HANGCHA CBD20-AEC1 Operation And Maintenance Manual Download

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3.2.4 Fault code table

This fault codes

This fault codes provide the following information:

provide the following information:

–

Fault code

–

Display fault name on the Curtis programmer

–

Display caused by the fault

–

Probable fault reason

–

Fault deep reason

–

Troubleshooting

When there is fault, if

When there is fault, if it’s affirmed not the wiring error or truck malfunction, you can

it’s affirmed not the wiring error or truck malfunction, you can try to restart

try to restart

through key switch. If fault still exists, please turn down key switch, check if the connector of pin

35 connects right or gets dirt, after repair and clean ,

35 connects right or gets dirt, after repair and clean , reconnect, and then start again.

reconnect, and then start again.

Fault code table

Code

Programmer display

Probable fault reason

Deep fault

reason/troubleshooting

Fault display

Controller Overcurrent

Motor stops working

Motor stops working
Main connector disconnects

Main connector disconnects
EM brake shutdown

EM brake shutdown
Throttle invalid

Throttle invalid
Brake

Brake
Pump stops working

Pump stops working

1. External short of phase U,V,W

1. External short of phase U,V,W
motor connections

motor connections
2. Motor parameters do not

2. Motor parameters do not
match.

match.

。

3. Controller malfunction

Reason

：

Phase current exceeds

limited current

limited current
Troubleshooting

Troubleshooting

：

restart the key

switch

Current Sensor Fault

Motor stops working

Motor stops working
Main connector disconnects

Main connector disconnects
Electromagnetic brake disconnects

Electromagnetic brake disconnects
Throttle invalid

Throttle invalid
Brake, Pump stops working

Brake, Pump stops working

1. Leakage to vehicle frame from

1. Leakage to vehicle frame from
phase U,V, or W

phase U,V, or W
2. Controller malfunction

2. Controller malfunction

Reason

：

Deviation reads out to

controller current

controller current sensor

sensor..

Troubleshooting

：

restart the key

switch

Precharge Failed

Motor stops working

Motor stops working
Main connector disconnects

Main connector disconnects
Electromagnetic brake disconnects

Electromagnetic brake disconnects
Throttle invalid

Throttle invalid
Brake

Brake
Pump stops working

Pump stops working

1. External load on positive

1. External load on positive
terminal of the capacitor that

terminal of the capacitor that
prevents

the

capacitor

from

prevents

the

capacitor

from

charging.

Reason

：

Key switch input voltage

failed to charge the

failed to charge the capacitor

capacitor..

Troubleshooting

：

Reset or

re-input interlock switch through

re-input interlock switch through
VCL function precharge().

VCL function precharge().

Controller Severe Undertemp

Motor stops working

Motor stops working
Main contactor disconnects

Main contactor disconnects
Electromagnetic brake disconnects

Electromagnetic brake disconnects
Throttle failure

Throttle failure
Brake

Brake
Pump stops working

Pump stops working

Severe

controller

working

Severe

controller

working

environment.

Reason

：

Radiator temperature is

lower than -40

℃

Troubleshooting

：

Raise the temp

above -40

℃

, restart the key

switch or interlock switch.

Controller Severe Overtemp

Motor stops working

Motor stops working
Main contactor disconnects

Main contactor disconnects
Electromagnetic brake disconnects

Electromagnetic brake disconnects
Throttle failure

Throttle failure
Brake, pump stops working

Brake, pump stops working

Severe

controller

working

Severe

controller

working

environment.

environment.
2. Truck overloads.

2. Truck overloads.
3. Incorrect controller mounting

3. Incorrect controller mounting

Reason

：

Radiator temperature is

higher than 95

℃

Troubleshooting

：

Drop the temp

below 95

℃

. Restart the key

switch or interlock switch.

Severe Undervoltage

Severe Undervoltage
Too low voltage

Too low voltage

Driving torque reduce

1. Setup error

1. Setup error of battery parameter.

of battery parameter.

2. Power consumption of non

2. Power consumption of non
controller system.

controller system.

3. Too large battery impedance.

4. Battery

4. Battery disconnects.

disconnects.

5. Fuse protector disconnect, or

5. Fuse protector disconnect, or
the main contactor disconnect.

the main contactor disconnect.

Reason

：

When MOSFEET axle

working, capacitor voltage is

working, capacitor voltage is
lower than the minimum voltage

lower than the minimum voltage

limit.

Troubleshooting

：

Raise

the

Raise

the

capacitor voltage.

https://www.besttruckmanuals.com/

Summary of Contents for CBD20-AEC1

Page 1: ...1 CBD20 AEC1 CBD20 AEC1S CBD20 AEC1S OPERATION AND MAINTENANCE MANUAL OPERATION AND MAINTENANCE MANUAL Original Instruction Original Instruction HANGCHA GROUP CO LTD HANGCHA GROUP CO LTD 7 2015 7 2015 Basic Range Basic Range https www besttruckmanuals com ...

Page 2: ...ain the truck safely operate and maintain the truck Part one of this manual is about the brief introduction and correct operation of the Part one of this manual is about the brief introduction and correct operation of the basic range basic range electric pallet truck which will tell you how to operate safely and maintain preventively part two electric pallet truck which will tell you how to operat...

Page 3: ...33 33 6 8 6 8 Unloading Unloading 34 34 6 9 6 9 Parking Parking 35 35 7 7 Deposit Deposit the the truck truck 36 36 7 1 7 1 Deposit the Deposit the truck for lon truck for long time g time 36 36 7 2 7 2 Sta Start running rt running after de after deposit for a posit for a long time long time 36 36 8 8 Maintenance Maintenance 37 37 8 1 8 1 Maintenance Maintenance general general 37 37 8 2 8 2 Perio...

Page 4: ...from linder from the truck o the truck or replace r replace 69 69 2 5 2 5 Hydraulic syste Hydraulic system fault dia m fault diagnosis an gnosis and correctio d correction n 72 72 3 3 Electric Electric system system 73 73 3 1 3 1 Electrical sche Electrical schematic diagra matic diagram m 74 74 3 2 3 2 AC motor co AC motor controller ntroller 75 75 3 2 1 3 2 1 Maintenance Maintenance 75 75 3 2 2 3...

Page 5: ...peration way nt operation way it has two types as it has two types as pedestrian pedestrian type and stand on type Uses type and stand on type Uses can get relevant information as rated load from the product model can get relevant information as rated load from the product model CBD20 AEC1 CBD20 AEC1 CBD20 AEC1S CBD20 AEC1S Mode Mode CBD CBD Electric Electric pallet pallet truck truck 20 20 Rated ...

Page 6: ...ure travelling safety It owns slope anti slide function to ensure safety It owns slope anti slide function to ensure safety Operation steering system Operation steering system New ergonomics designed control handle owns acceleration reversing horn braking New ergonomics designed control handle owns acceleration reversing horn braking lifting lowering emergency reverse functions thus makes operatio...

Page 7: ...od vision and equipment use license Max uphill grade when driving is 6 Max uphill grade when driving is 6 It is prohibited to travel crosswise or obliquely When go uphill with loads keep the loads in It is prohibited to travel crosswise or obliquely When go uphill with loads keep the loads in front when go downhill keep people in front front when go downhill keep people in front For truck operatio...

Page 8: ...3 3 4 4 5 5 6 6 5 5 7 7 8 8 9 9 12 12 11 11 10 10 CBD20 AE CBD20 AEC1 Pedestri C1 Pedestrian an type type 1 1 2 2 3 3 4 4 5 5 13 13 6 6 5 5 7 7 8 8 11 11 12 12 10 10 9 9 CBD20 AEC1S Stand on type CBD20 AEC1S Stand on type https www besttruckmanuals com ...

Page 9: ...er 9 9 Load Load wheel wheel 3 3 Key Key switch switch 10 10 Battery Battery cover cover 4 4 Hood Hood 11 11 Instrumen Instrument t 5 Auxiliary 5 Auxiliary wheel wheel 12 12 Emergency Emergency stop stop switch switch 6 6 Drive Drive wheel wheel 13 13 Pedal Pedal 7 7 Rear Rear frame frame 14 14 Fence optional Fence optional https www besttruckmanuals com ...

Page 10: ...3 3 1 4 1 4 Display Display and and control control 1 1 3 3 11 11 12 12 16 16 17 17 19 19 19 19 22 22 21 21 20 20 21 21 22 22 18 18 https www besttruckmanuals com ...

Page 11: ...hen battery remaining power less than 20 When battery remaining power less than 20 the yellow LED indicator lights flashing the yellow LED indicator lights flashing warned depleted at the same time LCD warned depleted at the same time LCD display shows 20 for 1 seconds after into display shows 20 for 1 seconds after into Low BDI Low BDI When the yellow LED indicator lights flashing When the yellow...

Page 12: ...ncy or no ise If re start needed pull emergency or no ise If re start needed pull upward upward Emergency reverse button Emergency reverse button 16 16 This switch is at the head of control lever This switch is at the head of control lever once touch this button the truck moves once touch this button the truck moves forward It is used to protect people from forward It is used to protect people fro...

Page 13: ... Horn button 20 The button is located on the front of the The button is located on the front of the control handle upper surface Press down the control handle upper surface Press down the button and the horn sounds button and the horn sounds Lifting button 21 lowering Lifting button 21 lowering button 22 button 22 The lifting button and the lowering button are The lifting button and the lowering b...

Page 14: ...r on the load wheel or its inner bearing suspend the truck off the ground or jack the front disrepair on the load wheel or its inner bearing suspend the truck off the ground or jack the front outrigger off the ground replace the worn load wheel or the worn bearing and renew sufficient outrigger off the ground replace the worn load wheel or the worn bearing and renew sufficient multi purpose grease...

Page 15: ...event the operator body out of balance was thrown the user can optional fence When open or put fence need to first filed a balance was thrown the user can optional fence When open or put fence need to first filed a guardrail slightly upward then rotate to guardrail slightly upward then rotate to open or folded up open or folded up barriers barriers 1 1 2 2 3 3 4 4 4 4 2 2 3 3 1 1 https www besttru...

Page 16: ...erall Overall length unfold length unfold the the pedal pedal L1 mm L1 mm 2252 2252 Overall Overall width width b1 mm b1 mm 750 750 750 750 Fork Fork size size s e L mm s e L mm 64 170 1150 64 170 1150 64 170 1150 64 170 1150 Outside Outside fork fork width width b5 mm b5 mm 540 680 540 680 540 680 540 680 Ground Ground clearance clearance center center of of wheelbase wheelbase min min m2 mm m2 m...

Page 17: ...10 10 a 2 a 2 a 2 a 2 Ast Ast L6 L6 e e W Wa a b b 5 5 b b 1 1 1 1 4 4 2 2 0 0 1 1 4 4 7 7 432 432 L L C C Q Q X X y y L1 L1 m2 m2 h h 3 3 h h 1 1 3 3 https www besttruckmanuals com ...

Page 18: ...dersta please understand the meaning of nd the meaning of the various identities the various identities V V kW kW mm mm kg kg kg kg kg kg kg kg ELECTRIC PALLET TRUCK ELECTRIC PALLET TRUCK MODEL TYPE MODEL TYPE SERIALNO SERIALNO LOADCENTER LOADCENTER BATTERY VOLTAGE BATTERY VOLTAGE RATED DRIVE POWER RATED DRIVE POWER YEAROF YEAROF MANUFACT MANUFACT URE URE RATED CAPACITY RATED CAPACITY WEIGHT WEIGH...

Page 19: ... Strap points for crane lifting Hoist label Strap points for crane lifting 28 28 Hazard label Risk of Hazard label Risk of trapping when cylinder extended trapping when cylinder extended 29 29 Emergency stop label Emergency stop label press this button when in emergency thus the truck power is press this button when in emergency thus the truck power is off off 30 30 Key switch Key switch OFF posit...

Page 20: ...or contactor coil coil or or horn horn between between controller B and B to discharge the controller B and B to discharge the controller capacity controller capacity 7 7 Whenever you find the forklift abnormal Whenever you find the forklift abnormal stop the truck put on the DANGEROUS stop the truck put on the DANGEROUS or FAULT sign to the truck remove the or FAULT sign to the truck remove the k...

Page 21: ...k and link mechanism mechanism 19 19 Make the loads in front when climbing the Make the loads in front when climbing the slope It s prohibite slope It s prohibited to turn on the slope d to turn on the slope or there s danger of tipping over Avoid or there s danger of tipping over Avoid working on the slope working on the slope 20 20 Do not use truck under the weather of Do not use truck under the...

Page 22: ...eration arranges for the modification or alteration to be designed tested and implemented to be designed tested and implemented by an engineer s expert in industrial by an engineer s expert in industrial trucks and their safety trucks and their safety maintains a permanent record of the maintains a permanent record of the design test s and implementation of the design test s and implementation of ...

Page 23: ...see truck nameplate see truck nameplate Do not stay under the truck when Do not stay under the truck when hoisting the truck hoisting the truck When hoisting or laying down it should be stable and slow to avoid collision or When hoisting or laying down it should be stable and slow to avoid collision or accident accident Procedure Procedure Park the truck securely Park the truck securely Secure the...

Page 24: ... it to the fastening rings of the the fastening rings of the transporting vehicle transporting vehicle Use wedges to prevent the truck Use wedges to prevent the truck from moving from moving Tighten the tensioning belt with the tensioner Tighten the tensioning belt with the tensioner WARNING WARNING The truck or The truck or trailer must have fastening rings trailer must have fastening rings Use w...

Page 25: ...ke of the truck is closed under normal circumstances Appropriate vehicles damaged since the brake of the truck is closed under normal circumstances Appropriate vehicles should be used to remove the broken trucks should be used to remove the broken trucks WARNING WARNING Do not tow the broken trucks on the ground directly or else the braking system Do not tow the broken trucks on the ground directl...

Page 26: ...e level is low you must When electrolyte level is low you must add distilled water to add distilled water to the level appointed the level appointed WARNING WARNING The shortage of the electrolyte will The shortage of the electrolyte will cause the storage battery cause the storage battery overheated even cause the system overheated even cause the system part of storage battery and electric part o...

Page 27: ...use corrosion and electrolyte will cause corrosion and electricity leakage electricity leakage Measures in winter Measures in winter Keep effective and good surrounding for Keep effective and good surrounding for charging charging When it is cold pull out the storage When it is cold pull out the storage battery pin to battery pin to prevent discharging prevent discharging Take measures such as cov...

Page 28: ...0 150 Allowable Allowable heaviest heaviest kg 220 kg 220 H H L L W W WARNING WARNING Battery weight and dimensions have considerable influence on Battery weight and dimensions have considerable influence on operational safety of operational safety of the truck the truck When installing or replacing battery be sure When installing or replacing battery be sure that battery in the fixed position tha...

Page 29: ...battery plug 38 38 with truck socket and cover the with truck socket and cover the battery hood 10 battery hood 10 After charg After charging the truck can ing the truck can be used be used 10 10 38 38 39 39 WARNING WARNING Please charge in the well ventilated and appointed site Please charge in the well ventilated and appointed site Mark No smoking when charging and prepare Mark No smoking when c...

Page 30: ... following case case a a discharge discharge voltage voltage often often drop drop down down final voltage final voltage b b discharge discharge current current is is often often larger larger c c not not charge charge in in time time after after discharge discharge d d the the electrolyte electrolyte is is mixed mixed with with impurity impurity with a little harm with a little harm e e It It oft...

Page 31: ...r The storage battery with a dobber When the red dobber rises the white line When the red dobber rises the white line appears please stop replenishing appears please stop replenishing The storage battery without a dobber The storage battery without a dobber When the electrolyte is above 15 20mm of the When the electrolyte is above 15 20mm of the electrode plate stop electrode plate stop replenishi...

Page 32: ...perature of 30 Charger Charger Storage battery of this truck equips with PCA Storage battery of this truck equips with PCA Automatic Char Automatic Charger Operat ger Operation Instruction ion Instruction 1 1 The charger is automatic high The charger is automatic high frequency charger The capacity voltage is frequency charger The capacity voltage is 220V AC The input current is not less 220V AC T...

Page 33: ...g of a crane Pull the battery out of the box vertically by using of a crane Install the battery in the reverse sequences Pay attention to the loading position of the Install the battery in the reverse sequences Pay attention to the loading position of the battery and the wiring Make sure they battery and the wiring Make sure they are correct are correct 38 38 41 41 40 40 10 10 37 37 WARNING WARNIN...

Page 34: ...operation is in a stage of 100 hours of operation Avoid the n Avoid the new battery ov ew battery over dischargin er discharging in early pe g in early period riod Perform specified preventive maintenance services completely Perform specified preventive maintenance services completely Avoid sud Avoid sudden stop star den stop start or turn t or turn Limited load is 70 Limited load is 70 80 of the ...

Page 35: ...cover board See whether the battery fixed the battery fixed reliable reliable Check proportion of electrolyte Refer to Check proportion of electrolyte Refer to battery section battery section Check the terminal for loose or damage Check the terminal for loose or damage Otherwise it will be adjust or Otherwise it will be adjust or replace replace Plug in and turn on the key switch Plug in and turn ...

Page 36: ...ck appearance for clean rust or Check the truck appearance for clean rust or paint spalling paint spalling 14 Others 14 Others Check whether there is any abnormal noise Check whether there is any abnormal noise whether wiring is regular or fastner loosens whether wiring is regular or fastner loosens etc etc https www besttruckmanuals com ...

Page 37: ...the peda to operate for the stand on type truck you need open the pedal If you need to stand on the peda to operate for the stand on type truck you need open the pedal and coaming and coaming 3 3 12 12 CAUTION CAUTION Make sure the work ground is Make sure the work ground is hard enough to support the hard enough to support the truck truck Be careful to contro Be careful to control the truck s spe...

Page 38: ...t fork go fork go Keep road clean and wipe greasy dirt Keep road clean and wipe greasy dirt water or other easiy causes slipping water or other easiy causes slipping dirty dirty Travelling on the slope Travelling on the slope When going uphill and downhill without load keep the fork to downhill direction when going uphill When going uphill and downhill without load keep the fork to downhill direct...

Page 39: ...dle to driving range F Swivel the control handle to driving range F Adjust the dir Adjust the direction speed ection speed control button 1 control button 17 to the desir 7 to the desired direction ed direction Control truck speed by direction speed control button 17 Speed is controlled by rotating the Control truck speed by direction speed control button 17 Speed is controlled by rotating the dri...

Page 40: ...ruck steering right to release truck steering When turn to left the truck turns left When turn to left the truck turns left When turn to right the When turn to right the truck turns right truck turns right 6 6 Stopping 6 6 Stopping Release the direction speed knob Decrease the speed Release the direction speed knob Decrease the speed Return the control handle to vertical position Return the contro...

Page 41: ... put the load on the unloading positon and then stop Travel forward put the load on the unloading positon and then stop Make sure the load are right above drop the forks slowly until the forks are out of the load Make sure the load are right above drop the forks slowly until the forks are out of the load Travel backwar Travel backward and make the f d and make the fork out of the ork out of the lo...

Page 42: ... appointed area safe area or appointed area Fully lower the forks Fully lower the forks Turn off the key switch 3 and remove the key Turn off the key switch 3 and remove the key Press the emergency stop switch 12 Press the emergency stop switch 12 Fold pedal 13 Fold pedal 13 If park for long If park for long time remove the battery plug time remove the battery plug 3 3 12 12 13 13 https www besttr...

Page 43: ...hole truck Cover the whole truck Check specific gravity of electrolyte and liquid level once a Check specific gravity of electrolyte and liquid level once a month month Do equalizing charge to the battery once a month Do equalizing charge to the battery once a month 7 2 7 2 Start Start running running after after deposit deposit for for a a long long time time Remove rust preventive oil on exposed...

Page 44: ...ording to the local environmental protection laws and regulations regulations Draw up complete maintenance plan Draw up complete maintenance plan After you ma After you make maintena ke maintenance you nce you d better make a d better make a record record Forbid to repair the forklift truck if Forbid to repair the forklift truck if you haven t been trained you haven t been trained CAUTION CAUTION ...

Page 45: ... 〇〇〇〇〇 Terminal looseness Terminal looseness 〇〇〇〇〇〇〇〇〇〇 Looseness of connecting wire Looseness of connecting wire 〇〇〇〇〇〇〇〇〇〇 Cleanness of the battery surface Cleanness of the battery surface 〇〇〇〇〇〇〇〇 If there are tools on the battery If there are tools on the battery 〇〇〇〇〇〇〇〇〇〇 The tightness and smoothness of The tightness and smoothness of air cap air cap 〇〇...

Page 46: ... current is Check if the temperature or current is normal normal 〇〇〇〇 Driving system Driving system Service Service item item Service Service required required T Tool ool D D W M W M T T S S R R e e d d u u c c t t i i o o n n b b o o x x Check for noise Check for noise 〇〇〇〇〇〇〇〇〇〇 Check for oil leakage Check for oil leakage 〇〇〇〇〇〇〇〇〇〇 Add lubricating grease Add lubricating gre...

Page 47: ...heck for oil level change oil 〇〇〇〇〇〇〇〇 Clean suction strainer Clean suction strainer 〇〇 Clean foreign matter Clean foreign matter 〇〇 s s o o l l e e n n o o i i d d v v a a l l v v e e Check for block return spring stuck or Check for block return spring stuck or damage damage 〇〇〇〇〇〇 Check for wiring looseness Check for wiring looseness 〇〇〇〇〇〇 S S a a f f e e t t y y v v a a l l ...

Page 48: ... 〇〇〇 Check for oil leak Check for oil leak 〇〇〇〇〇〇〇〇〇〇 Check lifting cylinder fixed bolt for Check lifting cylinder fixed bolt for looseness looseness 〇〇〇〇 F F o o r r k k Check forks for damage Check forks for damage deformation or wear deformation or wear 〇〇〇〇〇〇 Check fork base and hook welding for Check fork base and hook welding for defective cracks or wear defective cracks o...

Page 49: ...ark Mark code code Remark Remark A A Hydraulic oi Hydraulic oil l Normally Normally L HM32 L HM32 High and cold environment High and cold environment L HV32 L HV32 Hydraulic system Hydraulic system C Grease C Grease Automobile g Automobile general eneral 3 3 lithium lithium base lubricant base lubricant Nozzle and lubrication Nozzle and lubrication D D Grease Grease SHELL SHELL AL ALVA VANIA NIA R...

Page 50: ... oil tank container and then clean the oil tank Install the hydraulic power assembly to the Install the hydraulic power assembly to the oil tank and then retighten with the hook oil tank and then retighten with the hook T 9N m T 9N m Screw out the filler cap 4 of the oil tank Screw out the filler cap 4 of the oil tank add hydraulic oil to specified mark with the add hydraulic oil to specified mark...

Page 51: ...pectively remove the bolts respectively Remove the fixation clamp of the motor Remove the fixation clamp of the motor signal wire signal wire Strike the edge of the driving wheels with Strike the edge of the driving wheels with a rubber hammer and remove the old a rubber hammer and remove the old driving wheels from the drive unit driving wheels from the drive unit CAUTION CAUTION Strike the edge ...

Page 52: ...th a S 5mm hex wrench CAUTION CAUTION Screw up the bolts in a symmetrical Screw up the bolts in a symmetrical way by 2 times way by 2 times Apply appropriate torque to screw Apply appropriate torque to screw up the bolts Do not overexert which up the bolts Do not overexert which might do damage on the thread or might do damage on the thread or lead to future removing problem lead to future removin...

Page 53: ...ruck frame safely or place the truck on firm iron stand Hoist the truck frame safely or place the truck on firm iron stand Screw off the bolt Screw off the bolt Remove the wheel shaft Remove the wheel shaft Remove the load wheels Remove the load wheels Install new wheel in opposite order Install new wheel in opposite order https www besttruckmanuals com ...

Page 54: ...fely lift a certain height remove auxiliary wheel assembly Frame safely lift a certain height remove auxiliary wheel assembly From the old wheels on auxiliary wheel assembly to be removed and replaced with new From the old wheels on auxiliary wheel assembly to be removed and replaced with new wheels wheels The auxiliary module in the reverse order in forklift truck wheel assembly The auxiliary mod...

Page 55: ... time it should be replaced immediately before the replacing time it should be replaced immediately Key safe part s description Key safe part s description Term Term of of using using year year Hydraulic Hydraulic hose hose for for lifting lifting system system 1 2 1 2 High pressur High pressure e hose hose hose hose for for hydraulic hydraulic system system 2 2 Inner Inner sealing sealing element...

Page 56: ...1 General requirements for battery powered trucks General requirements for battery powered trucks EN1726 1 1998 EN1726 1 1998 Safety standard for Safety standard for machinery industrial vehicle machinery industrial vehicle EN12053 2001 EN1175 1 1998 EN13059 2002 EN1757 2 EN12053 2001 EN1175 1 1998 EN13059 2002 EN1757 2 2001 harmonized standard 2001 harmonized standard Main safety elements are in ...

Page 57: ...50 50 https www besttruckmanuals com ...

Page 58: ...clip 6 Circlip for for hole hole 55 7 End 55 7 End cap cap 8 Oil 8 Oil seal seal 9 Screw 9 Screw M6 16 M6 16 10 Baffle 10 Baffle 11 Circlip 11 Circlip for for shaft shaft 14 14 12 Circli 12 Circlip p for for shaft shaft 13 Driving 13 Driving gear gear 14 Flat 14 Flat key key 15 Driving 15 Driving motor motor 16 Bolt 16 Bolt M8 60 M8 60 17 Bearing 17 Bearing 6002 2RS 6002 2RS 18 Circli 18 Circlip p...

Page 59: ... shifting 3 Gear shaft 3 Gear shaft 4 Driven gear 4 Driven gear 13 Driving gear 13 Driving gear 15 Drive motor 15 Drive motor 22 Annular gear 22 Annular gear Fig 2 2 Drive diagram of drive unit Fig 2 2 Drive diagram of drive unit Data Data Speed ratio of reduction gear box Speed ratio of reduction gear box 31 4 31 4 Max wheel torque Max wheel torque N m N m 300 300 Max wheel load Max wheel load kg...

Page 60: ...g troubleshooting Fault Fault Probable Probable cause cause Corrective Corrective action action Abnorma Abnormal l gear gear noise noise when when travelling travelling Over Over large large gear gear clearance clearance Adjust Adjust Lack Lack grease grease Replenish Replenish Over Over large large gear gear wear wear Replace Replace Abnorma Abnormal noise when tu l noise when turning rning Rotar...

Page 61: ... with overload verload It s prohibited to coexist with strong magnetic object It s prohibited to coexist with strong magnetic object Make sure the correct of Make sure the correct of input voltage grade input voltage grade If there is abnormal odor in use park to check immediately If there is abnormal odor in use park to check immediately The cabling between motor and controller should be as short...

Page 62: ...h rated load Power voltage too low Power voltage too low Motor wrongly connected to Y Motor wrongly connected to Y Cage rotor open weld or crack Cage rotor open weld or crack Local coil of stator and rotor wrongly or oppositely Local coil of stator and rotor wrongly or oppositely connected connected Add too much n Add too much number of wind umber of windings when rep ings when repair motor air mo...

Page 63: ... quantity and contains impurity Bad oil quantity and contains impurity Mismatch between bearing and journal or end Mismatch between bearing and journal or end cap too loose or too tight cap too loose or too tight Eccentricity of bearing bore rub with the axle Eccentricity of bearing bore rub with the axle Motor end cap or bearing cap not even assembled Motor end cap or bearing cap not even assembl...

Page 64: ...By use of the pressure spring powerful braking torque would be generated when power off The brake could be released by the generated when power off The brake could be released by the electromagnetic effect electromagnetic effect 1 1 2 2 3 3 4 4 5 5 6 6 1 Mounting Bolt of the Brake 1 Mounting Bolt of the Brake 3 Brake Pad 3 Brake Pad 5 Friction Disk 5 Friction Disk 2 Stator Module 2 Stator Module 4...

Page 65: ...or at that Z between the armature and the stator at that moment When the brake needs to be moment When the brake needs to be relaxed the relaxed the stator is applied with direct current and the magnetic field would attract the armature 8 to move stator is applied with direct current and the magnetic field would attract the armature 8 to move towards the stator The movement of armature compresses ...

Page 66: ...ver the shaft sleeve with the friction disk 3 Install the stator module 2 to the friction disk 5 with three Install the stator module 2 to the friction disk 5 with three mounting bolts of the brake 1 mounting bolts of the brake 1 Note Remove the three rubber mats of the stator module Note Remove the three rubber mats of the stator module which is for stable transportation which is for stable trans...

Page 67: ...and using the brake dirt when installing and using the brake OIL OIL U x V DC 10 U x V DC 10 1 5 3 Maintenance 1 5 3 Maintenance Avoid rusting W Avoid rusting When truck hen truck is is used in used in a a high temperature for high temperature for a a long time long time The The actuation side actuation side with rust would with rust would affect the performance affect the performance Do not touch...

Page 68: ... Mounting Bolt the Mounting Bolt 8 8 N m N m 25 25 W W 0 2mm 0 2mm 0 5 0 5 mm mm 6 4 6 4 mm mm 5 5 5 5 N m N m On the condition of power disconnected through adjusting 3 mounting bolts of brake 1 and the On the condition of power disconnected through adjusting 3 mounting bolts of brake 1 and the hollow bolts 7 set the air gap between stator 11 and armature 8 to the rated Z by a feeler hollow bolts...

Page 69: ...uce load or replace large Reduce load or replace large specification specification Large load change Large load change Adjust Adjust load load peak peak or or large large the the specification specification High temperature High temperature T Too oo high high exciting exciting voltage voltage Check Check voltage voltage and and adjust adjust Clutch or motor interfere to the Clutch or motor interfe...

Page 70: ...bber tube and lifting cylinder 1 Bolt 1 Bolt 2 Washer 2 Washer 3 Pin shaft 3 Pin shaft 4 Composite bushing 4 Composite bushing 5 Lifting cylinder 5 Lifting cylinder 6 Screw 6 Screw 7 Hydraulic unit 7 Hydraulic unit 8 Washer 8 Washer 9 Bolt 9 Bolt 10 Washer 10 Washer 11 Hose assy 11 Hose assy 12 Bolt 12 Bolt Fig 2 6 Hydraulic system Fig 2 6 Hydraulic system https www besttruckmanuals com ...

Page 71: ...r and and the the loading loading in in its its original lifting position When the lifting cylinder reaches the end or the truck is over loaded the original lifting position When the lifting cylinder reaches the end or the truck is over loaded the working pressure is exceeding the safety pressure defaulted in the system the overflow valve working pressure is exceeding the safety pressure defaulted...

Page 72: ...65 65 https www besttruckmanuals com ...

Page 73: ...ric wire Electric wire 3 3 Motor Motor 4 4 Coupling Coupling 5 5 Flow control valve Flow control valve 6 6 Plug Plug 7 7 Flange Flange 8 8 Pump Pump 9 9 Shaft Shaft 10 10 Bolt Bolt 1 11 1 Suction tube Suction tube 12 12 Filter Filter 13 13 Anchor ear Anchor ear 14 14 Tank Tank 15 15 Tube Tube 16 16 Filter cap Filter cap 17 17 Return tube Return tube 18 18 Connector Connector 19 19 Cartridge Cartri...

Page 74: ... the pressure hole Take out the cap of the overflow valve Take out the cap of the overflow valve Loosen the nut of the Loosen the nut of the main safety valve main safety valve Adjust the pressure and the bolt Adjust the pressure and the bolts with a hexagon wrench The pressure of main safet s with a hexagon wrench The pressure of main safety valve y valve increases when adjusting the screws clock...

Page 75: ... and the cylinder Remove the wiring on the motor contactor and Remove the wiring on the motor contactor and control valve control valve Remove the tightening bolt that fix hydraulic Remove the tightening bolt that fix hydraulic unit unit Take down hydraulic unit Take down hydraulic unit Assembling Assembling order is opp order is opposite to the disa osite to the disassembling ssembling order orde...

Page 76: ...ke apart the hood Take apart the hood Instrument panel first four pieces of screws Instrument panel first four pieces of screws then switch the red mushroom head to the left then switch the red mushroom head to the left take it down and then dismantle instrument take it down and then dismantle instrument wiring wiring Dismantle piping joint from the cylinder Dismantle piping joint from the cylinde...

Page 77: ...m the cylinder supporting point supporting point Loosen battery fixed pin and hoist out the Loosen battery fixed pin and hoist out the battery battery Loosen two cylinder fixed bolt from the battery Loosen two cylinder fixed bolt from the battery https www besttruckmanuals com ...

Page 78: ...ion when hoisting the front truck frame hold Caution when hoisting the front truck frame hold the control handle to avoid tipping over of the rear the control handle to avoid tipping over of the rear truck truck Assembling Assembling order is opp order is opposite to the disa osite to the disassembling ssembling order order https www besttruckmanuals com ...

Page 79: ...y the high viscosity of hydraulic oil viscosity of hydraulic oil Replace new hydraulic oil whose viscosity suits Replace new hydraulic oil whose viscosity suits pump running speed pump running speed Work only when the oil temperature is normal Work only when the oil temperature is normal Bubble in the hydraulic oil Bubble in the hydraulic oil Check the reason for the bubble and then take Check the...

Page 80: ...e is DC24V DC24V 1 Instrument 1 Instrument 2 2 Emergency Emergency stop stop switch switch 3 3 Key Key switch switch 4 4 Electric Electric horn horn 5 5 Lifting Lifting limit limit switch switch 6 6 AC AC motor motor controller controller 7 Contactor 7 Contactor 8 8 Fuse Fuse protector protector 9 Fuse 9 Fuse 10 10 Main Main wiring wiring harness harness Fig 3 1 Electric system Fig 3 1 Electric sy...

Page 81: ...73 73 3 1 3 1 Electrical Electrical schematic schematic diagram diagram https www besttruckmanuals com ...

Page 82: ...he truck power supplied by battery Including but not limit to the Be careful when operating the truck power supplied by battery Including but not limit to the following correct training wear goggles do not wear loose clothing and jewelry following correct training wear goggles do not wear loose clothing and jewelry Carry out maintenance according to the following cleaning procedure Never clean the...

Page 83: ...put signal signal normal us normal us able able encoder encoder Check if Check if the output the output signal signal from from controller controller to motor is to motor is normal if normal if two two terminals terminals output output after after accelerato accelerato r input r input If If contactor contactor absorbs absorbs normally normally If other If other external external facility facility ...

Page 84: ...ht is on LCD displays fault type and code LCD displays fault type and code Get fault information by switching in handheld programmer Refer to Handheld Programmer Get fault information by switching in handheld programmer Refer to Handheld Programmer Get fault information by observe controller built in LED indicator lights Refer to LED Status Get fault information by observe controller built in LED ...

Page 85: ...controller all motor controller information uploads to the handheld programmer the handheld programmer 2 2 3 3 1 1 DISPLAY DISPLAY SCREEN SCREEN DATA DATA INC DEC INC DEC KEY KEY MENU MENU NAVIGATION NAVIGATION KEY KEY BOOKMARK BOOKMARK KEYS KEYS Display screen Display screen It can show seven line test and pictures at It can show seven line test and pictures at the same time the same time Menu na...

Page 86: ...78 78 programmer the bookmark button will not be kept programmer the bookmark button will not be kept https www besttruckmanuals com ...

Page 87: ...yellow lights flash alternately in a repeated interval Each code consists of two digits Numbers of yellow lights flash means the figure of the fault code relevant position Red flashes Numbers of yellow lights flash means the figure of the fault code relevant position Red flashes once or twice stands for the following yellow flashes stands for the first or second of the fault once or twice stands f...

Page 88: ...ects Electromagnetic brake disconnects Electromagnetic brake disconnects Throttle invalid Throttle invalid Brake Brake Pump stops working Pump stops working 1 External load on positive 1 External load on positive terminal of the capacitor that terminal of the capacitor that prevents the capacitor from prevents the capacitor from charging charging Reason Reason Key switch input voltage Key switch i...

Page 89: ...meter of battery parameter 3 Too large battery impedance 3 Too large battery impedance 4 When regenerating braking 4 When regenerating braking battery disconnects battery disconnects Reason Reason When MOSFEET axle When MOSFEET axle working capacitor voltage working capacitor voltage exceeds the maximum voltage exceeds the maximum voltage limit limit Troubleshooting Troubleshooting Reduce Reduce c...

Page 90: ...ted Troubleshooting Troubleshooting Correct open or Correct open or short circuit restart output short circuit restart output 34 34 Coil4 Driver Open Short Coil4 Driver Open Short Driver 4 output shut Driver 4 output shut 1 Connected load open or short 1 Connected load open or short 2 Connecting pin stained 2 Connecting pin stained 3 Wrong wiring 3 Wrong wiring Reason Reason Driver 3 Driver 3 outp...

Page 91: ...low end current restart the key switch current restart the key switch 46 46 EEPROM Failure EEPROM Failure Motor stops Motor stops Main contractor stops Main contractor stops EM brake stops EM brake stops Throttle stops Throttle stops Interlock stops Interlock stops Driver1 4 stop Driver1 4 stop PD stops PD stops Brake Brake Pump stops Pump stops 1 Error writing to the 1 Error writing to the EEPROM...

Page 92: ...ing Troubleshooting Restart the key Restart the key switch switch 72 72 PDO Timeout PDO Timeout Interlock stops Interlock stops CAN NMT State set to CAN NMT State set to Preoperational Preoperational 1 Time between CAN PDO 1 Time between CAN PDO messages received exceeds PDO messages received exceeds PDO Timeout Period Timeout Period Reason Reason Time between CAN Time between CAN PDO messages rec...

Page 93: ... activated due to motor installing or encoder fault motor installing or encoder fault Troubleshooting Troubleshooting Restart the key Restart the key switch switch if it is caused by motor if it is caused by motor installing make sure encoder installing make sure encoder work under normal condition work under normal condition Throttle Throttle Command 0 M Command 0 Motor otor RPM 0 RPM 0 94 94 Eme...

Page 94: ... 157 189 252 252 18 118 18 118 147 147 147 147 186 176 186 176 216 260 216 260 347 347 20 167 20 167 206 206 206 206 265 245 265 245 314 369 314 369 492 492 22 225 22 225 284 284 284 284 343 343 343 343 431 502 431 502 669 669 24 294 24 294 370 370 370 370 441 441 441 441 539 638 539 638 850 850 27 441 27 441 519 539 519 539 686 637 686 637 784 933 784 933 1244 1244 Note Note Use entirely 8 8 grad...

Page 95: ...87 87 Maintenance Record Maintenance Record Date Date Repair Repair maintenanc maintenance e content content Serviceman Serviceman https www besttruckmanuals com ...

Page 96: ...d Lin an Eco ad Lin an Economic Develo nomic Development Zone Zh pment Zone Zhejiang Chin ejiang China a Fax 0086 Fax 0086 571 88926789 0086 571 88132890 571 88926789 0086 571 88132890 ZIP 311305 ZIP 311305 Web Web http www hcforklift com http www hcforklift com E E mail mail sales hc sales hcforklift com forklift com https www besttruckmanuals com ...

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