or slippery road the truck should be decelerated 34 Operate the controls smoothly don t jerk the steering wheel Avoid sudden stop acceleration stop or turn In the case of improper operation the truck will turn over In case of this the driver must keep calm don t jump off the tr
70. n loosen the screw 7 When assembling the brush frame tighten the screw aimed on the marking to make the electric brush on the original neutral position 8 Check the coil insulating resistant periodically If the data is below normal when reaching the working temperature it s necessary to make it dry 9 Open the shutter regularly to check if the inner parts out of shape and the commutator operating normally 10 Usually clean the dirt on the casing to help radiating heat 11 Check the motor every half a year as follow methods a Check and clean the dust of the motor b Clean or replace the bearing Pay attention to the abnormal noise of the bearing when operating c Check the electric brush for wear replace it if necessary 4 Inspecting and polishing of electric brush 1 Inspection of brush and brush spring The line marked on the electric brush indicates wearing limit When roughness is excessive replace it Measure the tension of the brush spring on the rectifier with spring balance meter 2 Polishing of the electric brush a When replacing the electric brush polish it with 00 emery cloth When polishing pull the cloth left and right b After polishing electric brush and cleaning commutator for safety the motor should work in limited speed with capacity until the surface of electric brush is polished 81 Fig 5 4 Method of polishing 5 Inspection and maintenance of bearing 1 Inspection and main
71. nce can be adjusted The fork and bracket can be exchanged according to the international standard 8 1 1 Inner and outer mast Fig 8 1 and Fig 8 2 The inner and outer mast both are welded parts The bottom of outer mast is assembled on the drive axle with support The outside middle of outer mast is connected with the frame by tilt cylinders The mast assembly can be tilted forward and backward by operating tilt cylinders The outer mast has C shaped cross section fixed with main rollers and side rollers on the top of it The inner mast has J shaped cross section fixed with main rollers and side rollers at the bottom of it NOTICE Please pay more regard to safety when maintaining the main rollers and side rollers on the upper of the mast Inner mast Outer mast Main roller Shim Ring ZN N Main roller Gasket Slipper Shim 10 Pin shaft 11 Cap 12 Bushing v An EAS y e d Oo ON OO P OQ nm DD I E Fig 8 1 Inner and outer mast 1 1 5t 109 Retaining roller Inner mast ias gt Fig 8 2 Inner and outer mast 2 3t 110 8 1 2 Lift bracket The lift bracket moves up and down smoothly along the channel of the inner mast with main rollers The main roller is fixed on the axis of the main roller by snap ring And the axis of the main roller is welded on the lift bracket But the side roller is assembled on the lift brac
72. neral for saving electricity 1 Start the key switch press ENTER button for 3 seconds enter into adjust and diagnosis mode 2 When operating press for 3sec enter into diagnose mode 3 Quit when pressing ENTER under diagnosing mode the enter key Is used for setting new parameter 1 Reduce the parameter in adjusting mode when pressing this key 2 he parameter can be reduced in adjusting mode 3 Press the key for 1sec indicating mileage or weight Note The function of Up key is same to down key enter up and down key have some functions not activated Four LED signals on the left of compact meter indicate when operating the relevant switch Alarm indication red color LED Lamps indication green color LED Steering switch on steering signal activated green color LED Insufficient brake fluid red color warning LED optional 69 4 7 4 Process and instruction of meter 1 Turn on the key switch some initial value mode will indicate for 3sec on the meter The mode helping operators judge the type of the forklift truck will indicate on the position indicated speed such as the four wheel forklift truck is represented by CO The information about speed electric energy turning angle hand brake seat switch E S H selection and working hours is indicated on the meter which help confirm the working state 2 Alarm indication is on the first left line of the liquid crystal form indicating three working states when
73. o suitable position see Fig 3 1 Assembled on the rear end bracket of frame the steering axle consists of one steering knuckle separately on the left and right The steering cylinder piston pushes the steering knuckle to steer through lever then the steering wheel will be deflected and carry out steering Fig 3 1 Steering control device 3 1 1 Hand wheel Hand wheel is operated in normal way that is to say when turning the hand wheel right the truck will turn right when turning the hand wheel left the truck will turn left The rear wheels of the forklift truck are steering wheels which make the back of the truck swing out when turning The turning method can be mastered easily through practice 45 3 1 2 Powered steering unit Fig 3 2 The powered steering unit can transmit the pressure oil from the flow divider by metering to the steering cylinder in terms of the rotating angle of the hand wheel When the steering pump stops running a manpowered steering should be adopted The powered steering unit consists of a general steering unit and a combination valve The hole on the cover of combination valve is relief valve In the valve body there is a bipartite over load warning valve which protects the parts from damage when the truck wheels suffer unexpected impact and cause high pressure for hydraulic system We have adjusted the relief valve and bipartite over load warning valve the users can t adjust them without permi
74. of electric forklift truck 13 2 6 Brief operation instruction cece ccc cece eee e eee eee e eee e mmn 16 2 1 Caution plates eiie e toi ete t tonsa Pb tie Pra eb deed ost E daa bae odd 20 III Construction principle adjustment amp maintenance of electric forklift truck 26 1 Transmission system ssssssssssssssssssen Im eee 26 1 1 General desenplion usscsseccosuseu aute ET A eti 2 CDU Ld d qus 26 1 2 Assembly of wheel hub ssssssssssssssssssssssse e esee essem nnns 31 AMICcDCNSLICuMCITE U 32 2 1 General descripti siones eo daten abeo In ER ax DEN Uti BE Hei 32 2 2 Disassembly assembly and adjustment of wheel brake sssue 39 3 Steering SYSTEM u ee reinen 45 3 1Generaldeseriplionz Asurenietleenl auc iis a D Uie orit Cede ats 45 3 2 Adjustment and maintenance sssssssssssssssssses sens 49 4 Electri System u a ob ra a OR DET Dto Ita reb edere E ed 51 4 1 General description sssssssssssssssssssesssss nme eme e semen nnns 51 4 2 Multifunctional integration control system DC cce ccc cece cece eee eeeeeeeeeeeaee ees o6 4 3 SME AC electric controller assy sseesssssssese mnm 58 4 4 Distribution and setting of sensor AC ssssssssssee mne 58 2 9 ACC ITONO een er ae 61 4 6 LED instrument De ans damnet rtr
75. of goods Don t pick the loads with one fork tip 11 When handling bulky loads which restrict your vision operate the forklift truck in reverse or have a guide 12 When loading the goods lower the forks to the floor After the fork inserting stacked goods the fork arms should be in contact with the goods Drive the truck with mast tilting back for stabilizing the load Before traveling raise the forks for 200mm 300mm from the floor 13 While masts lifting and lowering anyone is absolutely prohibited from standing under the lifting rack or being lifted with forks Never permit anyone to stand or walk under upraised forks 10 14 When loading and unloading goods keep the mast vertical and the truck is in braking state 15 Because the rear wheels steer your truck the rear end swings wide when you turn Use care in aisles and other tight places 16 During operation pay attention to the performance and condition of machinery hydraulic electric and speed adjuster 17 Connect the power source turn on the key switch select the position of directional switch check the truck for normal operation by turning steering wheel depress the accelerator pedal softly to keep proper acceleration 18 When the voltage drops below 43 2V 1 2 5t forklift truck or below 72V 3t forklift truck during operation with load its necessary to charge the battery or replace a full charged battery at once 19 The shift distance of control valv
76. ols through the linking rod Tilting control lever Fitting lever Optional Lifting control lever a Ese Valve switch s ke re TE UE RE eee ch ine der ar pas sd NC HOC IS o 9 OT n R O HH 2 o m xy iThlile Valve reel Yale core o Fig 7 2 Operation of control valve A Install the inching switch Make the inching switch bulb and camshaft keep identical center with the tangency of bulb surface and reel then press the inching switch bulb with control valve rod make the stroke no less than 0 8x0 1mm make the inching switch keep ON position which can be opened or closed freely by adjusting the clearance properly 98 2 Setting pressure of the relief valve Fig7 3 The pressure of the relief valve has been set before delivery Don t adjust the pressure at will for it will bring danger for system and safety If the oil pressure is different with standard value as the following form according to the measure method specified in JB T3300 specialized servicemen adjust the pressure as follows a Screw out the measured hole plug from the inlet port of control valve and install the oil pressure gauge 20MPa on it b Operate the tilt lever measure the pressure when the stroke is to the bottom c When the oil pressure is different from the specified value loosen the lock nut of the surplus valve adjust the adjusting screw left and right to achieve the specified value Tu
77. oltage drop between the contact terminals with multimeter to make sure there is no resistance between terminals Make sure that the sound of turning on or off the micro switch is slivery The inspections of micro switch should be done every three months 3 Check the connecting lines of primary circuit and make sure good insulation and connecting tightness of cables of the battery controller and motor Check the cables every three months 4 Check the spring of foot pedal or levers make sure the usual deformation and smoothly resiling of spring Do the inspections every three months 5 Check if the contactor terminal is working freely and not felted Do the inspections every three months Notice The controller needn t be repaired by users so don t open it for it may be damaged and lose guarantee Make the controller clean and dry inspect and clear the diagnosis history documents periodically Never start the electric control of incorrectly installing vehicles Only trained people can do periodic maintenance and replace the damage parts with 19 genuine parts of controller Use the genuine parts produced by our company for ensuring the quality During inspection if there is status that may bring damage or cause dangerous inform the agent immediately they will make a decision of the operating security 2 6 5 Particular notice 1 As a special vehicle electric forklift trucks need professional maintenance and authorized persons
78. on lamp Steering potentiometer Controller assy Battery assy Socket and connector Flasher Fuse box Accelerator Traction motor Lifting motor CON O OF FB CO TO ho NM PNP PO P P NM Ee He EF HS oa oo o o CO Oo 01 A C051 0oO ODO AN OO BPW PS O NO N Fig 4 4 Construction of electric system AC 54 WN01140 t WOLIAS 1H913H NO11VI1INI1 i Hollas 1H913H NO 1V1 RN 1 W0108 01 031 Wd SNY3 HOLIMS 3xvug wava IL ca T AS wWN0 I19381G W01vu31320Y 4 Ta TINAA XDXD ND WOSN3S 310NY 0NINJ3IS Acl A138 u327n8 Avaya 3ATYA 108 MOSN3S 1411 HOLIMS 433 ISNA A33 due peay o el km LE Orro jo o19 21195 34317 LOTOO due asueseaj S due 3uiuaey X LI 16 yopims 6U0132811Q o due Suiysom Jeay SEN Gwe 9s19 8y x Q yan o eS 08 U93 MS usn H 1 due Quissaig SQ tat ysef gt 0 due sye g S O x t CRAT a l yaz ns ayeag ic 0L wr Mil AlgWN3SSV 31000W YIMOd YOSN3S QuV08 TOYLNOD 15 7 0 1 M A9N393383 Fig 4 5 Principle of electric system AC 55 4 2 Multifunctional integration control system DC Multifunctional integration control system consists of separately excited motor controller pump controller and contactor Separately excited motor controller is composed of controller and accelerator Fig 4 6 Fig 4 7 1 SX transistor controller SX transistor c
79. ontroller is introduced by GE in USA using the advanced technology it has the advantages as follows independently controlling the armature and excitation circuit the best attributes of both the series and the shunt motors can be combined it has high torque at low speed a plug braking regeneration control thermal protector and battery protector etc 2 The accelerator is composed of start switch and potentiometer The potentiometer converts the degree of the pedal into changes in the resistance of the potentiometer then transfer to the controller by means of voltage change Fig 4 8 Excitation S2 Excitation S1 3 4 2 15A Fuse E O oO lioc 10 Wire contactor 300A 142 a amr o o f o o 8 A Separate excitation controller Input wire a Power pump motor Fig 4 6 Controller assy DC CPD10 25 56 FU2C16A Key switch ee ie i Switch switch in Accelerate control J gt 10 AMP 9Core AMP 5 Core AMP 5 Core Soc la TPA Al O Fi Qe O SL N N A E i Onnin n na rif icd H aei 6 J Al Fal BN ADE IM en O16 ULL Iv e NT j Ae e XLI Wi MIA i 29 OMULO OL Tarmature excitation Pump motor fotH Hoito Hotel 9 N E L
80. ough the oil chambers A and B oil holes C D E and F and the chamber G to the lift is cylinder without any regulation When the lift Dona Kd spool is placed in the down position the oil d AER flows in the reverse direction When much oil g Se passes the orifice plate the pressure difference eu l gt overcomes the force of the spring and moves a the valve core right thus the oil flow being decreased by narrowing of the hole D and C and reduces the oil flow passing through the orifice plate the descending speed of the fork becomes slower ERE TU ETE TT Nipple Spring Ball Valve core Sleeve Orifice Spring O ring Case plate Fig 7 7 Flow regulator valve 102 7 1 4 Tilt cylinder The tilt cylinder is of double acting type Each truck has two tilt cylinders that are installed on two sides of the frame with pin while their piston rod ends are connected with the outer mast The tilt cylinder consists primarily of piston piston rod cylinder body cylinder base guide sleeve and seals The piston welded to the piston rod is fitted with two Yx rings and one wear ring on its circumference A bushing press fitted to the inner side of the guide sleeve supports the piston rod The guide sleeve is with dust seal snap ring Yx ring and O ring to prevent oil leakage and keep dust off Fitted with them the guide sleeve is screwed into the cylinder body The construction of tilt cylinder is referred to
81. place the levers in the neutral position Disconnect the power plug 3 Apply the parking brake 4 Wedge up the front and rear wheels 5 If the truck leaves unused for long time build the wheels on stilts Charge the battery once a month 2 3 Precautions before operation 1 Check all the instruments 2 Check the tyre inflation pressure 3 Check all the levers and pedals 4 Check if the voltage of the battery is in normal limit Check if the density and level of the electrolyte is appropriate 5 Check for all the terminals and plugs 6 Check hydraulic oil electrolyte and brake fluid for leakage 7 Check all connectors and fasteners for looseness 8 Check if all the lamps and signals are in normal state 9 Release the parking lever 10 Make trial of the mast for lifting and lowering forward and backward tilting and the truck for steering and braking 11 The contamination level of the hydraulic oil should be lower than grade 12 2 4 Information of safety operation 1 The forklift truck belongs to special equipment Only trained and authorized operator shall be permitted to operate and service the truck 2 Wear the safety guards such as clothing shoes helmet and gloves while operating the truck 3 When the distance between the gravity center of loads and the fork arms is 500mm the max capacity is the rated capacity When the distance exceeds 500mm the capacity shall be based on the load char
82. plays straight traveling direction save it j Quit the menu 59 Do trial operation check if the position of steering wheel and displaying angle of meter is consistent range over 0 90 90 4 4 3 Lifting potentiometer 1 Specification Resistance limitation OKO 5KO Effective straight travel 9 0 5mm Voltage 12V 2 Adjustment a Install potentiometer on the first level lift of multi way valve make sure that the top Potentiometer lever of potentiometer runs freely b Connect PC machine with controller connector c Enter LIFT CALIBRICATION menu LIFT COMMAHD VALUE 0 mV Parameter Value Default Min Max MIH vi RELEASE COMMAND Foo nv Mew m d Select MINIMUM parameter the minimum value will be indicated in lift calibration value frame save it e Enter MAXIMUM menu f Operate lift lever until the maximum potentiometer output value indicates and save g Enter MIDDLE menu 60 h Operate lift lever until indicating middle value between minimum value and maximum value save it i Quit the menu 4 5 AC microtron 1 Outline and port function Direction of motion Front backing Power positive input 12V Red Power negative input 12V Accelerator signal linear ranged from 0 38V 0 42V to 3 9V 4 1V Switch signal Non polarity opening contact Capacity 2A 100V 3 Setting for accelerator a Install potentiometer on front backing plate make sure t
83. r NS ad 1 1 5t forklift truck 2 2 bt forklift truck 3t forklift truck Drive motor Name XQ 5 3A1 XQ 7A3 XQ 10 2A Excitation Separately Separately Separately Rated power 5 3kw an hour 7kw an hour 10 2kw an hour Rated voltage 45V 45V 75V Rated current 139A 180A 162 5A Weight 95kg 60kg 115kg Lifting motor Name XQD 8 2 1 XQD 8 6 3D XQD 10 3D Excitation Series Series Series Rated power 8 2kw a quarter 8 6kw a quarter 10kw a quarter Rated voltage 45V 45V 75V Rated current 240A 248A 160A Weight 45kg 47kg 90kg 5 1 2 Drive motor Installed on reduction box of drive device the rotation of the drive motor is controlled by low power transistor H axle circuit in the controller Rotation status of the motor is determined by the current direction that flows through motor excitation coils 5 1 3 Lifting motor Lifting motor drives the main pump it is installed on the left frame of the forklift truck The sketch of structure and assembly refers to Fig 5 1 and Fig 5 2 The rotation of lifting motor is controlled by the pump controller assembled in the counterweight 75 Main pump Pump motor Fig 5 1 Assembly diagram of lifting motor Clip Electric brush Series excitation Backing wiring harness Motor seat electron Brush lever Fan Brush cover Figo 2 Lifting motor 76 5 2 SME three phase AC motor The power system of four wheel electric forklift truck is composed of three phase AC
84. rake Built in the wheel brake the parking brake device consists of pull rod and push rod Assembled on the side of primary brake shoe by pin the operation of the pull rod transmits to the side of secondary brake shoe through the push rod See Fig2 5 3 Clearance self adjuster The clearance self adjuster keeps appropriate clearance between the friction piece and brake drum This adjuster however actuates only when the truck is braked in reverse travel Its structure refers to Fig 2 6 Adjuster Fig 2 3 Braking operation Fig 2 4 Braking operation in forward travel in reverse travel 34 Pin Secondary shoe Spring pull wire Puli rod Adjusting lever y Primary shoe Fig 2 5 Parking brake device Fig 2 6 Clearance self adjuster A Motion of clearance self adjuster When the brake pedal is pressed in reverse travel the brake shoes are expanded as a result the primary and secondary shoes come into contact with the brake drum and rotate together This brings that the brake pull rod turns right round point A then point B is lifted On the other hand as the brake is released the lever turns left actuated by the spring point B descends The descending distance of point B becomes further with enlarging of clearance between friction pieces and brake drum This cause adjusts lever get long and clearance decrease See Fig 2 6 Fig2 7 Range of adjustable clearance al d 0 35 0 55mm 0 40 0 45mm Fig2 7
85. rance lamps light too 3 Steering signal Pull the steering lamp switch backward the front and rear combination turning signals on the left side of the truck light pull the turning lamp switch forward the front and rear combination turning signals on the right side light 4 Brake signal When braking press down the brake pedal and turn on rear combination brake lamps red light 5 Reverse signal When reversing the truck pull the direction switch backward then the travel motor reverses rear combination reversing lamps white light and the back up buzzers sound 2 6 3 Electric forklift truck with AC motor 1 Start Before starting put the hand brake switch on the brake position the shift direction switch and seat switch on neutral turn on the urgent power down switch If not the safe circuit plays its part and then the forklift truck can t start Turn the start switch clockwise to shift Ito turn on the power meter indicator and electric control circuit release the hand brake switch Push the shift direction switch forward press down the accelerator pedal then the truck goes forward If pull the direction switch backward the reverse lamps light and the back up buzzers sound If having operational errors or others the meter will show different error codes some common features as follows If pressing down the accelerator pedal first then turning on the direction switch the meter will show code 64 expressing start error
86. re between 15 Cand 35 C relative humidity is 9596 Careful operation must observe under other adverse circumstances 48 To prevent the fire accident or other unpredictable event prepare the fire extinguisher in advance and operate it according to the instructions 49 You can t change or add other working equipments on the truck without our company s permit or the rated capacity and safety operation will be affected 50 Keep safety when serving on high position 13 2 5 Periodic servicing and maintenance of electric forklift truck During operating the forklift truck it is necessary to operate carefully service and maintenance periodically to make the forklift truck keep in good condition 2 5 1 Handling a new forklift The performance and service life of forklift depends heavily upon the way you handle it during the break in period Drive with special caution while becoming familiar with a new forklift Retighten the fasteners after the replacing 1 Replace gear oil in the differential and reducer after the new forklift working for 100 hours Retighten the fasteners after replacing 2 Reagjust the clearance of the driving and driven gear in the reducer after the new forklift working for 200 hours 2 5 2 Cautions for starting 1 The amount of hydraulic oil The oil level should be at the middle position between the upper and lower scale marks of oil level meter 2 Check if any leak or damage found on the piping joints p
87. rn the screw left when pressure is high and turn right when it is low d After having adjusted tighten up the lock nut Setting pressure 1 1 5t 2 2 5t Pressure of relief valve 14 5MPa 17 5MPa 17 5MPa Pressure of steering uni Oil inlet Lock nut Cap Fig 7 3 Setting pressure of relief valve 7 1 2 Lift cylinder The lift cylinder is of single action piston type It consists of cylinder body piston rod piston and cylinder head The bottom of the cylinder is connected with the cylinder supporter of the outer mast by bolts and pins while its top i e piston rod head is connected with the upper beam of the inner mast 99 The piston fastened to the piston rod with spring wire is fitted with oil seals and wearing on its outer periphery At the bottom of the lift cylinder there is a cut off valve which operates when the high pressure hose bursts for any reason to prevent the load from dropping abruptly There are steel backed bearing and oil seal assembled on cylinder head to support the piston rod and prevent the dust The diagram of lift cylinder is referred to Fig7 4 Fig 7 4 Lift cylinder 100 NO N N aa l ja NO O O O N O Oo A C N e OO NOORA C N NO CO Upper beam Adjust shim Dust ring Oil seal Guide sleeve O ring seal Cylinder head Steel backed bearing Cylinder body Piston rod Piston Oil seal piston Oil seal
88. ry capacity Output voltage 7v 7v 108v 72V 50A 100A Weight 60kg 75kg 120kg 85 Current Intelligent control single phase AC steady voltage Form charger Rated power 4 5KVA 5 5KVA 9 5 KVA Voltage 220V 50HZ 380V 50HZ 380V 50HZ Charger 6 3 Usage and maintenance of battery The correct using and daily maintenance is very important for the performance and useful life of lead acid battery Operators must maintain and service the battery according to the manual and realities fill in the record card of charging The card can be copied as the daily inspection record referred to the attached list at the back of the manual 6 3 1 Information about battery operation 1 Before using the new battery clean the surface and check for the damage Smear butter or Vaseline on the connectors to retard corrosion 2 The battery is assembled on the truck for balance weight if it s lower than the Min weight the load capacity will be affected When assembling the battery on the truck fasten it with pin The pin must be assembled after lifting and replacing the battery The stability of the truck will be affected with no fixed pin 3 The first charge before using new battery is initial charge after that the current of common charging must keep the specified value and input capacity is 13096 15096 of output capacity the battery must charge for about 12 hours 4 When operating the battery avoid over discharging mean the voltage of singl
89. ssion 5 4 3 2 J Wa EJE BH 7 ZA SERA SN EN EI N ELITE SINN LEN TEE NA LLIN A E Fig 3 2 Powered steering unit 1 Spacing sleeve 4 Interlock axle 7 Rotor 2 Valve body 5 Spring piece 8 Stator 3 Valve core 6 Joint sleeve 9 Valve sleeve 46 3 1 3 Steering axle The steering axle is of section boxed welded construction type Fig 3 3 It includes axle body steering cylinder link lever steering knuckle and steering wheel The steering axle is of slider crank mechanism The cylinder piston rod pushes knuckle steering through link lever causing wheel s deflection and truck s steering The steering axle is pivoted in the bearing seats bolted to the rear frame thus causing the axle body be able to oscillate around the axles Left and right knuckles are positioned at two sides of the steering axle respectively The rear wheel hubs are fitted to the knuckle shafts through tapered roll bearings with oil seals keeping the grease in the chambers of the hubs and the knuckles The wheels with rims are bolted on the hubs The steering tyre rim and the pressure of the steering wheel Truck mode 1 15 2 2 51 5 00 8 8PR 18x7 8 14PR 18x7 8 3 50D 433R 433R 0 7MPa 0 9MPa Pressure of steering unit 7 5MPa 2 1 Oil seal JE 2 Needle bearing 3 Thrust bearing 27 6 4 Oil seal D AO 5 Hub nut Emni ER Q ett ae 6 Tapered roll bearing M E c 7 Tapered roll bearing NN NS WwW 8 Lock nut
90. ston cup and the dust cover in this order 2 Install the operating cylinder on the backing plate 3 Install the backing plate on the front axle 4 Apply grease on the points indicated in Fig 2 22 with care not to contaminate the friction piece with grease X a Contact surface between backing plate and brake shoes z b Anchor pin C d e The screw of the adjuster and other rotating parts Contact surfaces between brake shoe and spring seat Supporting pin of parking pull rod Fig 2 22 5 Install the brake cable assembly on the backing plate with an E retainer 6 Install shoes on the backing plate with hold down springs See Fig 2 23 7 Put the spring on the parking push rod then install the rod on the shoe 8 Install the shoe guide plate on the anchor pin and install the shoe return spring on primary brake shoe firstly and secondary brake shoe secondly See Fig 2 24 41 Fig 2 23 Fig 2 24 9 Install the adjuster adjuster spring push rod and its return spring Pay attention to the following points a Thread direction of the adjuster and its mounting direction b Adjuster spring direction Do not allow the adjuster gear teeth to contact with the spring c Return spring direction of the push rod Spring hook at anchor pin side should be located at the opposite side to push rod d Make sure that the adjusting lever lower end is in contact with the adjuster gear teeth 10 Instal
91. t Handle only loads within the allowable capacity of the truck The goods handled should not exceed the rated capacity of the truck 4 Operate your truck on a hard ground Operate on other ground the lift capacity and travel speed must be decreased Wipe off the oil and grease from the floor 5 Daily maintenance services should be done before or after using the truck Anytime you find that the truck is not functioning normally operation of the truck should be halted and check or repair at once 6 When operate one lever pay attention not to shift another lever Don t operate the lever at any position out of the driver seat 7 Don t handle unfixed or loose goods Be careful to handle bulky goods To prevent the collapse of stacked goods tighten them Forbid loading loose or little volume goods without tray 8 If the truck is equipped with a load handling attachment its usage sphere will be wider but its allowable load and stability is reduced The attachment and special device is not to be diverted to any other purpose It s very dangerous to rebuild the attachment Please read the additional instruction we supplied and operate the truck following it strictly 9 Fork can not be used to pull out any embedded goods if necessary the pulling force should be estimated 10 Insert forks deeply under goods Adjust fork s distance according to the capacity of goods Make the loads distribute on the forks evenly to avoid tilt and slide
92. tenance The service life of the bearing varies with the load and driving condition If the bearing was observed high temperature or abnormal noise replace it immediately Sealed bearing is of effective lubrication because it is sealed high quality lithium grease its structure also can prevent the dust from entering with no need of replenishing butter for long time Inspect the sealed bearing according to the following periods If necessary replace it Especially at thick dust place or the place that butter may flow for deterioration because of harmful gas or solvent adding inspection frequency is necessary Operation time More than 12 hours Less than 12 hours Check frequency Once every two years 2 Disassembly and assembly of bearing If the bearing has abnormal noise or firing disassemble the bearing from the shaft When disassembling give a force on the outer circle of bearing with a small dismantler The bearing disassembled can not be used again Fig 5 5 When assembling a new bearing give a force on the inner circle of the bearing with a barrel appliance Fig 5 6 A Disassemble bearing Disassemble bearing with special dismantler Bearing Fig 5 5 Disassemble bearing 82 A Assemble bearing Assemble bearing with steel pipe or retainer The temperature can t be out of 60 C80 Cwhen loosening the motor bearing i 1 Retainer Fig 5 6 Assemble bearing 6 Measure insulating resistance Connect negative
93. teries temperature is higher than others Pole plates are Exhaust the condition of sulphated sulphating 1 Density rises less Pole plates are Exhaust the condition of or stays sulphated sulphating Color and 2 After charging the Quick Much matter is in density d heavil density of ensity drops heavily Sal aseharane electrolyte replace electrolyte is when storage electrolyte abnormal 3 The color and smell is abnormal and with turbid sediment Electrolyte is not pure active matter gives away Replace electrolyte and clean the inner part 6 5 Charger Charger consists of controller power block and transformer It adopts intelligent closed cycle control it can display the status of charge and fault and can measure the battery automatically It s with dynamic tracking closed cycle controlling making the battery keep in the critical state of optimal charging electrochemical reaction 9 6 5 1 Charger panel 48v 804 N D F m Battery Full Power Intelligent charger 1 When connect to power and turn switch Power indication lamp lights 2 When the battery quantity is full Full indication lamp lights 3 When the battery needs balanced charging press Balance button and connect power JH displays on the display screen when pressing the button again the charger restores to normal 6 5 2 Usage of the charger and charging method 1 Daily charging When the under volt
94. trolyte is too low The connecting line isn t clear too high resistance Adjust the density of electrolyte Unblock the outer connection line and reduce the resistance Charging repeatealy to exhaust the condition of sulphating Pole plates are sulphated There is harmful Check electrolyte replace matter in electrolyte it if necessary The battery is localized short circuit The inner or outer short circuit of battery Check and remove Check and remove Exhaust the condition of sulphating The pole plates are sulphated Check signal voltage and exhaust it Opposite pole short circuit 90 1 No gas cr little Low charging during the end stage current or charging of charging not enough 2 No gas after Short circuit of the mE Repair the short circuit charging inner battery Abnormally giving off gas 3 Giving off too early with large quantity gas when charging Adjust charging current and go on charging Pole plates are Exhaust the condition of sulphated sulphating 4 Give off gas on the No laying after Discharge or replace process of laying or charging or there is electrolyte after laying for charging matter in electrolyte 1 hour 1 When charging normally the temperature raises abnormally Too large current or Agjust the charging short circuit when current or exhaust the Temperature charging short circuit of electrolyte Is high 2 Some bat
95. two half shaft gears and four planet gears Refer to Fig1 3 2 Drive axle The driving axle assembled on the front of frame mainly consists of housing wheel hubs and wheels The axle housing is of integrally casting construction The tyre with rim is fixed to the hub with stubs and nuts The power is transmitted through the differential to the half shafts which drives the front wheels through the hubs Each hub is fixed on the axle housing with conical roller bearing so that the half shafts bear only the torque transmitted to the hubs There are oil seals inside the hub to prevent the entering of water and dust or leaking of oil Refer to Fig1 4 The type of front tyre and rim and the pressure of front tyre is indicated in following table 2 5 00F 5 008 6 50F 10 6 50F 10 0 78MPa 0 84MPa 08MPa Notice For the difference of manufacturer s standard charge the tyre pressure Fully floated half shaft Drive 6 50 10 10PR 7 00 12 12PR 23x9 10 16PR 23x9 10 axle 2 according to the actual tyres 26 O6 0 PMA O GO AB Bier xs Nor u 0000 900 9 9 9 amp Fig 1 1 Gear box and differential 1 1 5t 1 Ring gear 2 Planet gear 3 Gear shaft 4 Differential housing 5 O ring 6 Cover 7 Bearing 8 Reducer housing 9 Bearing 10 Bearing seat 11 Bearing 12 Nut 13 Adjust shim 14 Adjust shim 15 Oil seal 16 Drivel gear amp shaft 17 Shim 18 Gear shaft 19 Bevel gear 20 Bearing 21 Bearing seat 22 Lock washer
96. uck The driver must hold tightly the control wheel with two hands meanwhile his body must incline in opposite direction of truck s turning over 35 The unloaded forklift truck with attachment should be operated as a loaded truck 36 Check the chains periodically to make sure that good lubrication condition exists between the chain elements the degree of tightness between left and right chain is identical If the variation value of the chain pitch exceeds 296 standard value it indicates that the chains have been worn excessively replace it immediately 37 Before the truck decelerating and stopping don t put it into reverse gear so as to ensure the safety of loading 38 Don t make a sudden braking when the truck traveling with loads 39 When leaving lower the forks on the ground and let the shift lever to neutral cut down the electric supply If parking on a slope is unavoidable apply the parking brake and 12 block the wheels 40 When tilting the mast forward or backward to the limit or lifting the fork to the maximum height return the directional lever to neutral 41 Don t adjust the control valve and relief valve at will to prevent the damage of hydraulic system and its components because of excessive pressure passing them 42 Tyres should be inflated according to the pressure valve specified in the marking plate of Tyre Pressure 43 According to the Directive 2000 14 EC and based on EN12053 standard when th
97. umps and valves 3 Check the traveling brakes The free stroke of brake pedal is 20 30 mm when achieving effective brake the clearance between the front floor and the pedal should be more than 20mm 4 Check the parking brake The unload truck can park on stated ramp when the parking lever is pulled to the bottom 5 Check the meters lamps connectors switches and electric circuit if they are running properly 2 5 3 Charging the battery 1 Please refer to Manual of Battery about the initial charging and normal charging of the battery 2 When the truck working with load the voltage of the battery reduces to 43 2V 1 2 5t forklift truck or to 72V 8t forklift truck or the voltage of each cell drops below 1 80V the warner of battery capacity flashes stop the truck until charge the battery or replace a full charged battery 3 Measure the density level and temperature of the electrolyte 4 After the battery is used it should be charged immediately the time left idle of the battery must be less than 24 hours You should try to prevent them from over being discharged or over charged Either way will affect their service time and functions 14 Refer to Manual of Battery about charging method and maintenance 2 5 4 Essentials of servicing 1 Some critical components must be replaced according to demands periodically Use genuine parts only 2 Use genuine or recommended oil only when replacing or adding 3 If any da
98. use the mast or the load backrest instead of a ladder these actions will lead to a dangerous condition unexpectedly 2 5 5 Recommended oil and grease ame Hydraulic HM32 winter To the Au summer NN dipstick level GL 5 85W 90 SAE85W 90 ca Brake fluid fluid DOT3 Compound brake fluid 0 4L 0 4L 0 4L 0 4L o 3 Lithium base Lubricant Grease drop point a Right amount grease 170 Adding oil grease and coolant should follow relevant automobile standard The waster of the forklift truck must be reclaimed obeying the relevant laws and regulations Incorrect treatment will pollute water soil and atmosphere etc Wear a helmet safety shoes and working clothes to avoid contacting with body when adding oil grease and coolant 2 6 Brief operation instruction 2 6 1 Operation device and meter Function and working condition of operation device and meter Working condition 1 Parking brake Park the truck Pull the lever backward fully 2 Adjust lever hand Adjust hand wheel s wheel angle Foot brake pedal Brake the truck Depress the pedal to brake Change traveling Pull the lever forward the truck 4 Shift lever S direction travels forward Meter panel Refer to Chapter Electric System in this manual Connect the meter and power mn Key switch Control electric system nentumingriohtchiith 2 green Control head Push or pull the double shift ij combination lamp switch when lighting Horn button Control t
99. y Install the inner rim and gasket inside the outer rim and assemble the outer rim and inner rim Pay attention to the following points a Put the air valve rod in the notch of the rim and make it face outside b Make the tops of the rim mounting bolts face outside c Don t stand near the tyre when inflating air d When the tyre pressure reaches 98KPa 1kgf cm knock the tyre lightly to make the inner tyre and gasket into the rim Fig 1 6 Measure starting torque 9 6 Fig 1 7 Wheel assembly Rim bolt construction 1 Tyre 2 Air valve 3 Bushing 4 Inner rim 5 Outer rim 6 Rim bolt 31 2 Brake system 2 1 General description The brake system is the front two wheel braking interior extended hydraulic type consisting of a master cylinder wheel brakes and brake pedal 2 1 1 Brake pedal The structure of the brake pedal which is assembled on meter rack with bracket is indicated in Fig 2 1 With the push rod of mast cylinder the pedal converts the force acting on pedal to brake oil pressure force Brake switch Oil tank Nast cylinder Brake switch clearance 5 1 0mm Bl direction Fig 2 1 Brake pedal 2 1 2 Master cylinder The cylinder contains a valve seat acheck valve a return spring primary cup piston and secondary cup which are all kept in place with a stop washer and a stop wire The exterior of the cylinder is protected from dust by means of a rubber dust cover The piston is actuated through the

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