Yale Forklift A7S4 (ERP15UX, ERP18UX, ERP20UX, ERP25UX, ERP30UX, ERP35UX) Service Manual - PDF

Maintenance

A7S4 ERP15UX, ERP18UX, ERP20UX, ERP25UX, ERP30UX, ERP35UX

PART NO. 550230249

8000 YRM 2353

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

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The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Yale® dealer.

Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

Do not lift heavy parts by hand, use a lifting mechanism.

Wear safety glasses.

DISCONNECT THE BATTERY before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

Keep the unit clean and the working area clean and orderly.

Use the correct tools for the job.

Keep the tools clean and in good condition.

Always use YALE ® APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

Be sure to follow the WARNING and CAUTION notes in the instructions.

Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.

Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.

Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual: WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol (and word, if present) are on orange background. The CAUTION symbol (and word, if present) are on yellow background.

WARNING Installing improper electrical accessories or installing an electrical accessory incorrectly can increase the risk of equipment damage, personal injury and fire. DO NOT install electrical accessories to the truck unless you have been trained and authorized to do so. Personnel installing the electrical accessories must document the changes made to the truck. DO NOT install accessories which affect the truck’s compliance with standard ANSI/ ITDF B56.1, UL 558, or UL 583, or which otherwise affect the safe operation of the truck.

WARNING Installing improper electrical accessories or installing an electrical accessory incorrectly can increase the risk of equipment damage, personal injury and fire. DO NOT install electrical accessories to the truck unless you have been trained and authorized to do so. Personnel installing the electrical accessories must document the changes made to the truck. DO NOT install accessories which affect the truck’s compliance with standard EN 1175:2020.

WARNING California Proposition 65 - Operating, servicing and maintaining a powered industrial truck can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information, go to www.P65Warnings.ca.gov.

INTRODUCTION The Service Manuals are updated on a regular basis, but may not reflect the latest design changes to the product.

Updated technical service information may be available from your local authorized YALE® distributor. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

1.5-3.5t Yale Four-wheel Counter Balanced Battery Forklift Truck is a new series of products developed and manufactured by our Company to satisfy market demands, based on assimilating domestic and foreign battery forklift trucks, in combination with foreign advanced technology introduced by our Company. They are especially applicable to stations, ports, freight yards, and warehouses, as well as foods, light textile industry, and general factories and mines for loading and unloading, conveyance, stacking, and other operations.

As wide visual field crane system, full hydraulic steering system, automatic power brake, new-type stepless speed regulator, open overhead guard, and other advanced pars are used for this forklift, and also equipped with quality motor, battery, MOSFET electric control, and large screen liquid crystal combination instrument, it is characterized by superior performance, easy operation, expanded visual field, flexible steering, small turning radius, reliable brake, good dynamic property, low noise, free pollution, nice outside appearance, etc.

This manual has briefly introduced the technical parameters, structures of respective main parts, and operating principle as well as operation, maintenance, service, and other aspects of 1.5-3.5t Yale Four-wheel Counter Balanced BatteryForklift Truck of our Company. It is able to help operators to rationally use the battery forklift truck, for the battery truck to play its maximum efficacy. It is hoped that operators and equipment management staff will seriously read the manual prior to operation of the battery forklift trucks.

The specifications and notices in this manual shall be strictly observed during operation, and elaborative use will allow your forklift truck to be under optimal working status, so as to play higher efficacy.

As parts and devices are being uninterruptedly improved, the contents in this manual will be subject to changes without separate notices. User’s understanding is kindly expected. This manual is also applicable to the forklift trucks assembled with affiliated attachments. The 1.5-3.5t Yale Four-wheel Counter Balanced Battery Forklift Truck have been CE certified.

NOTE: It is strictly prohibited for users to privately refit the forklift truck without permission!

FOREWORD The Service Manuals are updated on a regular basis, but may not reflect the latest design changes to the product.

Updated technical service information may be available from your local authorized Yale distributor. Service manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or follow instructions contained in the Service Manual could result in damage to the products, personal injury, propertly damage or death.

Series

Model ERP15UX ERP18UX

1.5-3.5T

ERP20UX ERP25UX ERP30UX ERP35UX

Drive Controller

Pump Controller

Rated Capacity (st)/ Load Center (mm)

1500 kg (3306 lb) / Curtis U15724-03100 Curtis U15724-03200 500 mm (19.7 in.)

Drive Controller Pump Controller 1800 kg (3968 lb) / 500 mm (19.7 in.)

2000 kg (4409 lb) / Curtis U25724-03100 Curtis U25724-03200 500 mm (19.7 in.)

Drive Controller Pump Controller 2500 kg (5512 lb) / 500 mm (19.7 in.)

3000 kg (6614 lb) / Curtis U30724-03100 Curtis U30724-03200 500 mm (19.7 in.)

Drive Controller Pump Controller 3500 kg (7716 lb) / 500 mm (19.7 in.)

This manual describes the structure and working principles of the 2-3.5T Electric forklift truck and provides instructions for servicing and maintenance. To ensure safety and get the best out of your forklift, all operators, equipment managers and maintenance personnel should carefully read this manual. Only trained and qualified personnel are permitted to carry out servicing and repairs on the forklift truck.

Table of Contents

TABLE OF CONTENTS Forklift Truck Main Parts......................................................................................................................................... 1 Battery.................................................................................................................................................................. 1 Overview............................................................................................................................................................ 1 Battery Specification.......................................................................................................................................... 1 Safety Instructions and Precautions...................................................................................................................2 Lead-acid Battery............................................................................................................................................ 2 Lithium Battery.................................................................................................................................................2 Battery Charging................................................................................................................................................ 3 Routine Lead-acid Battery Charging Steps..................................................................................................... 3 Notes When Lithim Battery Charging.............................................................................................................. 3 Service of Battery...............................................................................................................................................4 Lead-acid Battery............................................................................................................................................ 4 Lithium Battery.................................................................................................................................................5 Common Failures and Disposal Methods of Battery..........................................................................................5 Main Technical Specification of Forklift Truck......................................................................................................... 7 Driving Motor and Driving System......................................................................................................................... 11 Overview............................................................................................................................................................. 11 Axle Box and Differential.....................................................................................................................................11 Notes for Installation and Use..........................................................................................................................18 Front Tyre and Wheel Rim Models..................................................................................................................... 18 Installation of Wheel Hub................................................................................................................................. 18 Brake................................................................................................................................................................19 Parking Brake...................................................................................................................................................24 Clearance Self-Adjusting Mechanism.............................................................................................................. 25 Brake Disassembly and Assembly, Adjustment Essentials..............................................................................26 Disassembly of the Brake..............................................................................................................................26 Inspection of brake........................................................................................................................................ 28 Brake Assembly.............................................................................................................................................29 Operation Steps for Brake Clearance Adjuster................................................................................................30 Driving Motor....................................................................................................................................................31 Specification of Driving Motor........................................................................................................................31 Operating Environment Conditions................................................................................................................31 Pump Motor...........................................................................................................................................................32 Specification of Pump Motor...............................................................................................................................32 Operating Environment Conditions.................................................................................................................. 32 Electrical System...................................................................................................................................................33 Overview.............................................................................................................................................................33 Characteristics of AC Motor Controller............................................................................................................... 33 Electric System Schematic Diagram...................................................................................................................35 Miscellaneous.....................................................................................................................................................36 Trouble shooting................................................................................................................................................. 38 Steering Device and Installation............................................................................................................................74 Overview.............................................................................................................................................................74 Inspection of Steering System after Reassembly............................................................................................ 74 Steering System Fault Diagnosis.....................................................................................................................75 Steering Axle and Installation................................................................................................................................76 Overview of Steering Axle.................................................................................................................................. 76 Essentials of Adjustment and Maintenance........................................................................................................82 Steering Wheel Bearing Preload Adjustment...................................................................................................82 Parking Brake Operation.......................................................................................................................................83 Overview.............................................................................................................................................................83 Operating Device of the Parking Brake.............................................................................................................. 83

©2023 Yale Materials Handling Corp.

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Table of Contents

TABLE OF CONTENTS (Continued) Brake Pedal Operation..........................................................................................................................................84 Overview.............................................................................................................................................................84 Brake Pedal........................................................................................................................................................ 84 Adjustment of Foot Pedal Brake...................................................................................................................... 84 Adjustment of Brake Switch...........................................................................................................................85 Brake Master Cylinder........................................................................................................................................ 85 Brake Fault Diagnosis.........................................................................................................................................87 Hydraulic Oil Tank and Installation........................................................................................................................ 88 Overview.............................................................................................................................................................88 Hydraulic Oil Tank...............................................................................................................................................88 Hydraulic System.................................................................................................................................................. 89 Overview.............................................................................................................................................................89 Gear Pump......................................................................................................................................................... 92 Maintenance of Gear Pump............................................................................................................................. 92 Fault Diagnosis................................................................................................................................................ 95 Multi-Way Valve.................................................................................................................................................. 95 Fault Diagnosis.............................................................................................................................................. 102 Full Hydraulic Orbitrol....................................................................................................................................... 102 Speed Limit Valve............................................................................................................................................. 103 Hydraulic Pipeline.............................................................................................................................................104 Lifting System......................................................................................................................................................106 Safety Procedures when Working Near Mast...................................................................................................106 Overview...........................................................................................................................................................106 Inner and Outer Mast........................................................................................................................................106 Fork Carriage Assembly................................................................................................................................... 107 Adjustment for Height of Fork Carriage..........................................................................................................107 Roller Positions.................................................................................................................................................108 Replacement of Fork Backrest.......................................................................................................................108 Lifting Cylinder..................................................................................................................................................109 Working Status of Explosion Relieve Valve....................................................................................................112 Adjustment of Lifting Cylinder.........................................................................................................................113 Tilting Cylinder.................................................................................................................................................. 113 Installation of Mast............................................................................................................................................ 117 Disassembly of Mast.........................................................................................................................................119 Daily Checks and Maintenance...........................................................................................................................120 Periodic Maintenance Requirements................................................................................................................120 Periodic Maintenance Items............................................................................................................................. 120 Periodic Maintenance....................................................................................................................................... 121 Tire................................................................................................................................................................. 121 Front Wheel.................................................................................................................................................121 Rear Wheel..................................................................................................................................................121 Forks.............................................................................................................................................................. 121 Remove....................................................................................................................................................... 121 Inspect.........................................................................................................................................................122 Install........................................................................................................................................................... 124 Periodic Maintenance Tables............................................................................................................................124 General (CATL-based Lithium-ion Battery)......................................................................................................... 132 Description of Batteries.....................................................................................................................................132 Battery Types and Options............................................................................................................................... 132 Battery Working Environment Temperature......................................................................................................133 Glossary and Abbreviations..............................................................................................................................133 Warnings and Cautions (CATL-based Lithium-ion Battery).................................................................................135

ii

Table of Contents

TABLE OF CONTENTS (Continued) Safety................................................................................................................................................................135 Hazardous Overview........................................................................................................................................ 135 Hazard Pictograms.........................................................................................................................................135 Signal Word....................................................................................................................................................135 Hazard Statements........................................................................................................................................ 135 Precautionary Statements..............................................................................................................................135 Other Hazards................................................................................................................................................135 Composition and Ingredient Information...........................................................................................................135 Hazard Identification.........................................................................................................................................137 Fire Fighting Measures.....................................................................................................................................137 Hazard Analysis (electrical shock, fire, explode, population).........................................................................137 Material Preparation and Personnel Trainings ..............................................................................................137 Fire Extinguisher Instruction...........................................................................................................................138 Unusual Fire and Explosion Hazards.............................................................................................................138 Accidental Release Measures.......................................................................................................................... 138 Leak Emergency Measures..............................................................................................................................138 Handling and Storage.......................................................................................................................................138 Handling.........................................................................................................................................................139 Storage...........................................................................................................................................................139 First Aid Measures............................................................................................................................................139 Handling and Storage.......................................................................................................................................139 Exposure Controls and Personal Protection.....................................................................................................139 Physical and Chemical Properties....................................................................................................................140 Stability and Reactivity......................................................................................................................................140 Toxicological Information.................................................................................................................................. 140 Ecological information.......................................................................................................................................140 Toxicological Information.................................................................................................................................. 141 Regulatory Information..................................................................................................................................... 141 USA................................................................................................................................................................141 International................................................................................................................................................... 141 Air Transportation...........................................................................................................................................141 Ocean Shipping..............................................................................................................................................141 Land Transportation....................................................................................................................................... 141 Avoid Electrical Shock....................................................................................................................................141 Disposal Considerations...................................................................................................................................141 Transport Information....................................................................................................................................... 142 Transport Information.....................................................................................................................................142 Charging and Labeling..................................................................................................................................... 144 Charging.........................................................................................................................................................144 Charging Voltages and Currents:...................................................................................................................144 Labeling..........................................................................................................................................................144 Disposal......................................................................................................................................................... 145 Component Description (CATL-based Lithium-ion Battery)................................................................................ 146 Key Components.............................................................................................................................................. 146 Top Cover Components....................................................................................................................................146 Connection Points.............................................................................................................................................148 Module Connection...........................................................................................................................................148 Module Structure.............................................................................................................................................. 149 Connection Ports.............................................................................................................................................. 149 Charger Specification....................................................................................................................................... 150 Charger Selection.............................................................................................................................................152 Software and User Interface (CATL-based Lithium-ion Battery)......................................................................... 154

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Table of Contents

TABLE OF CONTENTS (Continued) Description of Software Tools for Technicians.................................................................................................. 154 Truck Instrument...............................................................................................................................................154 Battery Displayer.............................................................................................................................................. 157 Charger Displayer.............................................................................................................................................161 BMS Interface...................................................................................................................................................163 System Overview........................................................................................................................................... 163 Real-time Information.....................................................................................................................................164 Parameter Calibration.................................................................................................................................... 165 Force Control................................................................................................................................................. 166 Firmware Upgrading.......................................................................................................................................166 History Data................................................................................................................................................... 167 Real-time Information.....................................................................................................................................168 Maintenance (CATL-based Lithium-ion Battery)................................................................................................. 169 Battery Maintenance.........................................................................................................................................169 Battery Repair (CATL-based Lithium-ion Battery)............................................................................................... 170 Battery Disassembly.........................................................................................................................................170 Module Replacement........................................................................................................................................171 Module Failure............................................................................................................................................... 171 Module Aging................................................................................................................................................. 172 Principles of Operation (CATL-based Lithium-ion Battery)..................................................................................173 Functional Descriptions.................................................................................................................................... 173 Discharge Power-on Process.........................................................................................................................173 Discharge Power-off Process.........................................................................................................................173 Power Button Mode.....................................................................................................................................173 BMS Sleep Mode.........................................................................................................................................173 Fault Mode...................................................................................................................................................173 Charging Mode............................................................................................................................................173 Charging Power-on Process.......................................................................................................................... 173 Charger Mode..............................................................................................................................................173 Charging Power-off Process.......................................................................................................................... 174 Charger Mode..............................................................................................................................................174 SOC Mode...................................................................................................................................................174 Fault Mode...................................................................................................................................................174 Power Button Mode.....................................................................................................................................174 Module Heating Process................................................................................................................................174 Signal Detection Process...............................................................................................................................175 Cell Voltage and Temperature..................................................................................................................... 175 Total Circuit Current and Voltage.................................................................................................................175 Contactor Adhesion.....................................................................................................................................175 CAN Communication......................................................................................................................................175 Charging CAN ............................................................................................................................................ 175 Discharging CAN.........................................................................................................................................175 Battery Displayer (Optional)........................................................................................................................ 175 Personal Computer .....................................................................................................................................175 Child BMS (When Cell Quantity is over 48).................................................................................................175 Other Functions..............................................................................................................................................176 Alarm Buzzer...............................................................................................................................................176 Key Switch (Optional)..................................................................................................................................176 MSD.............................................................................................................................................................176 Discharge Current Control...........................................................................................................................176 Charging Current Control............................................................................................................................ 179 Schematics and Diagrams ...............................................................................................................................181

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Table of Contents

TABLE OF CONTENTS (Continued) System Electrical Schematic..........................................................................................................................181 Discharge Schematic Part (I)......................................................................................................................... 181 Discharge Schematic Part (II)........................................................................................................................ 182 Charging Schematic.......................................................................................................................................183 Module Heating Schematic............................................................................................................................ 184 Single Detection Schematic........................................................................................................................... 185 CAN Communication Schematic....................................................................................................................186 Other Functions Schematic............................................................................................................................187 Main Wire Harness Connection..................................................................................................................... 187 Link Wire and H Port Wire Connection.......................................................................................................... 188 CAN Wire Connection....................................................................................................................................189 Power Cable Connection............................................................................................................................... 190 Heating Cable Connection............................................................................................................................. 191 CSC Wire Connection....................................................................................................................................192 Wire Sequence Detector................................................................................................................................192 Troubleshooting (CATL-based Lithium-ion Battery)............................................................................................ 194 Troubleshooting................................................................................................................................................ 194 Charging Alarm Codes and Solutions............................................................................................................194 Charger Faults and Solutions.........................................................................................................................197 Discharge Alarm Codes and Solutions.......................................................................................................... 200 Battery System Alarm Codes and Solutions.................................................................................................. 203 Other Battery Faults and Solutions................................................................................................................ 205 Discharge Fault Threshold.............................................................................................................................207 Charging Fault Threshold...............................................................................................................................210 Other Fault Threshold.................................................................................................................................... 212 List of Wear Parts................................................................................................................................................213

v

8000 YRM 2353

Forklift Truck Main Parts

Forklift Truck Main Parts BATTERY

to play the due operating performance and service life of battery to a maximum extent thereon.

Overview Battery, as the energy supply center for the entire vehicle, plays a function for holding the balance of the normal work for the whole system, and correct operation produces extremely huge influence over the performance and service life of the battery group. On this account, routine use and maintenance of battery shall be placed at a quite important position, to enable

Battery Specification A battery is composed of several components called cells, which are combined into a single unit.

The Specifications of lead-acid battery and charger are shown in Table 1.

Table 1. Lead-acid Battery Specification (Zibo) Charger Plug Specifications Specifications

Type

Model

Capacity

Voltage

Individual Qty

ERP15UX, ERP18UX

24-6BD420

420Ah

48V

24 pcs

65A/48V

REMA 160

ERP20UX, ERP25UX

24-6BD600H

600Ah

48V

24 pcs

80A/48v

REMA 320

ERP30UX, ERP35UX

40-5DB500H

500Ah

80V

40 pcs

65A/80V

REMA 320

NOTE: The standard configuration of the lead-acid battery is Zibo and is optional equipped with HAWKER. There are different battery brands and different capacities.

requirements or other reasons and are not described in this manual.

The Specifications of optional Lithium Battery and charger are shown in Table 2.

NOTE: The brand model specifications of the battery, charger and plug are subject to change due to order Table 2. Lithium Battery Specification (EIKTO) Type

Model

Capacity

Voltage

Charger Specifications

Plug Specifications

ERP15UX, ERP18UX

LFP

350Ah

51.2 V

60/150

REMA 160

ERP20UX, ERP25UX

LFP

450Ah

51.2 V

60/175

REMA 320

ERP30UX, ERP35UX

LFP

450Ah

83.2 V

100/175

REMA 320

NOTE: The battery and charger may be subject to change based on actual orders.

1

Forklift Truck Main Parts

8000 YRM 2353

Safety Instructions and Precautions

Lithium Battery

Lead-acid Battery

The following instructions are for lithium battery.

1.

The battery that is delivered from factory without charge shall be stored indoors clean and dry at a temperature of 5-45°C (41-113°F). The storage period beginning from the date when battery is delivered from the factory is two years, and the battery initial charging time shall be properly prolonged, if it has been stored more than two years.

1.

The charge and discharge shall not exceed the maximum current specified in the technical parameters.

2.

Avoid charging in direct sunlight.

3.

Battery Operating temperature: -20 - 55°C (-4 - 131°F).

For the battery that has been initially charged and delivered from the factory, its storage shall comply with the following aspects:

4.

Storage environment temperature (for one month): -20 - 45°C (-4 - 113°F).

5.

Storage environment temperature (for six months): 0 - 35°C (32 - 95°F).

6.

Optimal charging and discharging temperature: 20 - 35°C (68 - 95°F).

7.

For the batterty used in the trucks that are not used for a long time:

2.

a.

b.

It shall be stored indoors clean and dry at a temperature of 5-45°C (41-113°F), and be ventilated regularly.

Dust dropped on the battery cover and electrolyte dripped on the battery during measurement shall be timely wiped up using (5-10) % soda water solution or main water, to maintain the cleanliness and dryness for the outside surface of battery.

Before long-term storage, ensure that the SOC of the battery system is 40% to 60%. Check the battery once every two weeks and charge the battery every three months to ensure SOC≥40%.

c.

Direct sunlight shall be avoided, and the battery stored away from heat sources.

d.

A supplementary charge or an equalizing charge shall be performed to the battery every 30 days using the 2nd-phase current of normal charge.

b.

Store in a dry, ventilated and cool environment, avoid direct sunlight, high temperature, high humidity, corrosive gas, violent vibration and other conditions

e.

Extended long storage will affect the general service life of battery.

c.

No stacking.

d.

Long-term storage should disconnect the battery from the truck.

e.

If the battery fails to work properly after longterm storage, contact technical support personnel.

3.

Battery shall be maintained clean and dry, to avoid generation of creeping current.

4.

Liquid must be sucked out immediately using suction pipe, if any in battery container.

5.

Damage of inside/outside paint or coating of battery shall be mended immediately, if any is found, and the outside container insulation shall be protected, free from corrosion.

6.

Replacement of battery unit shall be carried out by professional.

2

a.

8000 YRM 2353

Forklift Truck Main Parts

Battery Charging

floating at all), it shall be supplemented with distilled water that meets the standard or battery replenishment water produced by a regular manufacturer (the lowest point of the filling plug is 1-2cm upwards or the buoy floats), but any acid cannot be added.

Routine Lead-acid Battery Charging Steps 1.

Container cover and other coverings on battery box must be removed or opened before charge to ensure a full dispersion of flammable and combustible gas generated during charge, and steady 30 minutes when charge has been completed (only useable after 30 minutes when charge has been completed). Charging room shall be well ventilated and indoor charging house shall be installed with ventilating device.

2.

Turn off the forklift truck's power supply first, and then open the battery power plug to disconnect the plug from the body end power plug.

3.

Open the liquid filling plug cover on each battery unit and measure the density of electrolyte. If the density of electrolyte is smaller than 1.13kg/l (Hawker) or 1.15kg/l (Zibo), it indicates that the battery has been over-discharged (discharging depth having exceeded 80%). Repeated overdischarging may shorten the service life of battery.

4.

Measure the temperature of electrolyte. If it is higher than 45°C (113°F), the following steps shall be continued after waiting for battery to cool down.

5.

Connect the plug between the battery and the charger cable.

6.

If Trak® air (air disturbance system) is equipped, confirm that the air pipeline has been connected.

7.

If battery is equipped with automatic water supply system, connect the water pipe plug.

8.

Turn on the charging switch of charger, and begin charge.

9.

After charge is completed, turn off the charger power supply, poke the cable plug connection for battery and charger and other supporting auxiliary system connections (such as automatic water supply, etc.).

10. If the battery automatic water supply system is not equipped, check the liquid level of the electrolyte after the battery is charged. If the liquid level is lower than the allowable height (below the minimum of the liquid filling plug or the buoy is not

11. Water shall be added after charge, and water addition before charge may possibly give rise to overflow of acidic liquid.

12. Connect the battery cable plug.

NOTE: The energy charger can adjust the charging curve according to the actual situation (new and old batteries, different brands of batteries). The method is to open the charger, find the three-gear switch on the internal circuit board of the charger. I-O-II can be chosen. The default is O shift. For the specific operation, refer to the Charger Manual.

Notes When Lithim Battery Charging 1.

Must use the manufacturer's designated or confirmed charging machine to charge;

2.

Keep batteries away from dangerous goods or environments, such as corrosive chemicals, dangerous machinery, rain, and high temperature environments.

3.

Must choose to charge in a relatively safe environment, such as avoiding liquid, fire.

4.

Must turn off the truck key switch before charging.

5.

The charging equipment is equipped with the necessary safety extinguishing devices, so that in extreme cases, emergency extinguishing can be carried out. Before charging, make sure that there is no foreign matter such as dust and water in the charging plug and charging socket. If there is any foreign matter, clean it up before charging.

Otherwise, the charging interface will cause fire due to poor contact or short connection.

6.

Do not modify or remove the charging port and charging device, which may cause charging failure and fire

7.

After charging, do not disconnect the charging device with wet hands or while standing in the water, so as to avoid electric shock and personal injury

3

Forklift Truck Main Parts 8.

9.

If you need to stop charging during the charging process, you must first press the stop button or cut off the air switch of the charger. Only when the current drops to OA, can you disconnect the charging plug When the battery power is less than 20%, it should be charged immediately.In low temperature environment, when the battery is used up and low, it should be charged and full immediately

10. Batteries without heating function should be charged immediately after being used at 0°C (32°F) or below. If normal charging cannot be carried out, the battery should be moved to a high temperature environment for a few hours, after the battery temperature rises to 0°C (32°F) or above, then charge

8000 YRM 2353

Lead-acid Battery Daily Service a.

Battery shall be charged immediately after discharge each time.

b.

Discharge each time shall not exceed 80% of the total battery capacity.

c.

Battery must be wiped up if any acidic liquid is overspilled, in order to avoid corrosion of the container and the battery leakage.

Weekly Service a.

If battery is not equipped with automatic liquid adding system, it is required to examine the height of electrolyte after charge. When it is lower than the allowable liquid level (below the lowest point of the liquid filling plug or the buoy is not floating at all), it is required to add qualified distilled water to the specified height.

When electrolyte is excessive, it shall be extracted to the specified height.

b.

Examine whether or not water is accumulated inside the battery container. The accumulated water must be sucked up immediately if it is found.

c.

Check if the positive and negative lead wires and the pole terminal fastening nuts are loose.

If looseness is found, tighten immediately to prevent the spark from burning the pole when used.

11. If the battery with heating function is charged at 0°C (32°F) or below, the battery will be heated first, and the total charging time will be longer 12. The battery charging current will change with the change of battery temperature. When the battery temperature is above 35°C (95°F), the charging current will decrease with the increase of temperature. When the battery temperature is below 15°C (59°F), the charging current decreases with the decrease of the temperature.

WARNING Do not use charging devices at temperatures higher than 55°C (131°F). Do not directly insert or remove the charging plug-in when the charging device has current output. Otherwise, battery damage or personal injury may occur. Do not place battery packs near heaters or other heat sources.

Service of Battery WARNING To ensure personal safety, wear protective equipment such as safety shoes and insulating gloves before performing regular inspection. If any abnormal situation is found, please contact our after-sales service for handling, do not repair without authorization.

4

Monthly Service a.

Before charge is completed, examine the voltages of all the electrode units and the battery, and keep records.

b.

After charge is completed, it is required to measure the density and temperature of each battery unit, and keep records. If a huge difference from the previous measurement value is found, a professional shall be contacted for examination.

8000 YRM 2353

Forklift Truck Main Parts

Annual Service a.

b.

A professional shall examine the insulation resistance of forklift truck and the insulation resistance of battery once a year. The insulation resistance for battery is specified as 50Ω/V. The resistance to the entire battery (voltage to reach 20V) is 1000Ω.

Examine the charger once according to the instruction manual, to ensure that respective functions are under normal conditions.

b.

Use the air compressor to clean the dust, metal shavings and other sundries on the battery system cover, and avoid using water or water-soaked objects for cleaning.

c.

Check whether the power cable and communication cable connectors of the power battery are loose.

Quarterly Service a.

Lithium Battery Weekly Service a.

Do a full charge at least once a week to ensure the accuracy of the battery SOC.

Check whether the high and low voltage wiring harnesses of the battery system are damaged, bruised or loose. Check whether the charging plugs are overheating or damaged.

Common Failures and Disposal Methods of Battery

Table 3. For Lead-acid Battery

Active Matter Excessive Dropout

Pole Plate Salinization

Effect

Failure Characteristic

Cause

Solution

1. Initial charge insufficient.

dropped at 1. Capacity normal discharge.

2. Specific gravity dropped lower than normal value.

3. Quick voltage drop at discharge.

4. Early generation of air bubble at charge. crystallization 5. PbSO4 coarse and large.

2. Discharging status, and placement time too long. charge 3. Long-term insufficient. proportion 4. Electrolyte high.

5. Liquid level receded, the top of plate exposed to air.

6. Electrolyte impure.

found inside 1. Deposit electric liquid, brown matter rises at charge.

2. Batter capacity reduced.

1. Drown deposit due to over-large charging current.

2. White deposit due to excessive discharge. present 3. Contaminant inside battery.

4. Dropout in bulk, plate quality issue.

5. The cast in paste status, due to long-time proportion or temperature to the high end.

1. Overcharging method. charging 2. Repeated method.

3. Hydropathy method.

7. Internal short circuit.

1. Rubber shell battery, plate replaceable, and deposit removable.

2. To be charge with small current and electric liquid density and liquid level height to be adjusted.

5

Forklift Truck Main Parts

8000 YRM 2353

Table 3. For Lead-acid Battery (Continued)

Electrolyte Issue

Reversal

Internal Short Circuit

Effect

Failure Characteristic

Cause

1. Voltage fairly low at charge.

2. Air bubble rather few at the end stage of charge.

3. Quick temperature rise at charge, no change in electrolyte proportion.

4. Discharge capacity low and voltage dropped.

substance 1. Conductive dropped inside.

2. Plate bent, and separator damaged.

3. Lots of deposits.

1. Batter capacity dropped.

2. Voltage reduced.

obviously

1. Proportion, capacity, and voltage to the low end.

2. Proportion too high. impure, 3. Electrolyte present with contaminant.

1. Assembling issue.

2. Excessive discharge.

3. Insufficient charge, giving rise to plate salinization.

1. Excessive water addition or plate salinization. electrolyte by 2. Add mistake.

3. Contents of distilled water and electrolyte contaminants exceeding the specified requirements.

WARNING The contents above related to battery are for reference. Please operate and maintain the battery according to the Battery Use and Maintenance Manual. If you have any questions, please contact a professional.

6

Solution

1. Conductive substance to be removed.

2. Pole plate to be replaced.

3. Separator to be replaced.

1. Battery to be replaced.

2. Reversal battery to be charged separately.

1. Density to be adjusted and salinization to be eliminated.

2. Some electrolyte to be taken out and density to be adjusted.

3. Electrolyte to be replaced.

8000 YRM 2353

Main Technical Specification of Forklift Truck

Main Technical Specification of Forklift Truck

Figure 1. Forklift Truck Exterior

7

Main Technical Specification of Forklift Truck

Model

1

ERP15UX

ERP18UX

ERP20UX

ERP25UX

1500

1800

2000

2500

Rated Capacity

kg

2

Load Centre

mm

3

500

500

Lifting Height H2

mm

4

3000

3000

Free Lifting Height

mm

5

135

140 40 x 100 x 1070

40 x 120 x 1070

Fork Size

sxex1

mm

6

35 x 100 x 920

Mast Tilting Angle

F/B(a°/β°)

Deg

7

5/10

Length (to forkface)

mm

8

2106

Width B1

mm

9

1120

1266

Mast Height 1

mm

10

2000

2030

Height when mast extended H3

mm

11

4009

4017

Height to Safeguard H

mm

12

2155

2145

Min R

mm

13

1965

mm

14

410

454

Overall Dimensions

Turning Radius

Front Overhang G

5/10 2302

2317

2065

2080

Tread

Front Q/ Rear S

mm

15/16

955/920

1058/960

Ground Clearance

Unladen

mm

17

105

110

mm

18

1380

1485

Min/Max

mm

19

250/930

250/1000

800 x 1200 Horizontally

mm

20

3575

3719

3734

1000 x 1200 Longitudinally

mm

21

3775

3919

3934

Travel (Laden)

km/h

22

15

15

Travel (Unladen)

km/h

23

16

16

Lifting (Laden)

mm/s

24

310

310

Lifting (Unladen)

mm/s

25

500

500

Laden

%

26

15

15

Unladen

%

27

22

22

with battery

kg

28

Wheelbase F Fork Spread Aisle width of stacking, with pallets (Ast)

Speed

Gradeability Weight

8

8000 YRM 2353

3010

3275

4100

4300

8000 YRM 2353

Main Technical Specification of Forklift Truck

Model

1

ERP15UX

ERP18UX

Front x 2

29

6.00-9

21 X 8-9

Rear x 2

30

5.00-8

18 X 7-8

Tyre Motor

ERP25UX

23 X 9-10

Driving Motor

kw

21

6.5

8.5

Lifting Motor

kw

32

8.6

11

Standard

V/Ah

33

48/420

48/600

Optional (Capacity expansion)

V/Ah

34

48/660

48/660

Battery

Controller

ERP20UX

Type

35

AC

Manufacturer

36

Curtis

Operating Pressure

Mpa

37

14.5

17.5

NOTE: The standard configuration of the battery is Zibo and is optionally equipped with HAWKER. There are different battery brands and different capacities.

Model

1

ERP30UX

ERP35UX

3000

3000

Rated Capacity

kg

2

Load Centre

mm

3

500

Lifting Height H2

mm

4

3000

Free Lifting Height

mm

5

165

170

45 x 122 x 1070

50 x 122 x 1070

Fork Size

sxex1

mm

6

Mast Tilting Angle

F/B(a°/β°)

Deg

7

Length (to forkface)

mm

8

2544

2613

Width B1

mm

9

1266

1385

Mast Height 1

mm

10

2045

2120

Height when mast extended H3

mm

11

4140

4140

Height to Safeguard H

mm

12

2145

2140

Min R

mm

13

2320

2363

mm

14

476

495

Overall Dimensions

Turning Radius

Front Overhang G

5/10

Tread

Front Q/ Rear S

mm

15/16

1065/980

1124/1010

Ground Clearance

Unladen

mm

17

110

110

mm

18

1690

1690

Min/Max

mm

19

800 x 1200 Horizontally

mm

20

3996

4058

1000 x 1200 Longitudinally

mm

21

4196

4258

Wheelbase F Fork Spread Aisle width of stacking, with pallets (Ast)

250/160

9

Main Technical Specification of Forklift Truck

8000 YRM 2353

Model

Speed

Gradeability Weight Tyre Motor

Battery

Controller

1

ERP35UX

Travel (Laden)

km/h

22

15

Travel (Unladen)

km/h

23

16

Lifting (Laden)

mm/s

24

300

280

Lifting (Unladen)

mm/s

25

500

500

Laden

%

26

15

Unladen

%

27

22

with battery

kg

28

4915

5320

Front x 2

29

23 x 9-10

23 x 10-12

Rear x 2

30

18 x 7-8

200/50-10

Driving Motor

kw

21

11.5

Lifting Motor

kw

32

12

Standard

V/Ah

33

80/500

Optional (Capacity expansion)

V/Ah

34

80/550

Type

35

AC

Manufacturer

36

Curtis

37

17.5

Operating Pressure

Mpa

NOTE: The standard configuration of the battery is Zibo and is optionally equipped with HAWKER. There are different battery brands and different capacities.

10

ERP30UX

8000 YRM 2353

Driving Motor and Driving System

Driving Motor and Driving System OVERVIEW

AXLE BOX AND DIFFERENTIAL

The horizontally mounted axle box integrated gearbox is a mechanical gearbox consisting of three-stage cylindrical gear and differential gears. It is suitable for industrial vehicles such as ERP15UX-ERP35UX battery forklift trucks.

The horizontally mounted axle box integrated gearbox adopts the drive axle housing and the reduction gearbox housing. The two pairs of cylindrical helical gears of the mechanism reduce the rotational speed from the output shaft of the traveling motor and increase the torque transmitted from the output shaft, and then transmit this torque to the differential. The tire is mounted on the wheel hub by a wheel rim with studs and nuts. The wheel hub is supported by the tapered shell bearing on the axle housing, and the power is transmitted to the half shaft through the differential.

The wheel hub is driven by the half shaft and drives the front wheel to rotate. Half shaft only withstands the torque transmitted to the wheel hub. An oil seal is installed inside the wheel hub to prevent water or dust from entering or leaking oil. The structure of the axle box is indicated in Figure 2, Figure 3, and Figure 4.

The horizontally mounted axle-box integrated gearbox adopts the integration of the drive axle housing and the reduction gearbox housing. The drive axle tube adopts a steel pipe structure, and directly bears the weight of the frame together with the steering axle.

The power input device is an AC motor. The motor and axle box are arranged in parallel. The horizontally mounted axle-box integrated gearbox directly relies on the forward and reverse rotation of the motor to achieve forward or backward operation without the need for shifting and reversing operations. The parking and service brakes are drum brakes with automatic compensation for clearance. The wheel can be directly connected to the reduction gearbox through the half shaft to realize the power output of the reduction gear box. Compared with the vertical battery forklift truck reducer, it has the characteristics of compact structure, short axial dimension, small size and convenient use and maintenance.

The differential is mounted in the axle box through the bearing seats at both ends, and the front end is connected to the axle housing. The housing of the differential is split as left and right parts with two half axle gears and four planetary gears. The structure of the differential is indicated in Figure 5.

11

Driving Motor and Driving System

Figure 2. Axle Box (ERP15UX - ERP18UX)

12

8000 YRM 2353

8000 YRM 2353

Driving Motor and Driving System Legend for Figure 2.

1. BEARING 6207 2. BEARING 6208 3. PAPER CUSHION 4. INPUT SHAFT 5. LEFT BRAKE ASSEMBLY 6. GEAR COMBINATION 7. OIL SEAL RETAINER RING 8. SEAL RING 9. BEARING 6009 10. O-RING 11. NUT 12. BEARING 32208 13. GEAR COMPONENT 14. LEFT AXLE BOX ASSEMBLY 15. LEFT BRAKE CABLE 16. WASHER 14 17. BOLT M14 X 1.5 X 35 18. ROUND NUT M60 X 2

19. BRAKE DRUM 20. BEARING 30213 21. NUT M12 X 1.5 22. BEARING 32012 23. OIL SEAL SEAT 24. SEAL RING 25. SCREW PLUG M18 X 1.5 26. COMBINATION SEALING WASHER 18 27. BOLT 28. BALL NUT M12 X 1.5 29. WASHER 60 30. HALF SHAFT PAPER CUSHION 31. HALF SHAFT 32. WASHER 10 33. BOLT M10 X 1.25 X 45 34. PAPER CUSHION 35. SCREW PLUG 36. DIFFERENTIAL ASSEMBLY

37. MIDDLE BOX 38. RIGHT AXLE COVER COMPONENT 39. RIGHT SUPPORT PLATE 40. RIGHT BRAKE CABLE 41. RIGHT BRAKE ASSEMBLY 42. COMBINATION SEALING WASHER 20 43. VENT PLUG SCREW 44. VENTILATION PLUG Q901 45. BOLT M12 X 1.5 X 40 46. WASHER 12 47. BOLT M12 X 1.5 X 35 48. BEARING 32915 49. O-RING 50. O-RING 51. WASHER 16 52. BOLT M16 X 1.5 X 45 53. CYLINDRICAL PIN

13

Driving Motor and Driving System

Figure 3. Axle Box (ERP20UX - ERP30UX)

14

8000 YRM 2353

8000 YRM 2353

Driving Motor and Driving System Legend for Figure 3.

1. BEARING 6207 2. BEARING 6208 3. PAPER CUSHION 4. INPUT SHAFT 5. LEFT BRAKE ASSEMBLY 6. GEAR COMBINATION 7. OIL SEAL RETAINER RING 8. SEAL RING 9. BEARING 6009 10. O-RING 11. NUT 12. BEARING 32208 13. GEAR COMPONENT 14. LEFT AXLE BOX ASSEMBLY 15. LEFT BRAKE CABLE 16. WASHER 14 17. BOLT M14 X 1.5 X 35 18. ROUND NUT M60 X 2

19. BRAKE DRUM 20. BEARING 30213 21. NUT M12 X 1.5 22. BEARING 32012 23. OIL SEAL SEAT 24. SEAL RING 25. SCREW PLUG M18 X 1.5 26. COMBINATION SEALING WASHER 18 27. BOLT 28. BALL NUT M12 X 1.5 29. WASHER 60 30. HALF SHAFT PAPER CUSHION 31. HALF SHAFT 32. WASHER 10 33. BOLT M10 X 1.25 X 45 34. PAPER CUSHION 35. SCREW PLUG 36. DIFFERENTIAL ASSEMBLY

37. MIDDLE BOX 38. RIGHT AXLE COVER COMPONENT 39. RIGHT SUPPORT PLATE 40. RIGHT BRAKE CABLE 41. RIGHT BRAKE ASSEMBLY 42. COMBINATION SEALING WASHER 20 43. VENT PLUG SCREW 44. VENTILATION PLUG Q901 45. BOLT M12 X 1.5 X 40 46. WASHER 12 47. BOLT M12 X 1.5 X 35 48. BEARING 32915 49. O-RING 50. O-RING 51. WASHER 16 52. BOLT M16 X 1.5 X 45 53. CYLINDRICAL PIN

15

Driving Motor and Driving System

8000 YRM 2353

Figure 4. Axle Box (ERP35UX)

16

8000 YRM 2353

Driving Motor and Driving System Legend for Figure 4.

1. BEARING 6207 2. BEARING 6208 3. PAPER CUSHION 4. INPUT SHAFT 5. LEFT BRAKE ASSEMBLY 6. GEAR COMBINATION 7. OIL SEAL RETAINER RING 8. SEAL RING 9. BEARING 6009 10. O-RING 11. NUT 12. BEARING 32208 13. GEAR COMPONENT 14. LEFT AXLE BOX ASSEMBLY 15. LEFT BRAKE CABLE 16. WASHER 14 17. BOLT

18. ROUND NUT M60 X 2 19. BRAKE DRUM 20. BEARING 30214 21. WHEEL HUB 22. BEARING 32012 23. OIL SEAL SEAT 24. SEAL RING 25. SCREW PLUG M18 X 1.5 26. COMBINATION SEALING WASHER 18 27. BOLT 28. BALL NUT M18 X 1.5 29. WASHER 60 30. HALF SHAFT PAPER CUSHION 31. HALF SHAFT 32. WASHER 12 33. BOLT M12 X 1.25 X 45 34. PAPER CUSHION 35. SCREW PLUG

36. DIFFERENTIAL ASSEMBLY 37. MIDDLE BOX 38. RIGHT AXLE COVER COMPONENT 39. RIGHT SUPPORT PLATE 40. RIGHT BRAKE CABLE 41. RIGHT BRAKE ASSEMBLY 42. COMBINATION SEALING WASHER 20 43. VENT PLUG SCREW 44. VENTILATION PLUG Q901 45. BOLT M12 X 1.5 X 40 46. BOLT M12 X 1.5 X 35 47. BEARING 32915 48. O-RING 49. O-RING 50. WASHER 16 51. BOLT M16 X 1.5 X 45 52. CYLINDRICAL PIN

1. DIFFERENTIAL HOUSING ASSEMBLY 2. HALF SHAFT GEAR 3. CROSS AXLE 4. WASHER

5.

6.

7.

8.

9. BOLT 10. DEEP GROOVE BALL BEARING 6211 11. NUT M10 X 1.25

PLANETARY GEAR GEAR RING THRUST WASHER FASTENING GASKET

Figure 5. Differential (ERP15UX - ERP35UX)

17

Driving Motor and Driving System

8000 YRM 2353

Notes for Installation and Use 1.

Upon installation, oil dirt on this product surface shall be wiped off in order to avoid damaging the product.

2.

Do not knock mounting surfaces when installing to ensure the installation precision and normal use.

3.

During the assembly of the pinion assembly, tighten the nut to 3.0 - 3.5 N•m (2.21 - 2.58 lbf ft).

The nut tail is flattened and locked along the pinion groove.

4.

When assembling the brake, adjust the clearance adjuster of the brake to ensure that the clearance between the inner diameter of the brake drum and the friction plate is 0.5 - 1.0 mm (0.01 - 0.03 in.). Do not allow oil to enter in the left and right brakes.

5.

To install the wheel hub bearing, it is necessary to add No. 3 lithium-based grease with a dropping point of 170 to the wheel hub, the amount of

which is 50% to 70% of the volume of the wheel hub cavity, about 130 to 190 ml (0.13 to .20 qt).

After the wheel hub is installed, tighten the round nut and retract it about 1/8 circle to ensure that the wheel hub can rotate freely, and the torque is 10 - 30 N•m (7.38 - 22.13 lbf ft).

6.

During normal use, the oil level of the gear in the axle box shall be at the height of the oil level plug.

The oil temperature is 70 - 95°C (158 - 203°F), and the maximum is 110°C (230°F). The working fluid shall be kept clean and free of impurities.

The working fluid shall be replaced after 100 hours of initial operation at normal oil temperature. The working fluid shall be replaced after each 1,000 hours of use or after long-term deactivation.

7.

After removing the screw plug, retighten the screw plug with a tightening torque of 45 - 60 N•m (33.19 - 44.25 lbf ft).

FRONT TYRE AND WHEEL RIM MODELS

Table 4. Axle Box, Front Tyre, Wheel Rim Model and Tire pressure Forklift Model

ERP15UX

Axle Box (Central South)

ERP18UX

ERP20UX

HQX15 II

Tire

6.00-9

21 X 8-9

Rim

4.00E-9

6.00E-9

Tire Pressure (Optional)

860 kPa (124.7 psi)

1000 kPa (145.04 psi)

900 kPa ( psi)

1.

Fill the wheel hub with 100 cc (6.10 in.3) of grease and install it on the shaft.

2.

Tighten the adjusting nut using around 1kg.m torque and turn it back ½ circle.

ERP30UX

ERP35UX

HQX25

HQX35

23 X 9-10

23 X 10-12

6.50F-10

Installation of Wheel Hub

18

ERP25UX

6.50F-10 900 kPa (130.5 psi)

8.00G-12 NA

3.

Hang the spring scale on the bolt to measure the starting torque of the wheel hub, and after it reaches the specified value, slowly tighten the nut. Starting torque: 5 - 15 N•m (3.68 - 11.06 lbf ft).

4.

Install the locking piece and the lock nut and lock the locking plate to stop.

8000 YRM 2353

1. ADJUSTING NUT

Driving Motor and Driving System

2. LOCKPLATE

3. LOCKNUT

Figure 6. Wheel Hub

Brake The brakes are two-way brake booster mounted on either side of the drive axle.

The brake consists of two groups of brake shoes, brake wheel cylinder and regulator.

device. Press the parking spring with the return spring and the compressed spring pull rod.

In addition, a parking brake mechanism and an automatic adjustment device are also assembled on the brake. The brake structure is indicated in Figure 7, Figure 8, Figure 9.

One end of the brake shoe is in contact with the fixing pin, and the other end is in contact with the adjusting

19

Driving Motor and Driving System

Figure 7. Brake (ERP15UX - ERP18UX)

20

8000 YRM 2353

8000 YRM 2353

Driving Motor and Driving System Legend for Figure 7.

1. BOTTOM PLATE 2. BRAKE WHEEL CYLINDER 3. WHEEL CYLINDER SPRINGS 4. BRAKE CYLINDER CUP 5. WHEEL CYLINDER PISTON 6. COVER 7. SUPPORT PIN 8. DUST CUP 9. OIL PLUG 10. BRAKE SHOE WITH FRICTION PLATE ASSEMBLY (FRONT)

11. BRAKE SHOE WITH FRICTION PLATE ASSEMBLY (REAR) 12. GUIDE BLOCK 13. SPRING STAY DEVICE 14. CLEARANCE ADJUSTER ASSEMBLY 15. PAWL 16. SPRING 17. BRAKE SHOE RETURN SPRING 18. RETURN SPRING 19. PARKING BRAKE PULL ROD 20. PARKING BRAKE LEVER 21. SPRING

22. BOLT M6 X 16 23. WASHER 24. RESILIENT PAD 25. GUIDE BLOCK 26. COMPRESSED SPRING PULL ROD 27. COMPRESSED SPRING SEAT 28. COMPRESSED SPRING 29. RUBBER PLUG 30. BRAKE CABLE WIRE ASSEMBLY (LEFT) BRAKE CABLE WIRE ASSEMBLY (RIGHT) 31. PIN

21

Driving Motor and Driving System

Figure 8. Brake (ERP20UX - ERP30UX)

22

8000 YRM 2353

8000 YRM 2353

Driving Motor and Driving System Legend for Figure 8.

A. LEFT BRAKE ASSEMBLY 1. BOTTOM PLATE 2. CLEARANCE ADJUSTMENT SLEEVE 3. FRICTION PLATE ASSEMBLY 4. BRAKE PAD 5. PARKING BRAKE PULL ROD 6. RETURN SPRING 7. SHIM 8. EJECTOR ROB 9. PULL SPRING 10. PARKING BRAKE LEVER 11. COMPRESSION SPRING 12. ADJUSTMENT LEVER 13. COMPRESSED SPRING SEAT

B. RIGHT BRAKE ASSEMBLY 14. SPRING 15. COMPRESSED SPRING CUP 16. SPRING 17. COMPRESSED SPRING SEAT 18. COMPRESSED SPRING PULL ROD 19. SUPPORT PIN 20. SHIM 21. RUBBER PLUG 22. BRAKE CABLE WIRE ASSEMBLY (LEFT) 23. BRAKE CABLE WIRE ASSEMBLY (RIGHT) 24. WASHER 25. BRAKE WHEEL CYLINDER 26. BRAKE WHEEL CYLINDER SHIELD 27. BRAKE WHEEL CYLINDER PISTON EJECTOR ROB

28. PISTON 29. CUP WHEEL CYLINDER PISTON 30. BRAKE WHEEL CYLINDER SPRING 31. BRAKE WHEEL CYLINDER OIL PLUG 32. BRAKE WHEEL BLEEDER SCREW 33. WHEEL CYLINDER BLEEDER SCREW SHIELD 34. DUST COVER 35. RIVET 36. BASE PLATE 37. FULCRUM POST 38. CLEARANCE ADJUSTMENT BOLT 39. WASHER 40. CLEARANCE ADJUSTING ROD

23

Driving Motor and Driving System

1.

2.

3.

4.

5.

6.

7.

8.

9.

BOLT M8 X 25 SPRING WASHER 8 RUBBER PLUG COMPRESSED SPRING PULL ROD LEFT BRAKE BASEPLATE PIN LEFT PARKING BRAKE PULL ROD BRAKE SHOE WITH FRICTION PLATE ASSEMBLY COMPRESSED SPRING SEAT

8000 YRM 2353

10. COMPRESSED SPRING 11. PULL SPRING 12. LEFT PAWL 13. LEFT TORSION SPRING 14. LEFT CLEARANCE ADJUSTER ASSEMBLY 15. SPRING STAY DEVICE 16. LEFT RETURN SPRING (REAR) 17. GUIDE BLOCK 18. LEFT RETURN SPRING (FRONT)

19. GUIDE PLATE 20. LEFT BRAKE SHOE WITH FRICTION PLATE AND HANGING SPRING PIN ASSEMBLY 21. BRAKE WHEEL CYLINDER ASSEMBLY 22. PIN 23. LEFT PARKING BRAKE PUSHROD 24. POLE PIN RETAINER RING 25. BRAKE PAD 26. SPRING 27. BRAKE CABLE WIRE ASSEMBLY

Figure 9. Brake (ERP35UX)

Parking Brake The parking brake device is assembled in the brake and is composed of a pull rod and a push rod.

24

The pull rod is mounted on the driving shoe side by a pin, and the action of the pull rod is transmitted to the side of the driven shoe through the push rod.

8000 YRM 2353

1. PUSH ROD 2. PULL ROD 3. PIN

Driving Motor and Driving System

4. DRIVING SHOE 5. DRIVEN SHOE

Figure 10. Parking Brake

Clearance Self-Adjusting Mechanism Clearance self-adjustment mechanisms enable the appropriate clearance to be kept between the friction piece and brake drum.

Clearance self-adjustment action only in the reverse mode.

1. CABLE 2. GUIDE SLOT 3. PULL ROD

4. ADJUSTING MECHANISM 5. SPRING

Figure 11. Action of the Clearance Automatic Adjusting Mechanism When the forklift truck is backward, the brake operation is performed. The driven shoe is in contact with the driving shoe and rotates together, so that the pull rod rotates right around point A. As shown in Figure 10, point B is raised. After the brake is released, the pull rod rotates left under the action of the spring force and drops at point B. When the clearance between the friction plate and the brake hub becomes larger, the vertical distance for the rotation of point B increases, the adjuster is moved by one gear, and the adjustment rod becomes longer (as shown in Figure 11 and Figure 12), and the clearance is reduced accordingly. The range of clearance adjustment is shown in Table 5.

Table 5. Clearance Forklift Model

ERP15UX - ERP18UX

ERP20UX - ERP30UX

ERP35UX

Clearance

0.35-0.55 mm (0.0138-0.0217 in.)

0.40-0.45 mm (0.0157-0.0177 in.)

0.25-0.40 mm (0.0098-0.0157 in.)

25

Driving Motor and Driving System

8000 YRM 2353

2.

Remove the shoe return spring.

3.

Remove the spring from the driving shoe.

A. ELONGATION ALONG THIS DIRECTION Figure 12. Clearance Self Adjusting Mechanism

Brake Disassembly and Assembly, Adjustment Essentials This section describes the disassembly, assembly, and adjustment of the brake pedal in the disassembled state of the wheel and wheel hub. Although the adjustment structure of other models is different, the maintenance methods are basically the same.

Disassembly of the Brake 1.

26

Remove the support pin, adjusting rod, adjustment device and spring on the driven shoe.

8000 YRM 2353

4.

Remove the driving shoe and the driven shoe.

Remove the adjuster and adjuster spring at the same time.

5.

Remove the brake pin from the brake wheel cylinder, then remove the mounting bolts of the brake wheel cylinder and remove the brake wheel cylinder from the brake baseplate.

Driving Motor and Driving System

6.

Remove the E-shape retaining ring for fixing the brake cable on the brake baseplate. Then, remove the bolts for installing the brake baseplate and remove the brake base plate from the drive axle.

7.

Disassemble of brake wheel cylinder: Remove the dust ring. Press the piston on one side to push out the piston on the other side, then press the piston with finger.

27

Driving Motor and Driving System

8000 YRM 2353

Table 6. Friction Plate Thickness

Inspection of brake

Forklift Model

ERP15UX - ERP20UX ERP18UX ERP30UX

ERP35UX

Standard Numerical Value

6.3 mm (0.248 in.)

7.2 mm (0.283 in.)

8.8 mm (0.346 in.)

Limit Numerical Value

3.0 mm (0.118 in.)

4.5 mm (0.177 in.)

5.0 mm (0.197 in.)

Inspection of each component, repair or replacement of damaged parts.

1.

Check the inner surface of the pump and the outer circumference of the piston for rust. Then measure the clearance between the piston and the pump body.

Standard sizes: 0.03 - 0.10 mm (0.00118 - 0.00394 in.)

Limit size: 0.15 mm (0.00591 in.)

2.

Visually inspect the piston cup for damage and deformation and replace it if there is an abnormality.

3.

For measurement of the free length of a brake wheel cylinder spring, replace it when the benchmark is exceeded.

4.

The thickness of the friction plate is measured and replaced when the wear limit is exceeded, as shown in Table 6.

28

5.

Visually inspect the inner surface of the brake drum. If there is any damage or partial wear, the grinding correction is performed. When the correction limit is exceeded, replace it. See Table 7.

8000 YRM 2353

Driving Motor and Driving System

Table 7. Correction Limit

(a) The contact surface between the baseplate and brake shoe.

Forklift Model

ERP15UX - ERP20UX ERP18UX ERP30UX

ERP35UX

Standard Numerical Value

254 mm (10.00 in.)

310 mm (12.20 in.)

314 mm (12.36 in.)

Limit Numerical Value

256 mm (10.08 in.)

312 mm (12.28 in.)

316 mm (12.44 in.)

(b) Retainer pin. (c) Contact surface of shoe plate and compressed spring plate. (d) Support pin of parking brake pull rod. (e) Adjusting mechanism threads and other rotating parts.

Figure 13. Grease Application Sequence

Brake Assembly 1.

Apply brake fluid to the cup and piston of the brake wheel cylinder and assemble the spring, piston cup, piston and dust ring in sequence.

2.

Install the brake wheel cylinder on the brake baseplate.

3.

Install the brake baseplate on the drive axle.

4.

Apply heat-resistant grease as shown in Figure 13. Be careful not to apply it to the friction plate.

5.

The parking brake cable is clamped using an Eshape retaining ring.

6.

Install the brake shoe with a fixed spring.

7.

Install the compression spring to the parking brake push rod and attach the push rod to the brake shoe.

8.

Brake shoe’s guide plate shall be installed on support pin and then return spring shall be installed. First install main brake shoe before installation of auxiliary brake shoe.

9.

Install adjuster, adjuster’s spring, ejector rod and return spring of ejector rod. a.

Adjuster thread direction and its installation direction;

b.

Adjuster spring direction (not allowing the adjuster tooth to contact the spring);

29

Driving Motor and Driving System c.

The direction of the return spring (the spring hook at the support pin end should be fixed on the opposite side of the ejector rob);

d.

When adjusting the lower end of lever, it must connect with tooth of adjuster.

10. Brake pipe shall be connected with wheel cylinder.

8000 YRM 2353

Operation Steps for Brake Clearance Adjuster 1.

The diameter of brake shoe shall be close to the installation dimension as specified. Pull the adjustment lever with hand to rotate the adjuster.

When you release adjustment lever, it returns to its original position and adjuster’s gear remains unchanged.

2.

If the above actions cannot be performed on the adjuster while pulling the adjustment push rod, the following inspection shall be carried out: a.

Fix the adjusting lever, the ejector rob, the ejector rob spring and the compressed spring seat;

b.

Check the ejector rob return spring and adjuster spring for damage, and then check the rotation of the adjuster gear and its meshing parts for excessive wear or damage. Check whether lever and gear are connected.

Replace damaged parts.

11. Measuring the inner diameter of the brake drum, the outer diameter of the brake shoe, and adjusting the governor cause the difference between the inner diameter of the brake drum and the outer diameter of the brake shoe friction plate 0.5-1 mm (0.0197-0.0394 in.).

A. EXPANSION DIRECTION Figure 14. Brake Clearance Adjuster

30

8000 YRM 2353

Driving Motor and Driving System

Driving Motor Specification of Driving Motor Type

Driving Motor Model

Rated Power kW

Rated Voltage V

ERP15UX ERP18UX

AHT6.5-4030B (JHL)

6.5

48

ERP20UX ERP25UX

AHT8.5-4030B (JHL)

8.5

48

ERP30UX ERP35UX

AHT11.5-4030F (JHL)

11.5

80

Operating Environment Conditions

•

Relative humidity 30~98%.

Motor shall be able to operate normally under following environments:

•

Atmospheric 86 - 106 kPa (12.47 - 15.37 psi).

•

Altitude not exceeding 1200 m (47244 in.).

•

Range of change in ambient air temperature -25 - 40°C (-13 - 104°F).

pressure

31

Pump Motor

8000 YRM 2353

Pump Motor SPECIFICATION OF PUMP MOTOR Forklift Model

Pump Motor Model

Rated Power kW

Rated Voltage V

ERP15UX ERP18UX

AST8.6-401BK (JHL)

8.6

48

ERP20UX ERP25UX ERP30UX

AST11-401BK (JHL)

11

48

ERP35UX

AST15-4010FK (JHL)

15

80

Operating Environment Conditions

•

Motor shall be able to operate normally under following environments:

•

•

32

Altitude not exceeding 1200 m (47244 in.)

•

Range of change in ambient air temperature -25 - 40°C (-13 - 104°F) Relative humidity 30~98% Atmospheric 86 - 106 kPa (12.47 - 15.37 psi)

pressure

8000 YRM 2353

Electrical System

Electrical System WARNING This lift truck may be equipped with devices that can emit non-ionising radiation, such as radio transmitters or RFID card readers. Users may be exposed to radio frequency radiation. Users with implanted medical devices should consult their medical professional before using lift trucks equipped with devices that can emit such radiation.

representation. At the same time, the controller is also provided with comparatively self-contained fault self diagnosis function, able to give out fault codes of common failures, to facilitate maintainers to analyze the position of failure, to remove failure within a shortest time, and to minimize the loss of working time aroused by vehicle failures.

At the same time, the user can also select a variety of forklift truck operation modes through the instrument interface. Currently, there are E-Economy Mode, SStandard Mode, H-High Performance Mode and Turtle Speed Mode.

WARNING Installing improper electrical accessories or installing an electrical accessory incorrectly can increase the risk of equipment damage, personal injury and fire. DO NOT install electrical accessories to the truck unless you have been trained and authorized to do so. Personnel installing the electrical accessories must document the changes made to the truck. DO NOT install accessories which affect the truck’s compliance with standard EN 1175:2020.

OVERVIEW The electrical system mainly includes motor controllers, instruments and auxiliary electrical equipment (sensors, switches, lamps, buzzers).

According to the different forms of the motor and motor controller, it is divided into two models: full AC and DC excitation. The full AC model uses the Curtis controller of the United States.

CHARACTERISTICS OF AC MOTOR CONTROLLER The AC controller of this series adopts the 123X series controller of Curtis Company of the United States. The 123X series controller is the latest dual-core controller, see Figure 15 for an illustration of AC controller. Motor speed and temperature feedback signal microprocessing control, regenerated brake, and CANBUS communication interface area available, able to very easily conduct precision control over the traction and oil pump of the vehicle, and also able to adjust the motor controller according to different work conditions of operating environments and load type of driving online through hand actuating unit or vehicle-mounted instrument (to be authorized), with a view to achieving the most perfect operating efficiency and performance

1. FUSE 2. BASE 3. CONTACTOR 4. BAR 5. BRACKET OF CONTACTOR 6. BAR 7. CONTROLLER FOR PUMP 8. BAR 9. BAR 10. CONTROLLER FOR TRACTION 11. PLATE Figure 15. AC controller appearance （Illustration for 2.0-2.5T Truck） Use high quality copper lugs and observe the recommended torque ratings. (Tightening torque 10 -12 N•m (88.51 - 106.21 lbf in))

33

Electrical System

8000 YRM 2353 mounted via M5 tapped holes or mounting brackets – either supplied fitted, or as separate items. Mounting can be horizontal or vertical, when vertical the M10 contact studs should point upwards. If the requirement is for downwards orientation we can adjust the contactor to compensate for this.

1.

2.

3.

4.

BOLT SAFETY WASHER LUG TERMINAL

Figure 16. Section view of controller connection The contactor has M10 (Tightening torque 13.4 - 14.6 N•m (118.6 - 129.22 lbf in)) stud main terminals and 6.3mm spade coil connections. It can be

34

Figure 17. Contactor in Controller

8000 YRM 2353

Electrical System

ELECTRIC SYSTEM SCHEMATIC DIAGRAM

35

Electrical System

8000 YRM 2353

Figure 18. Electric System Schematic Diagram (Illustration for 1.5-3.5T Truck, Universal Purpose)

MISCELLANEOUS The Curtis 3401 display is a full LCD smart instrument connected to the vehicle system via the CAN bus. This smart instrument provides diagnosis and setup of CBU system. The diagnosis and setup include: smart display itself, traction controller, lifting controller, and

36

valve controller. The smart display menu is accessed by an operation button attached to the touch keyboard.

The 3401 display provides the operator with easy information about the condition of some vehicles. The LCD displays the battery level, travel speed, operating mode and run time, as well as a system fault code.

8000 YRM 2353

Electrical System

1. MODE INDICATION 2. PARKING BRAKE INDICATION 3. SEAT SWITCH INDICATION 4. FOOT BRAKE INDICATION 5. HYDRAULIC PROHIBITION 6. FAULT INDICATION 7. SAFETY BELT INDICATION 8. FORWARD AND BACKWARD INDICATION 9. S STANDARD MODE BUTTON 10. H HIGH PERFORMANCE MODE BUTTON

11. E ECONOMY MODE BUTTON 12. FAULT INDICATION AREA 13. F1-F5 FUNCTION BUTTON 14. SPEED INDICATION 15. TOTAL USE TIME 16. BATTERY INDICATOR 17. TRAVEL TIME AND PUMP TIME 18. FUNCTION SELECTION KEY 19. TURTLE SPEED MODE 20. FUNCTION SELECTION KEY

Figure 19. Display (Illustration for Curtis 3401 Controller) The vehicle has 4 modes to choose from: 1.

High Performance Mode: Speed, acceleration, are the designed maximum values, but the energy consumption is higher.

2.

Standard Mode: The performance parameter is 80% of the H mode, which is a mode of daily use with moderate energy consumption.

3.

Economic Mode: The performance parameters are the same as the standard mode, but the acceleration and other adjustments are lower, with the lower energy consumption.

4.

Turtle Speed Mode: The speed is slower and is default as 5km/h, and OEM settings can be made according to customer requirements. The adjustment range is 3-10km/h.

CAUTION Stop operation at once when fault code appears, until failure is eliminated. When electric quantity is displayed less than 20%, stop operation immediately, and charge the battery timely, this avoids the forklift trucks unable to operate midway due to lack of electricity.

The USB port has two plugs, respectively 5V/1A and 5V/2.1A, which can charge Phone, PAD and other conforming devices.

37

Electrical System

8000 YRM 2353 b.

Check that the acceleration enabling signal on the accelerator enters the controller, i.e., lines 6 and 15 on the accelerator.

c.

Check if the brake switch is active. The obvious phenomenon is that the oil pump motor automatically rotates at a low speed after the forklift truck starts, generating assistance.

The 5V/50W power port (if equipped) can provide power for more auxiliary function devices. However, it is worth noting that the power of the device must meet the power settings of the power supply, and only authorized professionals can install the device.

Electromagnetic radiation must be considered when installing devices to avoid injury to operators.

CAUTION Make sure the battery is powered off before you do anything. When the electric lock switch is disconnected, the internal capacitor will keep charging for a period of time. Therefore, for safety reasons, we recommend disconnecting the battery and using a resistance connection between the positive and negative terminals of the controller with a resistance value between 10 ohm and 100 ohm to form a short circuit, so that the capacitor can complete discharge. When the installation is complete, the drive wheel should be raised to the start controller to ensure that the installation error does not affect the security.

A. BRAKE SWITCH Figure 20. Brake Switch 2.

The forklift truck fails to move forward but backward, or moves forward rather than backward, and the hydraulic part of the mast works normally; a.

Check if the combination switch signal is normal and replace the combination switch.

b.

Check if the forward or backward signal is normal, line 8, 9 in the circuit, or use the handheld unit to enter the TESTER menu to view.

c.

Check the motor encoder. If there is a problem with one phase of the motor encoder signal phases A and B, the fault may occur.

TROUBLE SHOOTING In addition to the fault codes Table 8 below in this section, the forklift truck sometimes fails to operate normally for some other reason, and the forklift truck does not display the fault code. There are several common situations: 1.

The forklift truck cannot move forward and backward, and the hydraulic lifting part is normal; a.

38

Check that the seat switch is normal.

8000 YRM 2353

Electrical System b.

5.

A. TEMPERATURE SENSOR B. SPEED ENCODER

The forklift truck is operating normally, and the action of the hydraulic part is very slow; a.

Check if the oil pump motor encoder is normal.

If the encoder fails, the power supply may function normally, but the pulse signal may be wrong. In this case, the controller cannot detect the encoder fault.

b.

Whether the signals of the motor encoders A and B phase signals are reverse connection.

c.

Check that the mechanical installation of the lifting potentiometer is correct and reliable.

d.

If the lifting speed is slow, check whether the lifting potentiometer signal is incorrect, set the lifting potentiometer, or replace the lifting potentiometer.

Figure 21. Motor Encoder 3.

The forklift truck does not move forward and backward, and the hydraulic part of the mast fails to work;

Whether the signals of the motor encoders A and B phase signals are reverse connection.

6.

The forklift truck is operating normally, and one or several items have no action, such as lifting, tilting, and side shifting;

a.

Check that the seat switch is normal.

a.

b.

Check the general power supply of the vehicle, the fuse is burned out, and the whole vehicle has no power. In this case, the whole vehicle has no power when the vehicle starts.

Check whether the multi-way valve micro switch is installed reliably, and whether the 19, 20, and 21 lines on the circuit are connected properly.

b.

If the multi-way valve micro switch is damaged, replace the multi-way valve micro switch.

c.

Check the part of the fault (1) that is related to traveling.

d.

Check the part of the fault (3) that is related to the oil pump.

e.

Check if the multi-way valve micro switch is installed reliably and the line is connected properly.

4.

Driving speed of forklift truck is slow (Speed is less than 1 km), and the hydraulic part works normally; a.

Check if the driving motor encoder is normal. If the encoder fails, the power supply may function normally, but the pulse signal may be wrong. In this case, the controller cannot detect the encoder fault.

1. MICROSWITCH 2. LIFTING POTENTIOMETER Figure 22. Micro switch and Lifting Potentiometer

39

Electrical System

8000 YRM 2353

Common fault codes for Curtis AC power control, as shown in Table 8, Table 9, Table 10.

Table 8. Common Curtis (SE Series) Fault Codes Code

Description

Conditions for Fault Removal

Current overload of controller.

1. Short circuit of external U, V or W connections of a motor. Reason: The set phase current exceeds the limit current.

2. Motor parameters are not Troubleshooting: Restarting key matched. switch 3. Controller fault.

Current sensor fault.

1. The circuits of motor U, V, W Reason: Current sensor of controller on the body, resulting in reading deviation. leakage.

Troubleshooting: Restarting key switch 2. Controller fault.

14

Pre-charging failure.

1. The positive terminal of the Reason: The key switch input capacitor is externally voltage fails to charge the capacitor. connected to the load, so that the capacitor cannot be Troubleshooting: Re-input via VCL reset or interlock switch. charged normally.

15

Controller temperature is too low.

Reason: Temperature below -40° C. 1. The working environment of Troubleshooting: Restart the key the controller is excessively switch or interlock switch when the harsh. temperature rises above -40°C.

Controller temperature is too high

1. The working environment of Reason: Temperature is higher than the controller is excessively 95 °C. harsh.

Troubleshooting: The temperature is 2. Vehicle overload. reduced to below 95°C. Restart the key switch or interlock switch.

3. Controller installation error.

Voltage is too low.

1. Battery parameter setting error.

2. Power consumption of noncontroller system.

Reason: MOSFEET axle operates 3. Battery impedance is too with capacitor voltage below the large. minimum voltage limit. connection is Troubleshooting: Increase the 4. Battery capacitor voltage. disconnected.

5. The fuse is disconnected, or the main contactor is not connected.

Voltage is too high.

1. Battery parameter setting Reason: Capacitor voltage exceeds error. maximum voltage limit when 2. Battery impedance is too MOSFEET axle is operating. high.

Troubleshooting: Decrease the connection is voltage and then restart the key 3. Battery disconnected during switch. regenerative braking.

12

13

16

17

18

40

Fault Name

8000 YRM 2353

Electrical System

Table 8. Common Curtis (SE Series) Fault Codes (Continued) Code

22

Fault Name Controller temperature is too high, resulting in performance reduction.

Description

Conditions for Fault Removal

1. Working environment of the Reason: Heat dissipation controller is harsh. temperature exceeds 85℃.

2. Vehicle overload.

Troubleshooting: Reduce the 3. Controller is not installed temperature. correctly.

1. Low battery capacity.

23

Low voltage and performance reduction.

2. Battery parameter setting is erroneous.

3. Power consumption of noncontroller system.

Reason: Capacitor voltage is too 4. Battery impedance is too low. Troubleshooting: Increase large. capacitor voltage. connection is 5. Battery disconnected.

6. The fuse is disconnected, or the main contactor is disconnected.

24

Too high voltage and performance reduction.

1. Regenerative braking current during regenerative braking results to increase in battery voltage.

Reason: Capacitor voltage exceeds 2. Battery parameter setting maximum voltage limit when error.

MOSFEET axle is operating.

3. Battery impedance is too Troubleshooting: Reduce the large. capacitor voltage. connection is 4. Battery disconnected during regenerative braking.

25

Failure of controller output 5V power.

Reason: 5V output has an error of more than ±10%.

External load impedance is 1. too low.

Troubleshooting: Adjust the output voltage to the normal range.

Device 6 output overcurrent.

Reason: Drive 6 output current exceeds 15mA. 1. External load impedance is Troubleshooting: Adjust the load, too low. then restart the driver with the VCL setting “set_digout”.

Drive 7 output overcurrent.

Reason: Drive 7 output current exceeds 15mA. 1. External load impedance is Troubleshooting: Adjust the load, too low. then restart the driver with the VCL setting “set_digout”.

26

27

41

Electrical System

8000 YRM 2353

Table 8. Common Curtis (SE Series) Fault Codes (Continued) Code

28

29

31

31

32

32

42

Fault Name

Description

Conditions for Fault Removal

Motor overheating leads to performance reduction.

1. Motor temperature reaches or is higher than the program setting warning temperature results in reduction of current output.

Reason: The input voltage value of 2. Motor temperature parameter motor temperature sensor is 0 or setting is incorrect. greater than 10V. 3. If the motor does not use a Troubleshooting: Motor temperature temperature sensor, the returns to normal range. programming parameters “Temp compensation” and “Temp cutback” must be set to “OFF”.

Motor temperature sensor fault.

motor temperature 1. The sensor is connected Reason: The input voltage value of incorrectly. motor temperature sensor is 0 or 2. If the motor does not use a greater than 10V. temperature sensor, the Troubleshooting: Adjust the motor programming parameter temperature sensor input voltage “Motor Temp Sensor Enable” value to the normal range. must be set to “OFF”.

Drive 1 output connection coil circuit is open or short.

Reason: Drive 1 output circuit (6 1. Connecting load circuit is pins) is open or short. This fault can open or short. only occur if “Main Enable” is set to 2. Connection pin stained.

“OFF”.

Troubleshooting: Correct open/short 3. Wrong wiring. error and restart output.

Main contactor coil circuit is open/short.

Reason: The main contactor coil (6 1. Connecting load circuit is pins) circuit is open or short. This open or short. fault can only occur if “Main Enable” 2. Connection pin stained. is set to “ON”.

Troubleshooting: Correct open/short 3. Wrong wiring. error and restart output.

Electromagnetic brake coil circuit is open / short.

Reason: Drive 2 output (5 pins) is 1. Connecting load circuit is open or short. This fault can only open or short. occur if the “EM brake Type” is set 2. Connection pin stained. to 0.

Troubleshooting: Correct open/short 3. Wrong wiring. error and restart output.

Drive 2 output connection coil is open or short.

Reason: The electromagnetic brake 1. Connecting load circuit is output (5 pin) is open or short. This open or short. fault can only occur when the EM 2. Connection pin stained. brake Type setting is greater than 0.

Troubleshooting: Correct open/short 3. Wrong wiring. error and restart output.

8000 YRM 2353

Electrical System

Table 8. Common Curtis (SE Series) Fault Codes (Continued) Code

Fault Name

Description

Conditions for Fault Removal

Drive 3 output connection coil is open/short.

1. Connecting load circuit is Reason: Drive 3 output (4 pins) is open or short. open or short.

2. Connection pin stained.

Troubleshooting: Correct open/short error and restart output.

Wrong wiring.

3.

Drive 4 output connection coil is open/short.

1. Connecting load circuit is Reason: Drive 3 output circuit (3 pins) is open or short. open or short.

Troubleshooting: Correct the open/ 2. Connection pin stained. short circuit error and restart the 3. Wrong wiring. output.

35

Proportional drive circuit is open/short.

1. Connecting load circuit is Cause: Proportional drive (2 pin) open or short. circuit is open/short.

2. Connection pin stained.

Troubleshooting: Correct open/short error and restart output.

3. Wrong wiring.

36

Encoder failure.

33

34

37

38

Motor circuit is open.

Adhesion of main contactor.

1. Motor encoder fault.

2. Wrong wiring.

1. Motor phase loss.

2. Wrong wiring.

Reason: Encoder fault.

Troubleshooting: Restart key switch.

Reason: Motor phase loss, U, V, W one-phase or multi-phase circuit is open.

Troubleshooting: Check the phase and restart the key switch.

1. Welding of main contactor contact.

Reason: The main contactor stays 2. Motor U or V phase is connected too much and the disconnected or phase loss. capacitor voltage cannot be 3. There is a circuit connecting released. the B+ terminal to charge the Troubleshooting: Restart key switch. capacitor.

1. Main contactor is not closed.

39

41

Main contactor is not closed.

Accelerator output is high.

2. Main contactor contacts are Reason: When the main contactor is oxidized, melted, or required to be closed, the capacitor connected in an unstable voltage does not reach the B+ state. voltage.

3. Capacitor is charged by an Troubleshooting: Check the external device. contactor and restart the key switch.

4. Fuse disconnected.

Reason: The accelerator potentiometer (16 pin) output voltage is higher than the output voltage limit (the limit value can be Accelerator potentiometer 1. output voltage is too high. changed by VCL, setup_pot_faults).

Troubleshooting: Reduce the accelerator potentiometer output voltage.

43

Electrical System

8000 YRM 2353

Table 8. Common Curtis (SE Series) Fault Codes (Continued) Code

42

Accelerator output is low.

Description

Conditions for Fault Removal

Reason: Accelerator potentiometer (16 pin) output voltage is lower than the output voltage limit (the limit value can be changed by VCL, Accelerator potentiometer 1. output voltage is too low. setup_pot_faults).

Troubleshooting: Increase the accelerator potentiometer output voltage.

Reason: Potentiometer 2 (17 pin) output voltage is higher than the output voltage limit (the limit value Output can be changed by VCL, setup_pot_faults).

Troubleshooting: Reduce the potentiometer output voltage.

Potentiometer 2 output is too high.

2 1. Potentiometer voltage is too high

44

Potentiometer 2 output is too low.

Reason: Potentiometer 2 (17 pin) output voltage is lower than the output voltage limit (the limit value 1. Potentiometer 2 output is too can be changed by VCL, low. setup_pot_faults).

Troubleshooting: Increase potentiometer output voltage.

45

Potentiometer low end current is too high.

Reason: Potentiometer low end (181. Potentiometer impedance is pin) current exceeds 10mA. too low.

Troubleshooting: Lower the low end current and restart the key switch.

EEPROM Failure.

1. Write to EEPROM storage Reason: The controller operating failure. This may be due to system tries to write to the VCL writing to the EEPROM EEPROM and fails. memory, or CANBUS, or a Troubleshooting: Download the parameter error programmed into the controller after the correct software (OS), set the programmer parameters are parameters to control, then restart the key switch. adjusted.

High pedal protection/ operation sequence failure.

Reason: High pedal protection and 1. Key start, interlock, direction, incorrect startup sequence due to and accelerator input key activation, interlock, direction, sequence settings error. and accelerator input settings 2. Wiring, switch key, interlock, errors. direction, or accelerator input Troubleshooting: Enter the correct failure. order.

43

46

47

44

Fault Name

8000 YRM 2353

Electrical System

Table 8. Common Curtis (SE Series) Fault Codes (Continued) Code

47

49

Fault Name

Description

Emergency reverse high pedal protection.

Reason: At the end of the emergency reverse emergency reversal, various inputs 1. The operation has ended, but the are not reset, causing the fault to accelerator, forward and reverse input and interlock occur.

Troubleshooting: Re-enter each have not been reset. input in the correct order.

Parameter change failure/ error.

1. In order to ensure the safety of the vehicle, some specific Reason: Parameter change requires parameters must be changed restart of the key switch. after the key switch is Troubleshooting: Restart key switch. restarted.

1. CAN bus is open.

51

CAN bus fault.

2. CAN bus short circuit.

3. CAN bus short circuit.

52

53

Conditions for Fault Removal

Reason: OEM custom fault.

Troubleshooting: Restart the key switch and check the CAN bus.

Instrument CANPDO timeout fault.

1. CAN bus connection problem between instrument and controller.

Reason: OEM custom fault.

CAN communication port is Troubleshooting: Restart the key 2. damaged. switch and check the CAN bus. communication 3. CAN interference.

Pump controller CAN PDO timeout fault.

1. CAN bus connection problem between instrument and controller.

Reason: OEM custom fault.

2. CAN communication port is Troubleshooting: Restart the key damaged. switch and check the CAN bus. communication 3. CAN interference.

Reason: OEM custom fault.

Troubleshooting: Replace the pedal and check the pedal connection cable.

Pedal switch fault.

1. Pedal switch short circuit.

55

Walking operation sequence fault.

1. The accelerator has been stepped on when it is turned on.

Reason: OEM custom fault.

2. When the parking brake Troubleshooting: Correct operating switch is released, the procedures. accelerator has been stepped on.

55

Pump operation sequence fault.

1. The pump operating switch is Reason: OEM custom fault. closed when the machine is Troubleshooting: Correct operating turned on. procedures.

54

45

Electrical System

8000 YRM 2353

Table 8. Common Curtis (SE Series) Fault Codes (Continued) Code

Fault Name

56

Lifting potentiometer has open-circuit fault.

57

Redundant fault of Monotrol speed potentiometer.

58

Over range of Monotrol speed potentiometer.

59

Redundant fault of Monotrol direction.

61

Potentiometer over range in Monotrol direction.

66

Compatible fault of instrument.

67

Compatible fault of pump controller.

68

69

46

Description

Conditions for Fault Removal

to lifting Reason: OEM custom fault.

1. Damage potentiometer.

Troubleshooting: Replace the lifting 2. Lifting potentiometer cable or potentiometer and check the lifting potentiometer cable connection. connection fault.

Reason: OEM custom fault.

Troubleshooting: Replace the 2. Monotrol cable or connection Monotrol pedal and check the fault.

Monotrol pedal cable connection.

1. Monotrol pedal is damaged.

Reason: OEM custom fault.

Troubleshooting: Replace the 2. Monotrol cable or connection Monotrol pedal and check the fault.

Monotrol pedal cable connection.

1. Monotrol pedal is damaged.

Reason: OEM custom fault.

Troubleshooting: Replace the 2. Monotrol cable or connection Monotrol pedal and check the fault.

Monotrol pedal cable connection.

1. Monotrol pedal is damaged.

Reason: OEM custom fault.

Troubleshooting: Replace the 2. Monotrol cable or connection Monotrol pedal and check the fault.

Monotrol pedal cable connection.

1. Monotrol pedal is damaged.

Reason: OEM custom fault.

Troubleshooting: Replace the correct instrument.

1. Instrument damage.

2. Instrument is not matched.

1. Pump controller is damaged.

2. Pump controller matched.

is

Reason: OEM custom fault. not Troubleshooting: Replace pump controller.

Error of VCL running time.

Reason: Error of VCL code for running time.

Troubleshooting: Edit the VCL 1. Timeout of VCL code for application to fix the error, check the running time. new software to make sure that the parameters are correctly matched, and the key switch is restarted.

External power output over range.

Reason: External supply current (mixed current, 5V (26-pin) and 12V Supply current of external 1. load at 5V and 12V too big or (25-pin)) exceeds the limit. The too small. upper limit of the range is defined by parameter in the External Supply Max and the lower 2. The Checking Menu is incorrect, limit is defined by External Supply for example “Ext Supply Min. Max”, “Ext Supply Min”.

Troubleshooting: Adjust external current.

8000 YRM 2353

Electrical System

Table 8. Common Curtis (SE Series) Fault Codes (Continued) Code

Fault Name

Description

Conditions for Fault Removal

71

Operation / system fault.

1. Internal controller failure.

Reason: Internal controller failure.

Troubleshooting: Restart key switch.

PDO timeout.

Reason: CANPDO message acceptance time exceeds PDO time message limit.

1. CANPDO acceptance time exceeds Troubleshooting: Restart the key PDO time limit. switch or receive CANNMT information.

72

Motor stalling.

Reason: Motor encoder not detected.

2. Encoder failure.

Troubleshooting: Restart the key switch, or detect the motor encoder 3. Wrong wiring. valid signal in LOS mode, and set 4. Fault of input motor encoder the parameter to Throttle power.

Command=0, MotorRPM=0.

Motor matching failure.

1. 1. A code comparison occurs during the motor matching process: 0= Normal.

1= The controller receives the encoder signal, but the amount of pulses is undefined. Please set the pulse value manually.

2= Failure of motor temperature sensor.

3= Failure of high temperature reaction of Reason: Motor matching process failure. motor.

4= Failure of overheating Troubleshooting: Correct the error, reaction of motor. and restart the key switch.

5= Failure of low temperature reaction of motor.

6= Failure of low voltage response.

7= Failure of high voltage response.

8= The controller fails to detect the encoder signal, and the channel signal disappears.

9= Motor parameter setting over range.

Motor_type error.

Reason: Motor_type parameter is 1. Motor_Type parameter value set to an illegal value. over range.

Troubleshooting: Reset and restart the key switch.

1. Motor stalling.

73

87

89

47

Electrical System

8000 YRM 2353

Table 8. Common Curtis (SE Series) Fault Codes (Continued) Code

91

92

93

94

98

Fault Name

Description

Conditions for Fault Removal

VCL/OS is not matched.

Reason: The VCL program in the 1. The VCL program in the controller does not match the OS controller does not match the program.

OS program.

Troubleshooting: Update the correct VCL and OS programs.

Failure of electromagnetic brake setting.

1. The vehicle still moves after Reason: After the electromagnetic the electromagnetic brake brake is locked, the vehicle still command is set. moves. force of the Troubleshooting: Check if the 2. Braking electromagnetic brake is too accelerator is normal. small.

Limited operating state of an encoder.

Reason: Limited operating state is activated due to motor stalling or 1. Limited operating state is encoder fault. activated due to motor Troubleshooting: Restart the key stalling or encoder failure. switch. If it is caused by the motor 2. Wrong wiring. stalling, please ensure that the encoder works under normal Car stalling.

3. operation, Throttle Command=0, Motor RPM=0.

Emergency reverse reaction timeout.

1. Since the EMR Timer expires, the emergency reverse Reason: Emergency reverse is timeout is activated. activated because the EMR Timer emergency reverse expires.

2. The switch is always in the ON Troubleshooting: Check the status position. of the emergency reverse switch.

3.

Controller model error.

1. Controller model cannot be Reason: Controller model cannot be identified. identified.

2. Software and hardware are Troubleshooting: Select the correct not matched with each other. controller and download the correct controller software.

Controller is damaged.

3.

Table 9. Common Curtis (F Series Traction) Fault Codes Fault Code

Fault Name Controller Overcurrent 2. V phase Overcurrent

1. Motor U, V, W phase external connection short circuited 2. Speed encoder signal noise problem

3. W phase Overcurrent

3. Motor parameters misadjusted

4. Controller current > 135% current limit

4. Controller failure

1. U phase Overcurrent 12

48

Possible Causes

8000 YRM 2353

Electrical System

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code 13

Fault Name Current Sensor 1. Current sensor fault Precharge Failed

14

1. Precharge abort 2. Precharge energy limit 3. Precharge timeout

15

16

Controller Severe Undertemperature 1. Controller Severe Undertemperature Controller Severe Overtemperature 1. Controller Severe Overtemperature

Possible Causes 1. U, V or W phase leakage to the vehicle body (stator short circuited) 2. Controller failure 1. An external load on the controller B+ terminal affected the controller's precharge.

2. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

1. The controller works in extreme environments 2. Check programmer / System Monitor Menu / Controller / Controller Temperature.

1. The controller works in extreme environments 2. Check programmer/System Monitor Controller / Controller Temperature.

Menu

/

1. Devices outside the controller system deplete batteries.

2. The battery internal resistance is too high.

17

Severe B+ Undervoltage 1. Severe B+ Undervoltage

3. The battery was cut off while driving the motor.

4. The fuse connecting B+ is burnt out or the main contactor is not closed.

The battery parameters of the controller are 5. incorrectly set.

6. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

1. Devices outside the controller system deplete batteries.

2. The resistance of the KSI input line is too high.

17

Severe KSI Undervoltage 1. Severe KSI Undervoltage

3. The battery key switch is cut off while driving the motor.

4. The fuse is blown out.

5. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

18

Severe B+ Overvoltage 1. Severe B+ Overvoltage

1. The battery parameters of the controller are incorrectly set.

2. Regenerative braking, current recharging battery, battery internal resistance is too high.

3. Battery is not connected during regenerative braking.

4. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

18

Severe KSI Overvoltage 1. Severe KSI Overvoltage

1. The battery voltage to the KSI (pin1) end of the controller exceeds the severe high voltage setting.

2. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

49

Electrical System

8000 YRM 2353

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code

19

1A

Fault Name

Speed Limit Supervision 1. Speed Limit Supervision

Travel Control Supervision 1. Travel Control Supervision

Possible Causes 1. The motor speed exceeds the Max Speed Supervision setting.

2. The value of Max Speed Supervision is incorrect.

3. Check programmer / Application Setup / Max Speed Supervision.

1. When the vehicle is stopped, the output frequency and phase current of the controller are detected to exceed the parameter set value under Travel Control Supervision.

2. The parameters under Travel Control Supervision are incorrectly set.

3. Check programmer / Application Setup / Max Speed Supervision.

1. The controller works in extreme environments.

2. The controller is overloaded.

22

Controller Overtemperature Cutback 1. Controller Overtemp Cutback

3. The controller is improperly installed.

4. Controller performance is limited at this temperature.

5. Check programmer / System Monitor Menu / Controller / Controller Temperature.

1. The battery needs to be charged, and the controller's performance is limited at this voltage.

2. The battery parameters of the controller are incorrectly set.

3. Non-controller systems deplete batteries.

23

24

50

Undervoltage Cutback 1. Undervoltage Cutback

Overvoltage Cutback 1. Overvoltage Cutback

4. The battery internal resistance is too high.

5. Battery is not connected when driving motor.

6. The fuse connecting B+ is burnt out or the main contactor is not drawn.

7. Check programmer / System Monitor Menu / Controller / Currents / Undervoltage Cutback.

8. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

1. In normal operation, the current generated by regenerative braking is recharged to the battery. If the battery voltage is too high, the fault will occur, and the controller performance will be limited under this voltage.

2. The battery parameters of the controller are incorrectly set.

Regenerative braking, current recharging battery, 3. battery internal resistance is too high.

4. Battery is not connected during regenerative braking.

8000 YRM 2353

Electrical System

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code 24

Fault Name Overvoltage Cutback 1. Overvoltage Cutback

Ext 5V Supply Failure 25

1. The 5V output voltage is out of range.

2. The 5V output current is out of range.

Ext 12V Supply Failure

26

28

29

1. The 12V output voltage is out of range.

2. The 12V output current is out of range.

Motor Temp Hot Cutback 1. Motor Temp Hot Cutback

Motor Temp Sensor 1. Motor Temp Sensor

Possible Causes 5. Check programmer / System Monitor Menu / Controller / Currents / Overvoltage Cutback.

6. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

1. The external 5V load is the small pin 16.

2. The external 5V load is overloaded or open.

3. Examine the voltage and current of the 5V output displayed by the Programmer/System Monitor Menu/ Outputs 1. The external 12V load is the small pin 23.

2. The external 12V load is overloaded or open.

3. Examine the voltage and current of the 12V output displayed by the Programmer / System Monitor Menu / Outputs.

1. The motor temperature is greater than or equal to the Temperature Hot setting, resulting in controller output current limiting.

2. Motor temperature and sensor parameters are incorrectly set.

3. Check programmer / AC Motor Setup / Temperature Sensor.

1. The motor temperature sensor is not connected properly.

2. The sensor polarity connection is incorrect for pin 9 and pin 12.

3. Motor temperature and sensor parameters are incorrectly set.

4. Check programmer / System Monitor Menu / AC Motor / Temperature

Main Driver 1. Drive current exceeds hardware limit.

31

2. The drive current exceeds the set overcurrent value.

3. When the PWM control is activated, the detected signal should be low, but it is high.

4. When the PWM control is activated, the detected signal should be high, but it is actually low.

5. When PWM control is off, the detected signal should be high, but it is low.

6. The driving current is too low.

1. Drive load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The circuit is over-current.

51

Electrical System

8000 YRM 2353

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes

EM Brake Driver 1. Drive current exceeds hardware limit.

32

2. The drive current exceeds the set overcurrent value.

3. When the PWM control is activated, the detected signal should be low, but it is high.

When the PWM control is activated, 4. the detected signal should be high, but it is actually low.

5. When PWM control is off, the detected signal should be high, but it is low.

6. The driving current is too low.

1. Drive load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The circuit is over-current.

Pump Driver Fault 1. Drive current exceeds hardware limit.

33

52

2. The drive current exceeds the set overcurrent value.

3. When the PWM control is activated, the detected signal should be low, but it is high.

4. When the PWM control is activated, the detected signal should be high, but it is actually low.

5. When PWM control is off, the detected signal should be high, but it is low.

6. The driving current is too low.

1. Drive load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The circuit is over-current.

8000 YRM 2353

Electrical System

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes

Load Hold Driver Fault 1. Drive current exceeds hardware limit.

34

2. The drive current exceeds the set overcurrent value.

3. When the PWM control is activated, the detected signal should be low, but it is high.

When the PWM control is activated, 4. the detected signal should be high, but it is actually low.

5. When PWM control is off, the detected signal should be high, but it is low.

6. The driving current is too low.

1. Drive load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The circuit is over-current.

Load Hold Driver Fault 1. Drive current exceeds hardware limit.

35

2. The drive current exceeds the set overcurrent value.

3. When the PWM control is activated, the detected signal should be low, but it is high.

4. When the PWM control is activated, the detected signal should be high, but it is actually low.

5. When PWM control is off, the detected signal should be high, but it is low.

6. The driving current is too low.

IM Motor Feedback

36

37

1. Drive load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The circuit is over-current.

1. It is a motor encoder failure.

1. The controller detects a quick stop.

2. It is a crimping or wiring error.

2. Motor encoder has power supply problems.

3. Please contact dealer for technical support.

3. Check programmer / System Monitor Menu / AC Motor / Motor RPM. 4. Check programmer / AC Motor Setup / Quadrature Encoder / Encoder Fault Setup.

Motor Open 1. Motor Open

1. The motor phase line is open.

2. It is a crimping or wiring error.

1. It is the contact adhesion of main contactor

38

Main Contactor Welded 1. Main Contactor Welded

2. There is an open circuit on the V phase or U phase of the motor.

3. There is an external voltage directly connected to the controller B+ terminal.

53

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8000 YRM 2353

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes 1. The main contactor does not drawn.

2. The main contactor contact is defective.

Main Contactor Did Not Close 1. When there is a control command, the main contactor does not pull.

5. The main contactor parameters are incorrectly set.

39 2. The main contactor is disconnected during operation.

3. When the main contactor is prohibited, disconnect from the battery.

3A

44 46

47

49

54

2. The contactor coil is disconnected.

3. Contactor failure.

1. When the main contactor is disabled and the interlock is activated, the battery is not connected to the B+ terminal.

1. Motor Setup Needed 1. External ivoltage is too low or too high.

2. Input 1 failure as a voltage input type may be out of range, as a 2/3 wire potentiometer type may be a potentiometer failure.

Brake Input

1. Memory data read/write failure

NV Memory Failure 1. NV Memory Failure

2. Internal controller fault 1. Key switch, interlock, direction switch and accelerator input operation sequence is incorrect.

2. There're wiring or crimping errors in key switch, interlock, direction switch and accelerator input.

3. There's damp in Key switch, interlock, direction switch and accelerator input.

4. Check programmer / System Monitor Menu/Inputs / Switch Status.

5. Check programmer / System Monitor Menu/Inputs / Throttle Command.

HPD Sequencing 1. HPD Sequencing

1. Emergency protection

1. The accelerator input voltage exceeds the range of Analog Low and Analog High Settings, and the corresponding analog input is set.

2. Check programmer / Controller Setup / Analog Inputs / Analog 1 Type.

3. Check programmer / Controller Setup / Analog Inputs / Configure.

1. Corresponding fault is triggered by the brake input source (assigned analog input).

1. Brake Input

Emergency Reverse HPD 47

1. The main contactor is disconnected during operation.

Motor Setup Needed Throttle Input

42

3. The B+ terminal of the controller is connected to a large external load. As a result, the capacitor cannot be charged effectively.

4. The high current fuse is blown out.

reverse

Parameter Change 1. Parameter change fault

high

pedal

1. Emergency reverse operation has ended, but there's no return from accelerator input, direction switch, interlock.

1. After interlocking, the parameters related to security are modified, the parameters marked PCF.

8000 YRM 2353

Electrical System

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code 51

52

Fault Name CAN Bus Fault 1. CAN Bus Fault Display CAN PDO Timeout 1. Display CAN PDO Timeout

Possible Causes 1. The CAN bus fails to be initialized after being powered on.

1. CAN communication connection problem occurs between controller and instrument.

2. CAN bus communication is interfered.

3. The CAN port of the meter or controller is damaged.

53

Pump CAN PDO Timeout 1. Pump CAN PDO Timeout

1. CAN communication connection problem occurs between traction and oil pump controller 2. CAN bus communication is interfered.

3. CAN ports of traction and oil pump controller are damaged.

55

Electrical System

8000 YRM 2353

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code 54

Fault Name Pedal Switch Short 1. Pedal Switch Short Extra SRO Fault

55

56

57

58 59 61 62

1. The walking operation sequence is faulty Pump Steer Fault 1. Pump Steer Fault Throttle Mismatch Fault 1. Throttle Mismatch Fault Throttle input Out of Ranger Fault 1. Throttle input Out of Ranger Fault Throttle Direction Mismatch 1. Governor direction matching failure Direction Input Out of Range 1. Governor direction is out of range Brake and Accelerator Fault 1. Release pedal.

Battery Safe Operation Fault

63

64 65 66 67 5B 68 72

56

1. The battery compartment door fails to open.

2. Battery charging is prohibited.

Unmatched Battery Type 1. Error The battery type is faulty.

Steer Pot Fault 1. The Angle potentiometer is faulty.

Unmatched Display 1. Unmatched Display Unmatched Pump Controller 1. The pump controller fails to match CDF Fault 1. Configuration fault VCL Run Time Error 1. The VCL running time is incorrect.

PDO Timeout 1. CAN PDO Timeout

Possible Causes 1. Incorrect pedal operation sequence 2. Pedal switch damaged 1. Incorrect pedal operation sequence 2. Speed control pedal fault 3. Seat switch problem 1. Oil pump controller failure 1. Monotrol speed control pedal is faulty.

2. There're parameters setting problems related to speed control pedal.

1. Monotrol speed control pedal is faulty.

2. There's a speed control pedal connection problem.

1. Monotrol speed control pedal is faulty.

2. There's a speed control pedal connection problem.

1. Monotrol speed control pedal is faulty.

2. There's a speed control pedal connection problem.

1. Peristaltic operation is time out, brake pedal or speed pedal needs to be released.

1. The battery compartment door fails to open.

2. There's no fault of battery charging and no vehicle running.

1. The battery type is incorrectly configured.

1. Angle potentiometer problem 1. Meter models do not match.

1. The pump controller model does not match.

1. Parameter configuration problem 1. The VCL running time is faulty.

1. The packet receiving time of two adjacent PDOs exceeded the specified PDO timeout period.

8000 YRM 2353

Electrical System

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes 1. Stall Detected 2. Motor encoder fault

73

Stall Detected 1. Stall Detected

3. Incorrect crimping or wiring 4. The power supply of the motor encoder is abnormal.

5. Check programmer / System Monitor Menu / AC Motor / Motor RPM.

77 79 82 83 84 87

88

89 91

92

93

Supervision 1. Supervision Supervision Input Check 1. Input check monitor faults PDO Mapping Error 1. PDO mapping error Internal Hardware 1. Internal hardware failure Motor Braking Impaired 1. Motor brake damage Motor Characterization Error 1. Motor Characterization Error Encoder Pulse Error 1. Encoder Pulse Error Parameter Out of Range 1. Parameter Out of Range Bad Firmware 1. Bad Firmware EM Brake Failed to Set 1. EM Brake Failed to Set

Encoder LOS 1. Encoder LOS mode

1. Internal controller fault 1. Internal controller fault 1. Too many data bits are allocated during PDO mapping, or the target is not simultaneous.

1. An internal fault is detected in the controller.

1. Battery overcharge or controller overheating or misalignment parameters 1. Motor matching failed in the process of matching motor.

1. The encoder step Settings did not match the reality. the calibration parameter setting, 2. Check Programmer / AC Motor Setup / Quadrature Encoder / Encoder Steps.

1. Out-of-range parameter values were detected.

1. Controller Firmware issues.

1. Electromagnetic brake braking failure.

2. The electromagnetic brake cannot stop the motor from turning after braking.

1. AC asynchronous motor feedback fault code 36 or "fault or motor blocking fault" fault code 73, enter LOS mode.

2. Motor encoder malfunction.

3. Crimping or wiring error.

4. Truck stall

99

Parameter Mismatch 1. Parameter Mismatch

1. The controller parameter Settings are incorrect.

57

Electrical System

8000 YRM 2353

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code

9A

Fault Name

Interlock Braking Supervision 1. Interlock brake redundancy failure

Driver 1 Fault 1. Short circuit 2. Overcurrent A1

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high 5. Break line 6. No current in output circuit Driver 2 Fault 1. Short circuit 2. Overcurrent

A2

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high Break line 5.

6. No current in output circuit Driver 3 Fault 1. Short circuit 2. Overcurrent

A3

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high 5. Break line 6. No current in output circuit Driver 4 Fault 1. Short circuit

A4

58

2. Overcurrent 3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high

Possible Causes 1. During Interlock Braking, the motor speed exceeds the parameter set under Interlock Braking Supervision.

2. Check programmer / Application Setup / Interlock Braking / Supervision Enable.

3. Check programmer / Application Setup / Interlock Braking / Interlock Braking Supervision.

1. Driver load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 1 Overcurrent parameter value.

5. Check programmer / Controller Setup / Outputs / Driver 1 / Driver 1 Overcurrent.

1. Driver load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 2 Overcurrent parameter value.

5. Check programmer / Controller Setup / Outputs / Driver 2 / Driver 2 Overcurrent.

1. Driver load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 3 Overcurrent parameter value.

5. Check programmer / Controller Setup / Outputs / Driver 3 / Driver 3 Overcurrent.

1. Driver load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 4 Overcurrent parameter value.

8000 YRM 2353

Electrical System

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code

Fault Name Driver 4 Fault

A4

5. Break line 6. No current in output circuit Driver 5 Fault 1. Short circuit 2. Overcurrent

A5

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high 5. Break line 6. No current in output circuit Driver 6 Fault 1. Short circuit 2. Overcurrent

A6

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high 5. Break line 6. No current in output circuit Driver 7 Fault 1. Short circuit 2. Overcurrent

A7

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high 5. Break line 6. No current in output circuit

A8

Driver Assignment 1. Driver assignment failure

Possible Causes 5. Check programmer / Controller Setup / Outputs / Driver 4 / Driver 4 Overcurrent.

1. Driver load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 5 Overcurrent parameter value.

5. Check programmer / Controller Setup / Outputs / Driver 5 / Driver 5 Overcurrent.

1. Driver load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 6 Overcurrent parameter value.

5. Check programmer / Controller Setup / Outputs / Driver 6 / Driver 6 Overcurrent.

1. Driver load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 7 Overcurrent parameter value.

5. Check programmer / Controller Setup / Outputs / Driver 7 / Driver 7 Overcurrent.

1. One drive serves two or more functions.

Coil Supply Fault A9

1. With B- short circuit or hardware failure 2. Drive's internal short circuit, resulting in coil power cut 3. Coil power failure detection

1. Driver load short circuit.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

59

Electrical System

8000 YRM 2353

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes

Coil Supply Fault A9

power startup 4. Coil detection failure

prohibition

4. Controller failure.

Analog 1 Out of Range B1

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 1 input voltage is higher than Analog 1 High.

2. Analog 1 input voltage is lower than Analog 1 Low.

Analog 2 Out of Range B2

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 2 input voltage is higher than Analog 2 High.

2. Analog 2 input voltage is lower than Analog 2 Low.

Analog 3 Out of Range B3

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 3 input voltage is higher than Analog 3 High.

2. Analog 3 input voltage is lower than Analog 3 Low.

Analog 4 Out of Range B4

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 4 input voltage is higher than Analog 4 High.

2. Analog 4 input voltage is lower than Analog 4 Low.

Analog 5 Out of Range B5

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 5 input voltage is higher than Analog 5 High.

2. Analog 5 input voltage is lower than Analog 5 Low.

Analog 6 Out of Range B6

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 6 input voltage is higher than Analog 6 High.

2. Analog 6 input voltage is lower than Analog 6 Low.

Analog 7 Out of Range B7

60

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 7 input voltage is higher than Analog 7 High.

2. Analog 7 input voltage is lower than Analog 7 Low.

8000 YRM 2353

Electrical System

Table 9. Common Curtis (F Series Traction) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes

Analog 8 Out of Range B8

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 8 input voltage is higher than Analog 8 High.

2. Analog 8 input voltage is lower than Analog 8 Low.

Analog 9 Out of Range B9

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 9 input voltage is higher than Analog 9 High.

2. Analog 9 input voltage is lower than Analog 9 Low.

Analog 14 Out of Range BB

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 14 input voltage is higher than Analog 14 High.

2. Analog 14 input voltage is lower than Analog 14 Low.

Analog 18 Out of Range BD

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 18 input voltage is higher than Analog 18 High.

2. Analog 18 input voltage is lower than Analog 18 Low.

Analog 19 Out of Range BE

BC

C1

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

Analog Assignment 1. Analog quantity distribution failure Branding Error 1. Branding Error

1. Analog 19 input voltage is higher than Analog 19 High.

2. Analog 19 input voltage is lower than Analog 19 Low. 1. An analog serves two or more functions.

2. An analog input is out of range.

1. The software and hardware brands do not match.

2. Contact dealer for technical support to rectify the fault.

Analog 31 Out of Range C7

C9

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

VCL Watchdog 1. VCL Watchdog

1. Analog 31 input voltage is higher than Analog 31 High.

2. Analog 31 input voltage is lower than Analog 31 Low.

1. VCL Watchdog

61

Electrical System

8000 YRM 2353

Table 10. Common Curtis (F Series Pump) Fault Codes Fault Code

Fault Name Controller Overcurrent 2. V phase Overcurrent

1. Motor U, V, W phase external connection short circuited 2. Speed encoder signal noise problem

3. W phase Overcurrent

3. Motor parameters misadjusted

4. Controller current > 135% current limit

4. Controller failure

1. U phase Overcurrent 12

13

Current Sensor 1. Current sensor fault Precharge Failed

14

1. Precharge abort 2. Precharge energy limit 3. Precharge timeout

15

16

Possible Causes

Controller Severe Undertemperature 1. Controller Severe Undertemperature Controller Severe Overtemperature 1. Controller Severe Overtemperature

1. U, V or W phase leakage to the vehicle body (stator short circuited) 2. Controller failure 1. An external load on the controller B+ terminal affected the controller's precharge.

2. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

1. The controller works in extreme environments.

2. Check programmer / System Monitor Menu / Controller / Controller Temperature.

1. The controller works in extreme environments.

2. Check programmer/System Monitor Controller / Controller Temperature.

Menu

/

1. Devices outside the controller system deplete batteries.

2. The battery internal resistance is too high.

17

Severe B+ Undervoltage 1. Severe B+ Undervoltage

3. The battery was cut off while driving the motor.

4. The fuse connecting B+ is burnt out or the main contactor is not closed.

5. The battery parameters of the controller are incorrectly set.

6. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

1. Devices outside the controller system deplete batteries.

2. The resistance of the KSI input line is too high.

17

Severe KSI Undervoltage 1. Severe KSI Undervoltage

3. The battery key switch is cut off while driving the motor.

4. The fuse is blown out.

5. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

18

62

Severe B+ Overvoltage 1. Severe B+ Overvoltage

1. The battery parameters of the controller are incorrectly set.

Regenerative braking, current recharging battery, 2. battery internal resistance is too high.

8000 YRM 2353

Electrical System

Table 10. Common Curtis (F Series Pump) Fault Codes (Continued) Fault Code 18

18

19

1A

Fault Name Severe B+ Overvoltage 1. Severe B+ Overvoltage Severe KSI Overvoltage 1. Severe KSI Overvoltage

Speed Limit Supervision 1. Speed Limit Supervision

Travel Control Supervision 1. Travel Control Supervision

Possible Causes 3. Battery is not connected during regenerative braking.

4. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

1. The battery voltage to the KSI (pin 1) end of the controller exceeds the severe high voltage setting.

2. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

1. The motor speed exceeds the Max Speed Supervision setting.

2. The value of Max Speed Supervision is incorrect.

3. Check programmer / Application Setup / Max Speed Supervision.

1. When the vehicle is stopped, the output frequency and phase current of the controller are detected to exceed the parameter set value under Travel Control Supervision.

2. The parameters under Travel Control Supervision are incorrectly set.

3. Check programmer / Application Setup / Max Speed Supervision.

1. The controller works in extreme environments.

2. The controller is overloaded.

22

Controller Overtemperature Cutback 1. Controller Overtemp Cutback

3. The controller is improperly installed.

4. Controller performance is limited at this temperature.

5. Check programmer / System Monitor Menu / Controller / Controller Temperature.

1. The battery needs to be charged, and the controller's performance is limited at this voltage.

2. The battery parameters of the controller are incorrectly set.

3. Non-controller systems deplete batteries.

23

Undervoltage Cutback 1. Undervoltage Cutback

4. The battery internal resistance is too high.

5. Battery is not connected when driving motor.

6. The fuse connecting B+ is burnt out or the main contactor is not drawn.

7. Check programmer / System Monitor Menu / Controller / Currents / Undervoltage Cutback.

8. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

63

Electrical System

8000 YRM 2353

Table 10. Common Curtis (F Series Pump) Fault Codes (Continued) Fault Code

24

Fault Name

Overvoltage Cutback 1. Overvoltage Cutback

Possible Causes 1. In normal operation, the current generated by regenerative braking is recharged to the battery. If the battery voltage is too high, the fault will occur, and the controller performance will be limited under this voltage.

2. The battery parameters of the controller are incorrectly set.

3. Regenerative braking, current recharging battery, battery internal resistance is too high.

4. Battery is not connected during regenerative braking.

5. Check programmer / System Monitor Menu / Controller / Currents / Overvoltage Cutback.

6. Check programmer / System Monitor Menu / Controller / Capacitor Voltage.

Ext 5V Supply Failure 25

1. The 5V output voltage is out of range.

2. The 5V output current is out of range.

Ext 12V Supply Failure

26

28

29

64

1. The 12V output voltage is out of range.

2. The 12V output current is out of range.

Motor Temp Hot Cutback 1. Motor Temp Hot Cutback

Motor Temp Sensor 1. Motor Temp Sensor

1. The external 5V load is the small pin 16.

2. The external 5V load is overloaded or open.

3. Examine the voltage and current of the 5V output displayed by the Programmer/System Monitor Menu/ Outputs 1. The external 12V load is the small pin 23.

2. The external 12V load is overloaded or open.

3. Examine the voltage and current of the 12V output displayed by the Programmer / System Monitor Menu / Outputs.

1. The motor temperature is greater than or equal to the Temperature Hot setting, resulting in controller output current limiting.

2. Motor temperature and sensor parameters are incorrectly set.

3. Check programmer / AC Motor Setup / Temperature Sensor.

1. The motor temperature sensor is not connected properly.

2. The sensor polarity connection is incorrect for pin 9 and pin 12.

3. Motor temperature and sensor parameters are incorrectly set.

Check programmer / System Monitor Menu / AC 4.

Motor / Temperature

8000 YRM 2353

Electrical System

Table 10. Common Curtis (F Series Pump) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes

Main Driver 1. Drive current exceeds hardware limit.

31

2. The drive current exceeds the set overcurrent value.

3. When the PWM control is activated, the detected signal should be low, but it is high.

When the PWM control is activated, 4. the detected signal should be high, but it is actually low.

5. When PWM control is off, the detected signal should be high, but it is low.

6. The driving current is too low.

1. Drive load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The circuit is over-current.

EM Brake Driver 1. Drive current exceeds hardware limit.

32

2. The drive current exceeds the set overcurrent value.

3. When the PWM control is activated, the detected signal should be low, but it is high.

4. When the PWM control is activated, the detected signal should be high, but it is actually low.

5. When PWM control is off, the detected signal should be high, but it is low.

6. The driving current is too low.

1. Drive load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The circuit is over-current.

Pump Driver Fault 1. Drive current exceeds hardware limit.

33

2. The drive current exceeds the set overcurrent value.

3. When the PWM control is activated, the detected signal should be low, but it is high.

4. When the PWM control is activated, the detected signal should be high, but it is actually low.

5. When PWM control is off, the detected signal should be high, but it is low.

6. The driving current is too low.

1. Drive load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The circuit is over-current.

65

Electrical System

8000 YRM 2353

Table 10. Common Curtis (F Series Pump) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes

Load Hold Driver Fault 1. Drive current exceeds hardware limit.

34

2. The drive current exceeds the set overcurrent value.

3. When the PWM control is activated, the detected signal should be low, but it is high.

When the PWM control is activated, 4. the detected signal should be high, but it is actually low.

5. When PWM control is off, the detected signal should be high, but it is low.

6. The driving current is too low.

1. Drive load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The circuit is over-current.

Load Hold Driver Fault 1. Drive current exceeds hardware limit.

35

2. The drive current exceeds the set overcurrent value.

3. When the PWM control is activated, the detected signal should be low, but it is high.

4. When the PWM control is activated, the detected signal should be high, but it is actually low.

5. When PWM control is off, the detected signal should be high, but it is low.

6. The driving current is too low.

IM Motor Feedback

36

37

1. Drive load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The circuit is over-current.

1. It is a motor encoder failure.

1. The controller detects a quick stop.

2. It is a crimping or wiring error.

2. Motor encoder has power supply problems.

3. Please contact dealer for technical support.

3. Check programmer / System Monitor Menu / AC Motor / Motor RPM. 4. Check programmer / AC Motor Setup / Quadrature Encoder / Encoder Fault Setup.

Motor Open 1. Motor Open

1. The motor phase line is open.

2. It is a crimping or wiring error.

1. It is the contact adhesion of main contactor

38

66

Main Contactor Welded 1. Main Contactor Welded

2. There is an open circuit on the V phase or U phase of the motor.

3. There is an external voltage directly connected to the controller B+ terminal.

8000 YRM 2353

Electrical System

Table 10. Common Curtis (F Series Pump) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes 1. The main contactor does not drawn.

2. The main contactor contact is defective.

Main Contactor Did Not Close 1. When there is a control command, the main contactor does not pull.

5. The main contactor parameters are incorrectly set.

39 2. The main contactor is disconnected during operation.

3. When the main contactor is prohibited, disconnect from the battery.

3A

44 46

47

49

2. The contactor coil is disconnected.

3. Contactor failure.

1. When the main contactor is disabled and the interlock is activated, the battery is not connected to the B+ terminal.

1. Motor Setup Needed 1. External voltage is too low or too high.

2. Input1 failure as a voltage input type may be out of range, as a 2/3 wire potentiometer type may be a potentiometer failure.

Brake Input

1. Memory data read/write failure

NV Memory Failure 1. NV Memory Failure

2. Internal controller fault 1. Key switch, interlock, direction switch and accelerator input operation sequence is incorrect.

2. There're wiring or crimping errors in key switch, interlock, direction switch and accelerator input.

3. There's damp in Key switch, interlock, direction switch and accelerator input.

4. Check programmer / System Monitor Menu/Inputs / Switch Status.

5. Check programmer / System Monitor Menu/Inputs / Throttle Command.

HPD Sequencing 1. HPD Sequencing

1. Emergency protection

1. The accelerator input voltage exceeds the range of Analog Low and Analog High Settings, and the corresponding analog input is set.

2. Check programmer / Controller Setup / Analog Inputs / Analog 1 Type.

3. Check programmer / Controller Setup / Analog Inputs / Configure.

1. Corresponding fault is triggered by the brake input source (assigned analog input).

1. Brake Input

Emergency Reverse HPD 47

1. The main contactor is disconnected during operation.

Motor Setup Needed Throttle Input

42

3. The B+ terminal of the controller is connected to a large external load. As a result, the capacitor cannot be charged effectively.

4. The high current fuse is blown out.

reverse

Parameter Change 1. Parameter change fault

high

pedal

1. Emergency reverse operation has ended, but there's no return from accelerator input, direction switch, interlock.

1. After interlocking, the parameters related to security are modified, the parameters marked PCF.

67

Electrical System

8000 YRM 2353

Table 10. Common Curtis (F Series Pump) Fault Codes (Continued) Fault Code

53

55 56 57 67 5B 68 72

Fault Name

Pump CAN PDO Timeout 1. Pump CAN PDO Timeout Pump HPD Fault 1. Oil pump operation sequence is faulty Lift Pot High 1. Lifting potentiometer high fault Lift Pot Low 1. Lift potentiometer low fault Unmatched Traction Controller 1. The traction controller fails to match CDF Fault 1. Configuration fault VCL Run Time Error 1. The VCL running time is incorrect.

PDO Timeout 1. CAN PDO Timeout

Possible Causes 1. CAN communication connection problem occurs between traction and oil pump controller 2. CAN bus communication is interfered.

3. CAN ports of traction and oil pump controller are damaged.

1. Wrong oil pump operation sequence 1. Potentiometer lifting problem 2. Potentiometer connection problem 1. Potentiometer lifting problem 2. Potentiometer connection problem 1. The traction controller model does not match.

1. Parameter configuration problem 1. The VCL running time is faulty.

1. The packet receiving time of two adjacent Pdos exceeded the specified PDO timeout period.

1. Stall Detected 2. Motor encoder fault

73

Stall Detected 1. Stall Detected

3. Incorrect crimping or wiring 4. The power supply of the motor encoder is abnormal.

5. Check programmer / System Monitor Menu / AC Motor / Motor RPM.

77 79 82 83 84

68

Supervision 1. Supervision Supervision Input Check 1. Input check monitor faults PDO Mapping Error 1. PDO mapping error Internal Hardware 1. Internal hardware failure Motor Braking Impaired 1. Motor brake damage

1. Internal controller fault 1. Internal controller fault 1. Too many data bits are allocated during PDO mapping, or the target is not simultaneous.

1. An internal fault is detected in the controller.

1. Battery overcharge or controller overheating or misalignment parameters

8000 YRM 2353

Electrical System

Table 10. Common Curtis (F Series Pump) Fault Codes (Continued) Fault Code 87

88

89 91

92

93

Fault Name Motor Characterization Error 1. Motor Characterization Error Encoder Pulse Error 1. Encoder Pulse Error Parameter Out of Range 1. Parameter Out of Range Bad Firmware 1. Bad Firmware EM Brake Failed to Set 1. EM Brake Failed to Set

Encoder LOS 1. Encoder LOS mode

Possible Causes 1. Motor matching failed in the process of matching motor.

1. The encoder step Settings did not match the reality. the calibration parameter setting, 2. Check Programmer / AC Motor Setup / Quadrature Encoder / Encoder Steps.

1. Out-of-range parameter values were detected.

1. Controller Firmware issues.

1. Electromagnetic brake braking failure.

2. The electromagnetic brake cannot stop the motor from turning after braking.

1. AC asynchronous motor feedback fault code 36 or "fault or motor blocking fault fault code 73, enter LOS mode.

2. Motor encoder malfunction.

3. Crimping or wiring error.

4. Truck stall

99

9A

Parameter Mismatch 1. Parameter Mismatch

Interlock Braking Supervision 1. Interlock brake redundancy failure

Driver 1 Fault 1. Short circuit 2. Overcurrent A1

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high 5. Break line 6. No current in output circuit

1. The controller parameter Settings are incorrect.

1. During Interlock Braking, the motor speed exceeds the parameter set under Interlock Braking Supervision.

2. Check programmer / Application Setup / Interlock Braking / Supervision Enable.

3. Check programmer / Application Setup / Interlock Braking / Interlock Braking Supervision.

1. Driver load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 1 Overcurrent parameter value.

5. Check programmer / Controller Setup / Outputs / Driver 1 / Driver 1 Overcurrent.

69

Electrical System

8000 YRM 2353

Table 10. Common Curtis (F Series Pump) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes

Driver 2 Fault 1. Short circuit 2. Overcurrent A2

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high 5. Break line

1. Driver load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. Check programmer / Controller Setup / Outputs / Driver 2 / Driver 2 Overcurrent.

6. No current in output circuit Driver 3 Fault 1. Short circuit 2. Overcurrent A3

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high 5. Break line 6. No current in output circuit Driver 4 Fault 1. Short circuit 2. Overcurrent

A4

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high 5. Break line 6. No current in output circuit Driver 5 Fault 1. Short circuit 2. Overcurrent

A5

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high Break line 5.

6. No current in output circuit

70

1. Driver load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 3 Overcurrent parameter value.

5. Check programmer / Controller Setup / Outputs / Driver 3 / Driver 3 Overcurrent.

1. Driver load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 4 Overcurrent parameter value.

5. Check programmer / Controller Setup / Outputs / Driver 4 / Driver 4 Overcurrent.

1. Driver load is open or short circuited.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 5 Overcurrent parameter value.

5. Check programmer / Controller Setup / Outputs / Driver 5 / Driver 5 Overcurrent.

8000 YRM 2353

Electrical System

Table 10. Common Curtis (F Series Pump) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes

Driver 6 Fault

1. Driver load is open or short circuited.

1. Short circuit

2. The pin or contactor coil of the connector is dirty.

2. Overcurrent A6

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high 5. Break line 6. No current in output circuit Driver 7 Fault

1. Driver load is open or short circuited.

1. Short circuit

2. The pin or contactor coil of the connector is dirty.

2. Overcurrent A7

3. Open / short circuit detected high, should be low 4. Open / short circuit detected low, should be high 5. Break line 6. No current in output circuit

A8

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 6 Overcurrent parameter value.

5. Check programmer / Controller Setup / Outputs / Driver 6 / Driver 6 Overcurrent.

Driver Assignment

3. The connector is crimped incorrectly or connected incorrectly.

4. The Driver overflows. Procedure Driver 7 Overcurrent parameter value.

5. Check programmer / Controller Setup / Outputs / Driver 7 / Driver 7 Overcurrent.

1. One drive serves two or more functions.

1. Driver assignment failure Coil Supply Fault

A9

1. With B- short circuit or hardware failure 2. Drive's internal short circuit, resulting in coil power cut 3. Coil power failure detection power startup 4. Coil detection failure

prohibition

1. Driver load short circuit.

2. The pin or contactor coil of the connector is dirty.

3. The connector is crimped incorrectly or connected incorrectly.

4. Controller failure.

Analog 1 Out of Range B1

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 1 input voltage is higher than Analog 1 High.

2. Analog 1 input voltage is lower than Analog 1 Low.

Analog 2 Out of Range B2

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 2 input voltage is higher than Analog 2 High.

2. Analog 2 input voltage is lower than Analog 2 Low.

71

Electrical System

8000 YRM 2353

Table 10. Common Curtis (F Series Pump) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes

Analog 3 Out of Range B3

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 3 input voltage is higher than Analog 3 High.

2. Analog 3 input voltage is lower than Analog 3 Low.

Analog 4 Out of Range B4

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 4 input voltage is higher than Analog 4 High.

2. Analog 4 input voltage is lower than Analog 4 Low.

Analog 5 Out of Range B5

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 5 input voltage is higher than Analog 5 High.

2. Analog 5 input voltage is lower than Analog 5 Low.

Analog 6 Out of Range B6

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 6 input voltage is higher than Analog 6 High.

2. Analog 6 input voltage is lower than Analog 6 Low.

Analog 7 Out of Range B7

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 7 input voltage is higher than Analog 7 High.

2. Analog 7 input voltage is lower than Analog 7 Low.

Analog 8 Out of Range B8

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 8 input voltage is higher than Analog 8 High.

2. Analog 8 input voltage is lower than Analog 8 Low.

Analog 9 Out of Range B9

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 9 input voltage is higher than Analog 9 High.

2. Analog 9 input voltage is lower than Analog 9 Low.

Analog 14 Out of Range BB

72

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 14 input voltage is higher than Analog 14 High.

2. Analog 14 input voltage is lower than Analog 14 Low.

8000 YRM 2353

Electrical System

Table 10. Common Curtis (F Series Pump) Fault Codes (Continued) Fault Code

Fault Name

Possible Causes

Analog 18 Out of Range BD

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

1. Analog 18 input voltage is higher than Analog 18 High.

2. Analog 18 input voltage is lower than Analog 18 Low.

Analog 19 Out of Range BE

BC

C1

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

Analog Assignment 1. Analog quantity distribution failure Branding Error 1. Branding Error

1. Analog 19 input voltage is higher than Analog 19 High.

2. Analog 19 input voltage is lower than Analog 19 Low. 1. An analog serves two or more functions.

2. An analog input is out of range.

1. The software and hardware brands do not match.

2. Contact dealer for technical support to rectify the fault.

Analog 31 Out of Range C7

C9

1. The analog input exceeds the upper limit.

2. The analog input is lower than the lower limit.

VCL Watchdog 1. VCL Watchdog

1. Analog 31 input voltage is higher than Analog 31 High.

2. Analog 31 input voltage is lower than Analog 31 Low.

1. VCL Watchdog

73

Steering Device and Installation

8000 YRM 2353

Steering Device and Installation OVERVIEW The steering device and installation are mainly composed of a steering wheel, a directional column, a connecting shaft and a column bracket. The upper universal joint of the steering device is connected to the steering wheel through the direction column, and the lower portion is connected to the orbitrol through the connecting shaft, and the steering column can be tilted back and forth to an appropriate position. See Figure 23.

1. STEERING WHEEL 2. LOCKING HANDLE 3. ORBITROL CONTROL UNIT Figure 23. Steering Device

74

Inspection of Steering System after Reassembly 1.

Turn the steering wheel leftward and rightward and turn it thorough and thorough to find whether or not left and right force applications are uniform, and whether or not turning is stable.

2.

Examine whether or not the oil pressure piping layout is correct, and whether or not left/right steering is reversely installed.

3.

Jack up the rear wheel, slowly turn the steering wheel leftward and rightward, repeat it for several times, and remove the air in the hydraulic pipeline and the cylinder.

8000 YRM 2353

Steering Device and Installation

Steering System Fault Diagnosis Problem Steering Wheel Fails to Turn

Heavy Steering Wheel

The Forklift Snakes or Shakes

Large Working Noise

Oil Leak

Analysis of Cause

Removal Method

Damage or failure of oil pump

To be replaced

Hose or joint damaged or pipeline blocked

To be replaced or cleaned

Low safety valve pressure

Pressure to be adjusted

Air present in oil circuit

Air to be removed

Failure of orbitrol reset, positioning spring leaf broken or elasticity not enough

Spring leaf to be replaced

Internal leak of steering cylinder too large

Piston sealing to be examined

Low tank level

Oil to be added

Oil cylinder pin loose or rod bending Replace the oil cylinder Leakage in the oil cylinder

Replacement of the oil cylinder seal

Oil level in oil tank is low

To add hydraulic oil

Suction tube or oil filter plugged

To be cleaned or replaced

Steering cylinder guide sleeve seal is damaged or pipe or joint is damaged

To be replaced

75

Steering Axle and Installation

8000 YRM 2353

Steering Axle and Installation OVERVIEW OF STEERING AXLE The steering axle is a box-shaped cross-section welded structure consisting of steering axle body, steering cylinder, link, steering knuckle and hub. The steering trapezoid adopts a crank slider mechanism, and the oil cylinder piston rod pushes the steering

knuckle through the link to deflect the steering wheel, thereby achieving steering.

Steering axle structure is shown in Figure 24, Figure 25, and Figure 26.

The steering axle, tire, wheel rim model and tire pressure are shown in Table 11.

Table 11. Steering Axle Specifications Forklift Model

ERP15UX

ERP18UX

ERP20UX

ERP25UX

ERP35UX

Steering axle

Z01A1-20000

Tire

5.00-8 8PR

18×7-8 14PR

200/50-10

Rim

3.50D-8

4.33R-8

6.50F

Tire pressure (Optional)

790kpa

970kpa

N/A

76

Z02A1-20000

ERP30UX

Z03A2-20000

8000 YRM 2353

Steering Axle and Installation

1. LEFT STEERING KNUCKLE ASSEMBLY 2. STEERING AXLE ASSEMBLY 3. CYLINDRICAL PIN Φ8 X 18 4. WASHER 12 5. BOLT M12 X 40 6. WASHER 12 7. 45° CURVED NECK GREASE NIPPLE Z1/8 8. OIL SEAL Φ25 X Φ32 X 7 9. BEARING Φ25 X Φ32 X 22 10. BEARING 198905 11. BOLT M10 X 1.25 X 40 12. NUT M10 X 1.25 13. ADJUSTING SHIM Φ26 X Φ46 X 0.2

14. O-RING 24.8 X 4.3 15. BOLT M6 X 12 16. WASHER 6 17. LINK PIN 18. LINING 19. BEARING GE15ES 20. STRAIGHT-THROUGH TYPE GREASE NIPPLE M6 21. MASTER PIN 22. SCREW M12 X 30 23. NUT M12 24. RIGHT STEERING KNUCKLE ASSEMBLY 25. OIL SEAL Φ64 X Φ82 X 7 26. BEARING 30208 27. WHEEL HUB BOLTS

28. WHEEL HUB 29. WHEEL HUB NUT 30. BEARING 30206 31. WASHER 32. SLOTTED NUT M24 X 2 33. COTTER PIN 5 X 40 34. WHEEL HUB COVER 35. STEERING CYLINDER ASSEMBLY 36. ADJUSTING SHIM Φ76 X Φ43 X 0.5 37. ADJUSTING SHIM Φ76 X Φ43 X 1 38. LINING 39. REAR AXLE SUPPORT 40. LINK

Figure 24. Steering Axle (ERP15UX - ERP18UX)

77

Steering Axle and Installation

8000 YRM 2353

1. LEFT STEERING KNUCKLE ASSEMBLY 2. STEERING AXLE ASSEMBLY 3. BEARING Φ32 X Φ40 X 32 4. OIL SEAL Φ32 X Φ40 X 7 5. ADJUSTING SHIM Φ53 X Φ76 X 0.5 6. ADJUSTING SHIM Φ53 X Φ76 X2 7. LINING 8. SUPPORTING SEAT 9. 90° CURVED NECK GREASE NIPPLE Z1/8 10. WASHER 10 11. NUT M12 12. CYLINDRICAL PIN 10 X 20 13. WASHER 14

14. BOLT M14 X 40 15. BOLT M12 X 35 16. OIL SEAL Φ75 X Φ100 X 10 17. BEARING 32209 18. WHEEL HUB BOLTS 19. WHEEL HUB 20. WHEEL HUB NUT 21. BEARING 30207 22. WASHER Φ31 X Φ62 X 4 23. SLOTTED NUT M30 X 2 24. WHEEL HUB COVER 25. MASTER PIN 26. O-RING 31.8 X 4.8 27. SCREW M12 X 30

28. BEARING GE16ES 29. NUT M12 30. COTTER PIN 6.3 X 50 31. RIGHT STEERING KNUCKLE ASSEMBLY 32. ADJUSTING SHIM Φ32.5 X Φ65 X 0.2 33. BEARING 198906 34. LINING 35. LINK 36. LINK PIN 37. RETAINER RING 16 38. STRAIGHT-THROUGH TYPE GREASE NIPPLE M6 39. STEERING CYLINDER ASSEMBLY 40. 45° CURVED NECK GREASE NIPPLE Z1/8

Figure 25. Steering Axle (ERP20UX - ERP25UX)

78

8000 YRM 2353

1.

2.

3.

4.

Steering Axle and Installation

CYLINDRICAL PIN Φ10 X 20 WASHER 14 BOLT M14 X 45 90° CURVED NECK GREASE NIPPLE Z1/8 5. MASTER PIN OF STEERING KNUCKLE 6. OIL SEAL Φ32 X Φ40 X 7 7. BEARING Φ32 X Φ40 X 32 8. STEERING AXLE ASSEMBLY 9. BOLT M12 X 35 10. NUT M12 11. OIL SEAL Φ75 X Φ100 X 10 12. BEARING 32209 13. WHEEL HUB BOLTS

14. WHEEL HUB 15. WHEEL HUB NUT 16. BEARING 30207 17. WASHER Φ31 X Φ62 X 4 18. SLOTTED NUT M30 X 2 19. WHEEL HUB COVER 20. NUT M12 21. SCREW M12 X 30 22. COTTER PIN 6.3 X 50 23. RIGHT STEERING KNUCKLE ASSEMBLY 24. BEARING GE16ES 25. LINK 26. RETAINER RING 16 27. LINK PIN

28. STRAIGHT-THROUGH GREASE NIPPLE M6 29. STEERING CYLINDER ASSEMBLY 30. BEARING 198906 31. LEFT STEERING KNUCKLE ASSEMBLY 32. LINING 33. ADJUSTING SHIM Φ32.5 X Φ65 X 0.2 34. O-RING 31.8 X .8 X 4.8 35. WASHER 14 36. LINING 37. ADJUSTING SHIM Φ53 X Φ76 X 0.5 38. ADJUSTING SHIM Φ53 X Φ76 X 2 39. SUPPORT BASE 40. 45° CURVED NECK GREASE NIPPLE Z1/8

Figure 26. Steering Axle (ERP30UX - ERP35UX) 1.

Steering Knuckle The steering knuckle is mounted on the two ends of the steering axle by the steering master pin, the conical bearing, the dust cover and the Oring. The upper end of the master pin is fixed on

the axle body with the retaining pin, and the lower end of the master pin is fixed on the axle body with the cotter pin. The support is supported by a conical bearing that is pressed against the axle body. See Figure 27.

79

Steering Axle and Installation

1.

2.

3.

4.

8000 YRM 2353

THRUST BEARING STEERING KNUCKLE ASSEMBLY STOPPER SCREW ADJUSTMENT PAD OF STEERING KNUCKLE

5.

6.

7.

8.

MASTER PIN OF STEERING KNUCKLE NEEDLE BEARING LINING SUPPORT SEATING

Figure 27. Steering Knuckle 2.

Steering Cylinder

The steering cylinder is a double-acting piston type cylinder. Both ends of the piston rod are connected to the steering knuckle through a link. The pressure oil from the full hydraulic orbitrol moves the piston rod to the left and right through the steering cylinder, thereby

80

achieving left and right steering. The piston seal is sealed by a combination of a support ring and an Oring. The Yx ring is axially sealed between the cylinder cover and the piston rod, and the oil cylinder is fixed to the steering axle through the cylinder covers on both sides. See Figure 28.

8000 YRM 2353

1.

2.

3.

4.

5.

CYLINDER BODY O-RING STEEL-BACKED BEARING SHAFT SLEEVE SHUTTER

Steering Axle and Installation

6. CYLINDER HEAD 7. DUST RING 8. SEALING RING FOR SHAFT 9. PISTON ROD 10. SUPPORT RING

11. SEAL RING 12. STEEL BALL 13. O-RING 14. SHAFT SLEEVE 15. PISTON

Figure 28. Steering Cylinder 3.

Wheel Hub The wheel hub is mounted to the steering knuckle by two tapered roller bearings. The wheel is pried to the wheel hub through the wheel rim. The

inside of the bearing is equipped with an oil seal to keep the grease in the wheel hub and the steering knuckle cavity. The nut is used to adjust the tightness of the bearing.

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Steering Axle and Installation

8000 YRM 2353

ESSENTIALS OF ADJUSTMENT AND MAINTENANCE Steering Wheel Bearing Preload Adjustment Table 12. Hub nut tightening torque table Forklift Model

Name

(ERP15UX - ERP18UX)

Numerical value 125 - 150 N•m (92.20 - 110.63 lbf ft)

(ERP20UX - ERP35UX)

Front wheel rim nut tightening torque 450 - 550 N•m (331.90 405.66 lbf in)

(ERP15UX - ERP35UX)

Rear-wheel rim nut tightening torque 125 - 150 N•m (92.20 - 110.63 lbf ft)

1.

As shown in Figure 29, grease the inner cavity of the wheel hub, the inner and outer bearings and the wheel hub cover, and apply some grease to the lip of the oil seal.

A. FILL LUBRICATING GREASE Figure 29. Preload Adjustment Illustration

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2.

Attach the outer ring of the bearing to the wheel hub and install the wheel hub to the steering knuckle shaft.

3.

Install the flat washer and tighten the slot nut with a torque of shown in Table 12, loosen the slot nut, and then screw the nut with a torque of 9.8 N•m (7.2 lbf ft).

4.

Gently tap the wheel hub with a wooden hammer and turn the wheel hub 3?4 circles to ensure that the wheel hub is not loose.

5.

Tighten the slot nut so that the slot is aligned with the cotter pin hole on the steering knuckle.

6.

Gently tap the wheel hub with a wooden hammer and turn the wheel hub 3~4 circles by hand to ensure smooth rotation and measure the rotational torque of the wheel hub and value of which is 2.94 ~ 7.8 N•m (2.1 ~ 5.7 lbf ft).

7.

When the rotational torque is higher than the specified value, it can be returned by 1/6 circle, and then the rotational torque is measured.

8.

When the specified torque is reached, the slot nut is locked with a cotter pin.

8000 YRM 2353

Parking Brake Operation

Parking Brake Operation OVERVIEW

Adjustment of Braking Force

The parking brake operation is mainly composed of a parking brake assembly and a stay clamp.

Turn the adjuster clockwise to increase the braking force; turn the adjuster counterclockwise to reduce the braking force.

OPERATING DEVICE OF THE PARKING BRAKE

Pulling force value of parking brake is 100 - 200 N (22.48 - 44.96 lbf).

Parking brake handle is a cam-style and the adjuster at the end of brake handle can be used to adjust braking force.

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Brake Pedal Operation

8000 YRM 2353

Brake Pedal Operation OVERVIEW

BRAKE PEDAL

The brake operation consists of the brake pedal assembly, left and right brake oil line and brake fluid tank.

The structure of brake pedal is shown in Figure 30, and the brake cover is welded to the instrument stand of frame.

1. COVER PLATE 2. PEDAL 3. BRAKE FLUID TANK

4. BRAKE PUMP 5. BRAKE PIPEINE Figure 30. Brake Pedal Operation

Adjustment of Foot Pedal Brake 1.

Adjust the push rod to be short.

2.

Adjust the catch bolt, to adjust the pedal height as indicated in Figure 31.

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3.

Push down the brake pedal, and adjust the push rod to be long, until the front end of push rod contacts the master cylinder piston.

4.

Screw down the lock nut for the push rod.

8000 YRM 2353

Brake Pedal Operation

Adjustment of Brake Switch 1.

Loosen the lock nut for brake switch, after the height of brake pedal has been properly adjusted.

2.

Pull off the plug and allow the lead wire to separate.

3.

Turn the switch, for Clearance A =1 mm.

4.

Confirm that the brake light shall be turned on when brake pedal is pushed down.

BRAKE MASTER CYLINDER

1. CATCH BOLT 2. LOCK NUT 3. LOCK NUT PUSH ROD 4. PUSH ROD

5. FREE STROKE 6. EFFECTIVE STROKE 7. FLOORMAT

Figure 31. Adjustment of Foot Pedal Brake

The master cylinder includes a valve seat, an one-way valve, one and return spring, as well as cup, piston, and auxiliary cup. Its top part is fixed using stopping washer and stopping steel wire, and its outside part is protected through rubber dust cover. The master cylinder piston acts through push rod based on operation of brake pedal. When brake pedal is pushed down, the push rod pushes the piston forward, and the brake fluid in the cylinder body returns to the oils storage tank through return oil port, until the main cup blocks up the return oil hole. After the main cup has pushed the return oil port, the brake fluid in the front cavity of cylinder body is compressed and opens the one-way valve, thus flows to the wheel cylinders through brake pipeline, the way respective wheel cylinders extend outwards, for brake block friction plate and brake drum to contact each other, achieving the effect of speed reduction or brake. At this point, the rear cavity of piston is supplied with brake fluid from return oil port and oil inlet port. When brake pedal is loosened, the piston is pressed backward by return spring, and at the same time the brake fluid in respective brake wheel cylinders will also be compressed by brake block return spring, for the brake fluid to return to the master cylinder (the front cavity of piston) through one-way valve. The piston will return to its original position, the brake fluid in the master cylinder will return to the return oil tank through return oil port, and the pressure of one-way valve is adjusted to a certain proportion with the remaining pressure in brake pipeline and brake wheel cylinders, for the cup of wheel cylinder to be correctly placed to prevent oil leak, as well as to eliminate air resistance possibly generated during emergency brake. The structure of brake master cylinder is indicated as in Figure 32.

Schematic diagram of brake system is indicated as in Figure 33.

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Brake Pedal Operation

8000 YRM 2353

A. TO SELF-ADJUSTING STORING TANK B. TO SELF ADJUSTING WHEEL BRAKE Figure 32. Brake Master Cylinder

1.

2.

3.

4.

5.

RIGHT WHEEL CYLINDERS LEFT WHEEL CYLINDERS BRAKE PIPELINE BRAKE FLUID TANK PEDAL

Figure 33. Schematice diagram for Brake System

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8000 YRM 2353

Brake Pedal Operation

BRAKE FAULT DIAGNOSIS Problem

Poor Brake

Analysis of Cause for Generation

Removal Method

Oil leak with brake system

To be repaired

Clearance of brake clearance not properly adjusted

Regulator to be adjusted

Brake over-heated

Examine whether or not skidding exists

Poor contact of brake drum and friction plate

To be re-adjusted

Contaminant attached on friction plate

To be repaired or replaced

Contaminant blended into brake fluid Brake fluid to be examined Brake pedal (brake switch) improperly adjusted

To be adjusted

Surface of friction plate hardened or To be repaired or replaced contaminant attached on it

Abnormal sound present with Brake

Un-uniform Brake

Weak Brake

Bottom plate distorted or bolt loosened

To be repaired or replaced

Brake block distorted or installation incorrect

To be repaired or replaced

Friction block worn-out

To be Replaced

Wheel bearing loosened

To be repaired

Oil stain present on friction surface

To be repaired or replaced

Brake clearance not properly adjusted

Regulator to be adjusted

Failure of wheel cylinder

To be repaired or replaced

Return spring of brake block damaged

To be replaced

Brake drum deflected

To be repaired or replaced

Oil leak with brake system

To be repaired or replaced

Clearance between brake blocks not Regulator to be adjusted properly adjusted Air blended in brake system

Air to be bled

Brake pedal wrongly adjusted

To be readjusted

87

Hydraulic Oil Tank and Installation

8000 YRM 2353

Hydraulic Oil Tank and Installation OVERVIEW Hydraulic oil tank and installation are mainly composed of oil tank, oil tank cover plate, magnet, fuel

1. MAGNET 2. BREATHER 3. OIL TANK COVER

filter, breather, drain plug, and gasket, etc. See Figure 34.

4. GASKET 5. FUEL FILTER 6. DRAIN PLUG Figure 34. Hydraulic Oil Tank

HYDRAULIC OIL TANK The hydraulic oil tank of the ERP15UX - ERP35UX model is on the rear side of the battery. Oil suction

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filter is fitted in the oil tank, to ensure a supply of clean hydraulic oil.

8000 YRM 2353

Hydraulic System

Hydraulic System OVERVIEW Hydraulic system is composed of oil pump, multi-way valve, orbitrol, oil pipe, joint, and other components.

The high-pressure oil from the main oil pump reaches the multi-way valve and is divided into two sections by the multi-way valve and through the diverter valve: One part of high-pressure oil is distributed into the lifting cylinder or the tilting cylinder, and the other part is distributed to the orbitrol to control the steering cylinder. In the load sensing type steering system, the sensing type orbitrol of load has a LS port connected

to the LS port of the multi-way valve, so that the steering load pressure signal of the orbitrol is transmitted to the LS port of the multi-way valve through the oil pipe for the control system to provide the oil supply to the orbitrol. When the load sensor is in the neutral position, only a small amount of oil in the steering system is directly returned to the oil tank, which fully reflects the obvious energy saving effect.

Figure 35, Figure 36 are the hydraulic schematic diagrams.

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Hydraulic System

8000 YRM 2353

Figure 35. Hydraulic Schematic Drawing (Standard)

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8000 YRM 2353

Hydraulic System

Figure 36. Hydraulic Schematic Drawing (OPS)

91

Hydraulic System

8000 YRM 2353

GEAR PUMP Gear pump is driven by lifting motor. The structure of gear pump is indicated as in Figure 37.

Maintenance of Gear Pump 1.

Disassembly Before disassembly, it shall be thoroughly cleaned. The demounted parts shall be put on clean paper or cloth. Take care not to contaminate or injure the parts. a.

Clamp the flange part of pump on the clamp bench.

b.

Remove the Connecting Bolt 11, Pump Cover 5, and Pump Housing 1.

c.

Detach the Lining Plate 6, the Driving Gear 2, and the Driven Gear 3.

d.

Remove the Seal Ring 7 and 3-Shape seal ring 8 from the front and rear end caps.

NOTE: Don’t remove the seal ring if it is not to be replaced.

1.

2.

3.

4.

5.

6.

PUMP BODY DRIVING GEAR DRIVEN GEAR FRONT END CAP REAR END COVER GASKET

7. SEAL RING 8. 3-SHAPE SEAL RING 9. OIL SEAL 10. SPRING RETAINER RING 11. BOLT 12. WASHER

Figure 37. Gear Pump 2.

Examination Examine the disassembled parts, and clean them using gasoline (except rubber parts). a.

Examination of Pump Body The pump body shall be replaced, if the contact length of pump body internal cavity and the gear is larger than the circumference by ½.

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8000 YRM 2353

Hydraulic System d.

Examine the driving and driven gears from front and rear. A pair shall be replaced in the case of excessive wear, and they shall be replaced in pairs if side D as indicated in Figure 40 is smaller than the specified value.

Figure 38. Pump Body b.

Examination of Lining Plate Examine the contact face of lining plate, and the lining place shall be replaced if the surface is damaged or the thickness of lining plate is smaller than the specified value. The specified value for thickness of lining plate: 4.94 mm (0.19 in.).

Figure 40. Minimum Dimension e.

3.

A. INLET PORT B. LINING PLATE C. OUTLET PORT Figure 39. Lining Plate c.

Front and Rear Pump Caps The inner surface lining shall be replaced, if lining color change (brown color).

Replace seal ring, gasket, retainer ring, and spring retainer ring, as per requirements.

Assembly

a.

Mount on a new seal ring and new retainer ring on the front end of the pump.

b.

Mount on the lining plate in the groove part of front end cover, and take care not to mistake the oil suction port and oil drain port.

c.

Mount on the driving and driven gears on the front end cover.

d.

Mount on the lining plate on the side of gear for the groove to be aligned with gear point. Take care not to mistake the oil suction port side and the oil drain port side.

e.

Mount on a new seal ring and new retainer ring on the groove part of rear cap. Refer to Figure 41.

f.

Mount the rear cap on the pump body.

g.

Tighten the connecting bolts to the specified torque 9 - 10kg.m ( (65.10 - 72.33 lbf ft)) after everything has been properly assembled.

93

Hydraulic System

8000 YRM 2353 b.

Loosen the adjusting screw of overflow valve, for pump to run for about 10 minutes at 500 ~ 1000rpm, to ensure that the oil pressure is lower than 10kg/cm² ( (142.23 psi)).

c.

Speed up the pump rotation to 1500 ~ 2000rpm, and run for about 10 minutes.

CAUTION 1.

2.

3.

4.

5.

RETAINER RING ROOTAGE SEAL RING PUMP BODY INTERNAL CAVITY UNDERSIDE LINING Figure 41. Pump Body Rear Cap

4.

d.

Maintain the pump speed at 1500 ~ 2000rpm, and increase the pressure by 20 ~ 30kg/cm² ( (284.47 - 426.70 psi)) each time, run for 5 minutes, until it reaches 175kg/cm² ( (2489.08 psi)) .

e.

After completing the above procedures, the overflow valve is re-adjusted to the original working condition, and the unloading test is carried out.

f.

Whether loading or not loading, an unloading test shall be carried out to ensure that the device is at the proper speed.

Test The test is for oil pump to run in. Examine whether or not the pump moves normally, and it is best to test the oil pump on test bench, but it may also be tested on forklift truck in following steps:

NOTE: If oil pump is disassembled for maintenance due to severe worn-out or block-up because of hydraulic oil, the hydraulic oil and the filter shall be replaced, prior to trial run on forklift truck. a.

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Test the temperature of oil, the temperature of pump surface, and running sound, when oil pressure is increased, and reduce the load for oil temperature to drop if oil temperature or pump surface temperature too high, before test is continued.

Mount the pump on the forklift truck, and mount on pressure gauge at the pressure test port of multi-way valve.

8000 YRM 2353

Hydraulic System

Fault Diagnosis Failure Oil Drainage Quantity Small

Cause

Repair Method

Oil level of oil tank low

Oil to be added to specified quantity

Oil pipe or oil filter blocked

To be cleaned or replaced as per requirement

Lining plate damaged Bearing damaged Seal ring, lining seal part or retainer ring under poor condition Pump Pressure Low

Overflow valve misadjusted

Air present in system

To be replaced

Overflow valve to be adjusted to specified value using pressure gauge Oil pipe at oil suction side to be refastened Oil to be added Oil seal of oil pump to be replaced

Oil suction pipe damaged or oil filter Pipe to be examined or oil filter to be blocked maintained Oil suction side loosened and air leak

Loosened area to be fastened

Oil viscosity too high

To be replaced with oil with viscosity adaptive to pump operating temperature

Air bubble present in oil

Cause of air bubble to be found out and actions to be taken

Noise Present during Operation

Pump Oil Leak

Pump oil seal or seal ring damaged Pump damaged

MULTI-WAY VALVE Two-piece and four-body type is applied to multi-way valve, and the hydraulic oil from hydraulic oil pump is controlled through multi-way valve stem, to distribute the high-pressure oil to lifting cylinder or tilting cylinder.

Safety valve and self-lock valve are available inside the multi-way valve. The safety valve is set on the oil inlet port of multi-way valve, able to control system pressure, while self-lock valve is set on the valve plate

To be replaced

of tilting cylinder, mainly used for preventing severe aftereffect caused by misoperation of control rod under the condition when tilting cylinder has no pressure source. One-way valve is installed between the oil inlet port and the oil suction port of lifting valve as well as between the oil inlet port of lifting valve and the oil inlet port of tilting valve plate.

The shape of multi-way valve is indicated as in .

95

Hydraulic System

1.

2.

3.

4.

8000 YRM 2353

LIFTING VALVE TILTING VALVE AUXILIARY VALVE AUXILIARY VALVE

5.

6.

7.

8.

TO OIL TANK TO STEERING TO OIL PUMP SAFETY OVERFLOW VALVE

Figure 42. Multi-Way Valve 1.

Operation of Tilting Valve (Tilting slide valve as example) a.

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Neutral Position (Figure 43)

At this point the high-pressure oil drained from oil pump returns to oil tank through neutral position.

8000 YRM 2353

1.

2.

3.

4.

Hydraulic System

OIL INLET ONE-WAY VALVE MAIN OIL INLET PORT CYLINDER POINT A RESET SPRING

5.

6.

7.

8.

TILTING VALVE LOW PRESSURE PASSAGE MIDDLE PASSAGE CYLINDER POINT B

Figure 43. Tilting Slide Valve b.

Push-in Tilting Valve (Figure 44) At this point, the middle passage is closed, and the oil from the oil inlet port opens the one-way valve and flows to cylinder interface B, while the oil from cylinder interface A flows to the oil tank through low-pressure passage, able for slide valve to return to neutral position, depending on the return spring.

Figure 44. Push-In Tilting Valve

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Hydraulic System c.

Pull-out Slide Valve (Figure 45) At this point the neutral position is closed, and the oil from the oil inlet port opens the one-way valve, and flows to cylinder interface A, while the oil from cylinder interface B flows to the oil tank through low-pressure passage, able for slide valve to return to the neutral position, depending on return spring.

8000 YRM 2353 The pressure set in the oil pump “HP” passage acts on the spring of guide valve, and the oneway valve “E” will open. Oil passes around the valve and flows into the low-pressure “LP” side via through hole, as indicated in .

Figure 47.

Figure 45. Pull-Out Slide Valve 2.

Action of Safety Overflow Valve Overflow valve is installed between the oil pump “HP” interface and low-pressure “LP” passage.

Through function of lifting valve “C” oil on the different areas of “A” and “B”, in this way the oneway valve “K” and the overflow lifting valve “D” both drop on the valve seat, as indicated in Figure 46.

Once the guide valve “E” is opened, the pressure of the inner side of valve “C” will drop, and valve “E” and valve “C” both drop on the valve seat.

The fluid flow in the back of flow valve “D” will be closed, for which the pressure of the inner-side part will drop, as indicated in .

Figure 48.

Figure 46. Safety Overflow Valve

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The pressures on the oil pump “HP” passage side and the inner side are imbalanced, and the valve “D” will open under the action of pressure difference, for oil to directly flow into the low-pressure “LP” circuit, as indicated in .

8000 YRM 2353

Hydraulic System

Figure 49.

3.

Action of Tilting Self-Lock Valve

1. OIL PORT A 2. OIL PORT B 3. PRESSURE VALVE Figure 50. Valve Core Pushed In (Pump Working)

The tilting slide valve is equipped with a self-lock valve, which is mainly used to prevent vibration caused by the negative pressure inside the tilting cylinder and avoid serious consequences caused by the action. Generally, the conventional structure can also operate the tilting slide valve to make it tilt forward after the engine is turned off.

However, in case that this tilting self-lock valve is adopted, when the engine is flameout, the mast cannot be tilted forward even when the operating valve is pushed.

b.

When valve core is pushed in (pump not working) Push in the valve core when oil pump is not working, no oil will enter into cylinder interface “B, and thus the pressure in the P part will not rise. On this account, piston will not move, the oil of cylinder interface “A” cannot return to oil tank, and the cylinder does not move.

The flow direction of oil is the same as indicated in Figure 45 when valve core is pulled out, and at this point the mast is in the tipping-back status.

The status when valve core is pushed in is described below. a.

When valve core is pushed in (pump working) The oil from the main pump passes interface “B” to the tilting cylinder, the oil returning from cylinder passes oil port A and acts on the piston, and the oil returns to the oil tank through the LP oil circuit holes A and B on valve core.

1. OIL PORT A 2. OIL PORT B 3. PRESSURE VALVE Figure 51. Valve Core Pushed In (Pump Not Working) 4.

Multi-Way Valve Control

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Hydraulic System

8000 YRM 2353

Figure 52. Multi-Way Valve Control

1. LIFTING

2. TILTING

Figure 53. Logo of Multi-Way Valve Control

Multi-way valve is controlled by control rod, and all the control rods are installed on one piece of connecting shaft. The shaft is fixed on instrument panel through bracket, and the control rods control slide valves through connecting rod.

According to what’s indicated in Figure 53, push forward and pull up backward the lifting handle, the mast will rise and drop, respectively. Push forward and pull backward the tilting handle, the mast will tip forward and backward, respectively.

5.

Adjustment of Multi-way Valve Pressure

ERP15UX - ERP18UX

ERP20UX - ERP25UX

ERP30UX - ERP35UX

Safety valve Pressure Control Value

14.5 MPa (2103.05 psi)

17.5 MPa (2538.16 psi)

17.5 MPa (2538.16 psi)

Orbitrol Pressure Setting

12 MPa (1740.45 psi)

12 MPa (1740.45 psi)

12 MPa (1740.45 psi)

Pressure Adjusting Method for Safety Valve (Figure 54) The pressure of safety valve shall not be randomly adjusted, and please adjust the pressure in the following steps. a.

100

Screw off the measurement hole screw plug for the inlet part of multi-way valve, mount on the oil pressure gauge that is able to measure 20 MPa (2900.75 psi).

b.

Operate the tilting handle, and measure the pressure when stroke of cylinder has moved to the end.

c.

When oil pressure and specified value are different, loosen the lock nut of overflow valve, and adjust the left/right turning adjusting screw to the specified value.

d.

Tighten the nut after it has been properly adjusted.

8000 YRM 2353

Hydraulic System Legend for Figure 54.

1.

2.

3.

4.

OIL INLET PORT LOCK NUT CAP PRESSURE VALVE

Figure 54. Pressure Adjustment Method for Safety Valve

101

Hydraulic System

8000 YRM 2353

Fault Diagnosis Failure

Cause

Pressure of Lifting Oil Circuit Fails to Valve blocked be Increased Oil hole blocked Slow Pressure Rise

Repair Method To be cleaned after disassembly

Valve blocked

To be cleaned after disassembly

Air Exhaust insufficient

Air to be fully exhausted

Pressure of Steering Oil Circuit Larger than Specified Value

Valve blocked and stagnant

Specified Oil Quantity Cannot Be Reached

Adjustment of overflow valve improper

To be adjusted

Noise Present

Adjustment of overflow valve improper

To be adjusted

Slide Surface Worn-out

Overflow valve to be replaced

O-ring aged or damaged

O-ring to be replaced

Spring broken

Spring to be replaced

Valve seat surface damaged

To be adjusted or overflow valve to be replaced

Oil Leak (Internal)

Valve seat surface damaged

Valve seat surface to be amended

Set Pressure High

Valve blocked and stagnant

To be cleaned after disassembly

Oil Leak (External) Set Pressure Low

Oil hole blocked

FULL HYDRAULIC ORBITROL Full hydraulic orbitrol (Figure 55) is able to measure the size of angle according to the rotation of steering

102

To be cleaned after disassembly

wheel and transmit the pressure from oil pump to bypass valve through pipeline. When oil pump fails to supply oil, steering can be achieved manually.

8000 YRM 2353

1.

2.

3.

4.

5.

6.

VALVE CORE SPRING LEAF VALVE SLEEVE PIN PULL-OUT LARGE RETAINING RING THRUST NEEDLE ROLLER BEARING 7. SMALL RETAINING RING 8. O-SEAL RING 77.5 X 2.65

Hydraulic System

9. STEEL BALL S Φ8 10. VALVE BODY 11. O-SEAL RING 50 X 3.1 12. X-SHAPE SEAL RING 13. O-SEAL RING 25.8 X 2.65 14. FRONT COVER 15. SPRING WASHER 8 16. INNER HEXAGON SCREW M8 X 20 17. HEXAGON HEAD BOLT M10 X 1.25 X 50

18. COMBINATION SEALING WASHER 19. PIN 4 X 32 20. REAR COVER 21. LIMITED POST 22. O-SEAL RING 79 X 2 23. ROTOR AND STATOR ACCESSORIES 24. UNIVERSAL DRIVING SHAFT 25. DIAPHRAGM PLATE

Figure 55. Full Hydraulic Orbitrol

SPEED LIMIT VALVE The speed limit valve (i.e., the throttle valve) is installed in the lifting cylinder oil circuit to limit the descent speed of the fork when it is under heavy load.

Refer to Figure 56 for working status of speed limit valve.

Return oil of lifting cylinder enters into the valve cavity G, and returns to multi-way valve through FEDCB and A.

When a large quantity of oil flows through the valve core hole C, the pressure difference generated in valve core enables the valve core to move rightward.

Thus the passage between the holes D and C turns narrow, the return oil quantity is reduced for it, and the dropping speed of fork turns slow.

If fork is to be lifted, the HP oil from multi-way valve enters into lifting cylinder through ABCDEF and G.

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Hydraulic System

8000 YRM 2353

Figure 56. Speed Limit Valve

HYDRAULIC PIPELINE Refer to Figure 57 for hydraulic oil pipeline of ERP15UX - ERP35UX hydraulic system.

104

8000 YRM 2353

1. HOSE CLAMP 2. OIL PUMP SUCTION PIPE 3. OIL PUMP INLET FITTING 4. GEAR PUMP 5. WASHER 6. WASHER 7. BOLT 8. OIL PUMP OUTLET FITTING 9. MULTIWAY VALVE OIL INLET HOSE 10. HOSE CLAMP 11. STEERING OIL RETURN HOSE 12. BOLT 13. WASHER 14. WASHER 15. CLAMP 16. O-RING 17. STEERING CYLINDER FITTING 18. STEERING CYLINDER OIL HOSE I 19. STEERING CYLINDER OIL HOSE II 20. STEERING OIL RETURN JOINT 21. FITTING I 22. FITTING II 23. OIL INLET HOSE 24. STEERING PUMP

Hydraulic System

25. O-RING 26. FITTING 27. RUBBER HOSE 28. SIX-WAY VALVE HOSE I 29. SIX-WAY VALVE HOSE II 30. MULTIWAY VALVE LIFTING CYLINDER 31. O-RING 32. TILT CYLINDER FITTING 33. O-RING 34. FITTING 35. O-RING 36. THREE-WAY FITTING 37. MULTIWAY VALVE 38. MULTIWAY OIL RETURN HOSE I 39. SIX-WAY VALVE 40. TILTING CYLINDER OIL HOSE I 41. TILTING CYLINDER OIL HOSE II 42. BOLT 43. O-RING 44. TILTING CYLINDER FITTING 45. TILTING CYLINDER OIL HOSE III 46. TILTING CYLINDER OIL HOSE IV 47. MULTIWAY VALVE OIL RETURN HOSE II Figure 57. Hydraulic Pipeline

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Lifting System

8000 YRM 2353

Lifting System SAFETY PROCEDURES WHEN WORKING NEAR MAST

3.

Use a 3/8 inch minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast.

4.

Lower mast until there is tension in the safety chain and the free-lift cylinder (three-stage) is completely retracted. If running, stop the engine.

Apply parking brake. Install a DO NOT REMOVE tag on the safety chain(s).

5.

Install another safety chain (3/8 inch minimum) between the top or bottom crossmember of the carriage and a crossmember on the outer weldment. See Figure 69.

WARNING The following procedures MUST be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

•

• •

• •

Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed. Also make sure that the power is off and the key is removed. Put a DO NOT OPERATE tag in the operator's compartment. Disconnect the battery on electric lift trucks and put a tag or lock on the battery connector.

Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

DO NOT use blocks to support the mast weldments or to restrain their movement.

Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the Mast.

WHEN WORKING NEAR THE MAST ALWAYS: •

Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered.

OR •

If parts of the mast must be in a raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures:

1.

Put mast in vertical position.

2.

Raise mast to align bottom crossmember of weldment that moves in the outer weldment with a crossmember on the outer weldment. On the two-stage and free-lift mast, the moving part is the inner weldment. On the three-stage mast, it is the intermediate weldment. See Figure 69.

106

NOTE: Apply parking brake. After lowering or restraining the mast, shut off power and remove key.

Put a DO NOT OPERATE tag in the operator's compartment. Disconnect battery on electric lift trucks and put a tag or lock on battery connector.

OVERVIEW The lifting system is mainly composed of inner mast, outer mast, fork carriage, lifting cylinder, and tilting cylinder, etc.

INNER AND OUTER MAST The inner and outer masts are the welded parts. The bottom part of outer mast is installed on driving axle using support. See Figure 58.

The middle part of outer mast is connected together with vehicle chassis through tilting cylinder, and able to tip forward and backward under the function of tilting cylinder.

The channel steels for inner is J type and outer mast is C type, the main roller and side rollers are installed on the top of the outer mast, and the composition roller is mounted on the bottom of inner mast.

The maintenance and service of the composite rollers for the inner and outer mast are high-position service, and attention shall be paid to safety.

8000 YRM 2353

1.

2.

3.

4.

5.

6.

7.

ROLLER STOP PLATE OUTER MAST SHAFT PIN SUPPORT COVER BUSHING ROLLER Figure 58. Two-Stage Mast

Lifting System

1.

2.

3.

4.

FORK CARRIAGE ASSEMBLY Fork carriage is composed of fork carriage, composite roller, backrest, and fork. The fork rolls inside the inner mast through composite roller, Composite roller shaft head is directly welded on the carriage, and the rolling clearance is to be adjusted by traverse roller inside the composite roller. See Figure 59.

BACKREST ROLLER FORK CARRIAGE Figure 59. Fork Carriage Assembly

Adjustment for Height of Fork Carriage 1.

Park the vehicle on a level ground and keep the mast to be vertical.

2.

Allow the underside of fork to contact the ground, adjust the adjusting nut of the joint on the top end of chain for there to be a distance A between the composite roller and the inner mast.

Forklift Model

A (mm / in)

ERP15UX - ERP18UX

36 - 41 / 1.378 1.614

ERP20UX - ERP25UX

24 - 29 / 0.945 1.142

ERP30UX - ERP35UX

19 - 24 / 0.748 0.945

107

Lifting System

3.

Allow the fork to drop to the ground and tilt backward in place. Adjust the joint on the top part of chain, and adjust the nuts for the tensioning degrees of the two chains to be the same.

8000 YRM 2353

1.

2.

3.

4.

5.

6.

7.

SIDE ROLLER INNER MAST ROLLER BACKREST TILTING CYLINDER LIFTING CYLINDER OUTER MAST Figure 61. Schematic Diagram of the Roller

NOTE: Adjust the side clearance of composite roller to be 0.5mm0.5 mm (0.0197 in.).

1.

2.

3.

4.

LOCKNUT 1 LOCKNUT 2 END CONNECTOR CHAIN Figure 60. Chain LH1634

ROLLER POSITIONS Rollers are divided into composite roller and side roller, installed on outer mast, inner mast, and fork carriage, respectively. The composite roller bears the front/rear, and side loads, while the side rollers mainly bear the side loads, thus for the inner mast and the fork carriage to move freely. (Figure 61)

108

Add grease on the surface of composite roller and the contact fact of mast.

Replacement of Fork Backrest 1.

Park the truck on a level ground, with one pallet on the fork.

2.

Drop the fork and the pallet on the ground.

3.

Detach the joint on the top end of chain, and take off the chain from sprocket wheel.

4.

Lift inner mast (1 in Figure 62).

5.

Reverse the fork, after it is confirmed that the fork carriage has been disengaged from the outer mast. (2 in Figure 62).

8000 YRM 2353

Lifting System

Figure 62. Replacement of Fork Backrest

LIFTING CYLINDER Lifting cylinder is in a single-function piston type, composed of cylinder body, piston rod, piston, and cylinder head, etc. For this series of forklift trucks, two pieces of lifting cylinders are installed behind the outer mast, and its bottom part is fixed using pins and bolts on the support of the lifting cylinder on outer mast, while the top part of the cylinder (namely the top part of piston rod) is connected with the upper crossbeam of the inner mast.

One explosion relieve valve is mounted on the bottom part of the cylinder, and it can play the safety protective function if HP pipe suddenly cracks when mast is lifted up. Steel-backed bearing and oil seal are installed on the cylinder cover, used to support piston rod and prevent dust entry.

ERP15UX - ERP18UX Lifting Cylinder as indicated in Figure 63.

The piston is fixed on the piston rod using spring steel wire, and oil seal and support ring are installed on the outer ring of piston.

109

Lifting System

8000 YRM 2353

1. BOLT M12 X 1.25 X 25 2. CYLINDRICAL PIN B10 X 25 3. WASHER 12 4. CYLINDER BODY 5. O-RING 22 X 2.4 6. EXPLOSION RELIEF VALVE 7. HOOP 8. RUBBER SLEEVE 9. HOOP SEAT 10. WASHER 10 11. NUT M10 X 1.25 12. BOLT M12 X 1.25 X 30

13. NUT M12 X 1.25 14. ROUNDWIRE SNAP RING 24 15. VALVE SLEEVE 16. HOLE SEAL 45 X 35 X 6 17. RETAINER RING 18. HOLE SUPPORT RING 19. PISTON 20. SPACER SLEEVE Φ35 X 50 21. PISTON ROD 22. LINING 23. O-RING 49.7 X 3.5 24. STEEL-BACKED BEARING Φ35 X Φ39 X 30 25. NYLON CUSHION Φ6 X 3

26. SCREW M8 X 8 27. CYLINDER HEAD 28. SHAFT SEAL 35 X 45 X 6 29. DUST RING 35 X 45 X 5/6.5 30. WASHER 14 31. BOLT M14 X 1.5 X 35 32. RETAINER RING 40 33. SPROCKET WHEEL 34. CHAIN 35. COTTER PIN B3.2 X 30 36. SPHERICAL NUT M14 X 1.5 37. NUT M14 X 1.5

Figure 63. Lifting Cylinder (ERP15UX - ERP18UX ) ERP20UX - ERP35UX Lifting cylinder is indicated in Figure 64.

110

8000 YRM 2353

Lifting System

Figure 64. Lifting Cylinder (ERP20UX - ERP35UX )

111

Lifting System

8000 YRM 2353 Legend for Figure 64.

1. BOLT 2. CYLINDRICAL PIN 3. WASHER 4. CYLINDER BODY 5. O-RING 6. EXPLOSION RELIEF VALVE 7. HOOP 8. RUBBER SLEEVE 9. HOOP SEAT 10. WASHER 11. NUT 12. BOLT

13. NUT 14. ROUNDWIRE SNAP RING 15. VALVE SLEEVE 16. HOLE SEAL 17. RETAINER RING 18. HOLE SUPPORT RING 19. PISTON 20. SPACER SLEEVE 21. PISTON ROD 22. LINING 23. O-RING 24. STEEL-BACKED BEARING 25. NYLON CUSHION

Working Status of Explosion Relieve Valve One explosion relieve valve is available at the bottom part of lifting cylinder, and refer to Figure 65. It is used to prevent abrupt drop of cargo, when HP hose is suddenly cracked. The oil from the lifting cylinder passes the cutoff slide valve, and the oil holes around the slide valve allow the two cavities to generate pressure difference. At this point when differential

A. NORMAL

26. SCREW 27. CYLINDER HEAD 28. SHAFT SEAL 29. DUST RING 30. WASHER 31. BOLT 32. RETAINER RING 33. SPROCKET RING 34. CHAIN 35. COTTER PIN 36. NUT 37. NUT

pressure is smaller than the spring force, the slide valve will not act. In the case if HP hose is cracked, a very big differential pressure is formed, for the slide valve to move and block up the oil holes around it, while only a small quantity of oil is allowed to flow through the pores at the top part of slide valve, for fork to drop slowly.

B. DISCONNECTED Figure 65. Working Status of Explosion Relief Valve

112

8000 YRM 2353

Lifting System

Adjustment of Lifting Cylinder

TILTING CYLINDER

When lifting cylinder, inner mast or outer mast is disassembled and replaced, it is required to re-adjust the stroke of lifting cylinder. The adjusting method is given as follows. Refer to Figure 66.

Tilting cylinder is in double function type, and its end part of piston rod is connected with mast through ear ring. The tilting cylinder bottom is connected with vehicle chassis using pins, and one piece of tilting cylinder is available on the two sides of forklift truck, respectively.

1.

Mount the head part of piston into the upper crossbeam of inner mast without adding the adjusting shim.

2.

Slowly lift the mast to the maximum stretching range of cylinder, and examine whether or not the two lifting cylinders are synchronous.

3.

After movement is stopped, add adjusting shim between the head of piston and the upper crossbeam of mast. The thicknesses of adjusting shim are 0.2 mm (0.0079 in.) and 0.5 mm (0.0197 in.).

4.

Adjust the tensioning degree of chain. The adjustment of lifting cylinder is also a highposition service, and attention shall be paid to safety.

NOTE: If the forklift truck is not used for up to 10 days, the oil cylinder shall be lifted to the top for 2 or 3 times for the lubrication and maintenance.

1.

2.

3.

4.

The tilting cylinder is mainly composed of piston, piston rod, cylinder body, cylinder cover, guide sleeve, and seal part, etc. Piston and piston rod are in the welded structure. One support ring and two Yx seal rings are mounted at the outer edge of piston, while shaft sleeve is press fitted for and Yx seal ring, retainer ring, and dust ring are mounted in the inner hole of guide sleeve. This shaft sleeve supports the piston rod, the seal ring, the retainer ring, and the dust ring, able to prevent oil leakage and dust, screwed onto the cylinder body together with O-ring, indicated as in Figure 67, Figure 68 and Figure 69.

When tilting slide valve is pushed forward, HP oil enters from the cylinder bottom, thus to push the piston forward for the mast to tip forward. When the slide valve is pulled backward, HP oil enters from the front end of cylinder body, to push the piston backward, for the mast to tip backward.

INNER MAST LIFTING CYLINDER ADJUSTING SHIM UPPER CROSSBEAM OF INNER MAST Figure 66. Adjustment of Lifting Cylinder

113

Lifting System

8000 YRM 2353

1. NUT M12 X 1.5 2. WASHER 12 3. OIL CUP M10 X 1 4. EAR RING 5. KNUCKLE BEARING GE30ES 6. HOLE SPRING BLOCK D47 7. BOLT M12 X 1.5 X 40 8. DUST RING D30 X 38 X 5/6.5 9. RETAINER RING 10. SHAFT SEAL Φ30 X Φ40 X 6 11. STEEL-BACKED BEARING Φ30 X Φ34 X 30 12. GUIDE SLEEVE 13. RETAINER RING 14. O-RING 63 X 3.1

15. PISTON ROD 16. O-RING 22 X 2.4 17. SPACER SLEEVE I 18. HOLE SEAL 63 X 53 X 6 19. HOLE SUPPORT RING 20. PISTON 21. COTTER PIN 4 X 40 22. SLOTTED NUT M20 X 2 THICKNESS 20 23. CYLINDER SLEEVE II 24. CYLINDER BODY 25. PIN SHAFT 26. WASHER 10 27. BOLT M10 X 20

Figure 67. Tilting Cylinder (ERP15UX - ERP18UX )

114

8000 YRM 2353

Lifting System

1. NUT M12 X 1.5 2. WASHER 12 3. OIL CUP M10 X 1 4. EAR RING 5. KNUCKLE BEARING GE30ES 6. HOLD SPRING BLOCK D47 7. BOLT M12 X 1.5 X 40 8. DUST RING D32 X 52 X 8/11 9. HOLE SPRING BLOCK D52 10. SHUTTER 11. RETAINER RING 12. SHAFT SEAL Φ32 X Φ48 X 10 13. STEEL-BACKED BEARING Φ32 X Φ36 X 25 14. GUIDE SLEEVE 15. RETAINER RING D70 X Φ61.5 X 1.5

16. O-RING 70 X 5.7 17. PISTON ROD 18. O-RING 38 X 3.5 19. ADJUSTING SLEEVE I 20. HOLE SEAL D70 X 60 X 6 21. RETAINER RING D70 X Φ60 X 2.5 22. HOLE SUPPORT RING D70 X 16 X 2.5 23. PISTON 24. COTTER PIN 5 X 40 25. SLOTTED NUT M22 X 1.5 THICKNESS 22 26. ADJUSTING SLEEVE II 27. CYLINDER BODY 28. PIN SHAFT 29. WASHER 10 30. BOLT M10 X 20

Figure 68. Tilting Cylinder (ERP20UX - ERP25UX )

115

Lifting System

8000 YRM 2353

1. NUT M14 X 1.5 2. WASHER 14 3. OIL CUP M10 X 1 4. EAR RING 5. KNUCKLE BEARING GE30ES 6. HOLE SPRING BLOCK D47 7. BOLT M14 X 1.5 X 40 8. DUST RING D35 X 43 X 5/6 9. RETAINER RING Φ45 X Φ35 X 3 10. SHAFT SEAL 35 X 45 X 6 11. STEEL-BACKED BEARING Φ35 X Φ39 X 35 12. GUIDE SLEEVE 13. RETAINER RING Φ80 X Φ71.5 X 1.5 14. O-RING 80 X 5.7

15. PISTON ROD 16. O-RING 41 X 3.5 17. ADJUSTING SLEEVE I 18. HOLE SEAL D80 X 70 X 6 19. RETAINER RING Φ80 X Φ70 X 2.5 20. HOLE SUPPORT RING D80 X 16 X 2.5 21. PISTON 80 22. COTTER PIN 5 X 45 23. SLOTTED NUT 27 X 2 X 27 24. ADJUSTING SLEEVE II 25. CYLINDER BODY 26. PIN SHAFT 27. WASHER 10 28. BOLT M10 X 20

Figure 69. Tilting Cylinder (ERP30UX - ERP35UX )

116

8000 YRM 2353

INSTALLATION OF MAST 1.

2.

3.

4.

Lifting System 5.

Set the part 6 the tilting cylinder liner into 4 the mast tilting cylinder support.

6.

Pass the part 8 the tilting cylinder pin shaft (in the place of vehicle chassis) through the tilting cylinder and its support installation holes.

Pass the part 5 the tilting cylinder pin shaft (in the place of mast) through the tilting cylinder and its support installation holes, and tighten the fastener (bolt, spring washer, and flat washer).

7.

Tighten the part 9 the tilting cylinder pin shaft fasteners (bolt and spring washer).

Connect the part 11 the multi-way valve – speed limit valve hose.

8.

Set the part 12 the return oil pipe on the tee of the mast, and fix the return oil pipe fast using part 13 the return oil pipe collar clamp, and the assembly of the mast is now completed.

Set the part 6 the tilting cylinder liner on the part 7 of vehicle chassis tilting cylinder support. Refer to Figure 70.

The supporting seat of 3 masts are placed on the mounting position of the upper mast of 10 drive axle. After the left and right clearance are adjusted, 2 supporting cover is also be covered, and the 1 support cover fastener (bolt, spring washer, flat washer) is tightened (one for the left, and one for the right).

117

Lifting System

8000 YRM 2353

NOTE: DURING INSTALLATION OF MAST, SAFE HOISTING OF MAST SHALL BE ENSURED, AND THE INSTALLERS MUST BE RELEVANTLY TRAINED. 1. SUPPORT COVER FASTENERS (BOLTS, SPRING WASHER, FLAT WASHER) 2. SUPPORT COVER 3. MAST SUPPORT BASE 4. MAST TILTING CYLINDER SUPPORT 5. TILTING CYLINDER PIN SHAFT (IN THE PLACE OF MAST) 6. TILTING CYLINDER 7. FRAME TILTING CYLINDER SUPPORT

8. TILTING CYLINDER PIN SHAFT (IN THE PLACE OF FRAME) 9. TILTING CYLINDER PIN SHAFT FASTENERS (BOLT, SPRING WASHER) 10. MOUNTING POSITION OF THE UPPER MAST OF DRIVE AXLE 11. MULTI-WAY VALVE - SPEED LIMIT VALVE HOSE 12. RETURN OIL PIPE 13. RETURN OIL PIPE COLLAR CLAMP

Figure 70. Mast

118

8000 YRM 2353

DISASSEMBLY OF MAST 1.

Dismount the part 11 the multi-way valve –speed limit valve hose. Refer to Figure 70.

2.

Detach the part 13 the return oil pipe collar clamp.

3.

Demount the part 12 the return oil pipe.

4.

Remove the fasteners (bolt, spring washer, and flat washer) on the part 5 the tilting cylinder pin shaft (in the place of mast), and then detach the part 5 the tilting cylinder pin shaft (in the place of mast).

5.

Loosen and remove the part 1 the support cover fasteners 2 (bolt, spring washer, and flat washer) and at the same time demount the part 9 the support covers (one for left and right, respectively).

6.

Hoist out the mast and complete the disassembly of mast.

Lifting System On carriages where there is no backrest, the lateral fork stops are made of two metal plates (one for each side of the carriage) whose part number is available in parts manual, fixed with two bolts. See Figure 71. Before operating the lift truck, make sure that the backrest or the lateral fork stop plates are always present and the bolts are properly tightened. Under no circumstances should the truck be used without these stops.

NOTE: Safe hoisting of mast shall be ensured, during disassembly and assembly of mast, and the installers must be trained relevantly.

Figure 71. Laterl Fork Stop

WARNING The backrest installed on the carriage has the function of lateral fork stop and must not be removed.

119

Daily Checks and Maintenance

8000 YRM 2353

Daily Checks and Maintenance A daily inspection of the forklift truck may avoid truck failure and inability to reach its due service life. The number of hours listed in this section and Regular Maintenance Timetable, based on 8-hour work a day and 200-hours a month.

Detailed records should be kept after inspection, and the records should be retained for 3 years.

• •

Only trained, qualified personnel can maintain and repair forklift truck.

Daily and monthly inspections and maintenance may be accomplished by operators.

PERIODIC MAINTENANCE REQUIREMENTS 1. Ensure only authentic parts and components are used.

2. Ensure only authentic or designated oils and greases are used.

3. Clean up the oil filler port and grease nipple using brush or cleaning cloth prior to oil or grease addition.

4. The truck should be parked on a level ground for inspection of oil level and oil addition.

5. Preventive Maintenance and service should be regularly performed, and attention should be paid not to injure yourself.

6. When inspecting or repairing suspended forks or attachments, the proper support brace should be used to support the forks or the attachment, to prevent downslide of fork and inner mast.

7. It should be reported to the managerial personnel if any damage or failure is found. It is prohibited to use this forklift truck before it is repaired.

PERIODIC MAINTENANCE ITEMS Inspection for Leakage of Hydraulic Oil and Transmission Case Oil 1. Inspect whether or not oil leaks exist within the joints of hydraulic drive system.

2. Check whether there are impurities in the fuel.

WARNING •

120

After tires and rims have been assembled, all the bolts and nuts shall be tightened to the specified torques. This must occur before air is added to the tires. Tire pressure must not exceed the specified pressure.

•

When an air compressor is used, the pressure should be properly adjusted. As the maximum output of pressure for an air compressor is very high, it may cause severe accident if it is improperly adjusted.

Inspection of Wheel Hub Nut Torque 1. Inspect whether or not the hub nut torque is correct.

2. All the wheel hub nuts shall be tightened to 150-175 N•m (110-129 lbf ft) for 1.5-1.8T trucks, 480-560 N•m (354-413 lbf ft) for 2-3.5T trucks.

WARNING •

•

When wheel hub nut is removed, never remove a separate wheel hub nut by mistake.

It is very dangerous for wheel hub nut to be torqued improperly. In case, the wheel may come off, leading to turnover of the truck.

Inspection of Overhead Guard The overhead guard plays a protective function, and it should be ensured that it is firmly mounted and all the structural components are secure and not damaged.

Inspection of Brake Fluid Level Inspect the level of brake fluid reservoir. The fluid level should be between the two scale marks. Ensure dust or water do not enter into the fluid reservoir during addition.

Level of Hydraulic Oil Inspection Inspect the hydraulic oil level using the dipstick.

Remove the dipstick and wipe it off. Re-insert it and then pull it out to see whether or not the oil level is located between the high and low two scale lines.

NOTE: Power supply shall be turned OFF. The forks should be dropped to the ground and the forklift truck should be parked on a level surface when oil level is inspected.

Inspection of Backrest Inspect whether or not the mounted bolts for backrest are secure. They should be tightened when required.

Fork and Fork Positioning Pin Inspection Inspect the mounting condition of positioning pin and whether or not the forks are distorted or cracked.

8000 YRM 2353

Daily Checks and Maintenance Inspection for Operation of Horn Button Press the horn button to ensure whether or not the horn sounds.

PERIODIC MAINTENANCE Tire Front Wheel

Front Headlight and Front Combination Light Inspection Inspect whether or not the lamp screens are clean or damaged.

Seat Adjustment Ensure that the seat is at a proper position. To adjust, pull the adjusting handle rightward.

Ensure the seat position where it is easy for foot and hand operations. After adjustment, ensure that it is reliably locked up.

Inspection of Direction Control Lever Inspect whether or not direction control lever is operational.

Inspection of Control Levers Inspect whether or not operating levers (Lifting, Tilting, and Attachments) are operational.

Inspection for Operation of Parking Brake Ensure that the parking brake is safe and reliable, after the parking brake lever is activated.

Preparation prior to Start Before turning ON the power supply, ensure that the directional control lever is located in NEUTRAL, and parking brake is activated.

Instruments Hourmeter, trouble meter and running speedometer enable operators to understand the condition of truck during operation.

Lamplights Turn on the light switch, and confirm that corresponding lights are all under normal conditions.

Inspection of Turn Signal Operate the turn signal handle to ensure the normal work of turn signal.

1.

Park the truck on a firm and hard pavement and turn OFF the engine.

2.

Pull up the parking brake handle and block wheels using a wedge block. Place the jack under the truck body.

3.

Jack up the truck and keep the tire on the ground.

Loosen the nuts for wheel hub, but don’t remove the tire.

4.

Continue jacking up the truck until the tire is off the ground. Take off the nuts and remove the tire.

5.

The installation of the tire is opposite to the disassembly sequence. The wheel hub nuts should be tightened up in a diagonal order.

Rear Wheel 1.

The procedure is the same as the repair and replacement methods for the front wheel, except that the jack should be placed under the counter weight.

Forks The identification of a fork describes how the fork is connected to the carriage. These lift trucks have hook forks.

Remove WARNING DO NOT try to move a fork without a lifting device.

Each hook fork for these lift trucks can weigh 45-115 kg (99-253 lbf ft).

NOTE: Forks are to be replaced only in sets and not individually.

NOTE: If lift truck is equipped with a fork positioner attachment, perform Step 1 and Step 2. If lift truck is not equipped with a fork positioner attachment, go to Step 2.

121

Daily Checks and Maintenance 1.

Lower carriage and remove four capscrews from inner fork carriers. Remove inner fork carriers from integral sideshift carriage. See Figure 72.

2.

A fork can be removed from the carriage for replacement of the fork or other maintenance.

Slide a hook fork to the fork removal notch on the carriage. See Figure 73.

8000 YRM 2353

Lower the fork onto blocks so that the bottom hook of the fork moves through the fork removal notch. SeeFigure 73.

Lower the carriage further so that the top hook of the fork is disengaged from the top carriage bar.

Move the carriage away from the fork, or use a lifting device to move the fork away from the carriage.

1. CARRIAGE BARS 2. HOOK FORK 3. BLOCKS Figure 73. Remove a Hook Fork

Inspect WARNING DO NOT try to correct for tip alignment by bending the forks or adding shims. Replace bent forks.

1. FORK 2. FORK REMOVAL NOTCH 3. INNER SLIDE FRAME Figure 72. Carriage and Forks

Never repair damaged forks by heating or welding.

Forks are made of special steel using special procedures. Replace damaged fork. Forks are to be replaced only in sets and not individually.

1.

Inspect the forks for cracks and wear. Check that the fork tips are aligned as shown in Figure 74.

Check that the bottom of the fork is not worn (Item 4 in Figure 74).

CAUTION Remove fork latch pins if adding a fork positioner attachment. Damage to forks and other carriage components can occur if fork latch pins are not removed prior to using attachment.

2.

122

Replace any damaged or broken parts that are used to keep the forks locked in position.

8000 YRM 2353 3.

Daily Checks and Maintenance

Inspect fork wear. Ensure heel wear is not more than 10% of original thickness. if fork wear is more than 10%, fork must be replaced. Perform fork wear inspection using a BOL256N1 caliper ruler as follows. See Figure 75. a.

Determine normal thickness of "N" of fork using scale or ruler portion of caliper ruler.

Measurement has to be done on fork shank using caliper ruler.

b.

Position caliper at end of heel internal radius (item 4, Figure 74) with opening corresponding to measured thickness of fork shank in Step a above. (e.g. for N 1.75 use N 1.75 opening).

This is typically the section of fork where wear is greatest. Note that opening distance has been reduced by 10% from nominal thickness.

c.

If fork enters opening, it is mandatory to replace it. DANGER OF BREAKING. Furthermore, a 10% reduction in fork blade thickness results in 20% reduction in operating capacity.

Fork Tip Alignment Length of Forks

3% Dimension

914 mm (36 in.)

27 mm (1.08 in.)

1016 mm (40 in.)

30 mm (1.2 in.)

1067 mm (42 in.)

32 mm (1.26 in.)

1207 mm (47.5 in.)

36 mm (1.42 in.)

1219 mm (48 in.)

37 mm (1.46 in.)

1372 mm (54 in.)

41 mm (1.61 in.)

1524 mm (60 in.)

45 mm (1.81 in.)

1829 mm (72 in.)

55 mm (2.17 in.)

1. TIP ALIGNMENT (MUST BE WITHIN 3% OF FORK LENGTH) 2. CRACKS 3. LATCH DAMAGE 4. HEEL OF FORK (MUST BE 90% OF DIMENSION "X") 5. CARRIAGE 6. LOAD BACKREST EXTENSION 7. MAXIMUM ANGLE 93% 8. FORK REMOVAL NOTCH Figure 74. Fork Check

123

Daily Checks and Maintenance

8000 YRM 2353

Install 1.

Move the fork and carriage so that the top hook on the fork can engage the upper carriage bar.

Raise the carriage to move the lower hook through the fork removal notch. Slide the fork on the carriage so that both upper and lower hooks engage the carriage. Engage the lock pin with a notch in the upper carriage bar.

2.

If lift truck is equipped with a fork positioner attachment, install fork carriers using four capscrews. Tighten capscrews to 35 N•m (25.8 lbf ft).

PERIODIC MAINTENANCE TABLES This timetable is set based on the standard working time and operating conditions. Perform the maintenance at regular intervals (C = Check, R = Replace). See Table 13 through Table 19.

Figure 75. Fork Wear Table 13. Wheel

Item

Inspecting Item Charged pressure

Tool Tire Gauge

Crack or damage Tire

Monthly (200 Hours)

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

R

R

Ground touchdown wearing condition Abnormal wear condition

Depth Gauge

C

Whether or not nail, stone, or other foreign substance present on tire Tire Installation

Whether or not nuts are loosened to be inspected Inspect for damage

Wheel Rim Inspect condition of wheel Wheel Spoke rim, rim spoke, and Disc wheel Axle Bearing Inspect condition To be wiped up and refilled with lubricating oil

124

Detection Hammer

SemiQuarterly annually (600 (1200 Hours Hours)

Daily (8 Hours)

Annually (2400 Hours)

8000 YRM 2353

Daily Checks and Maintenance

Table 13. Wheel (Continued)

Item

Inspecting Item

Axle

Distortion, crack, and damage condition of axle body to be inspected

Tool

Daily (8 Hours)

Monthly (200 Hours) C

SemiQuarterly annually (600 (1200 Hours Hours) C

C

Annually (2400 Hours) C

Table 14. Steering System

Item

Inspecting Item

Tool

Daily (8 Hours)

Monthly (200 Hours)

SemiQuarterly annually (600 (1200 Hours Hours)

Annually (2400 Hours)

Steering Wheel

Inspect clearance

C

C

C

C

C

Inspect operating condition

C

C

C

C

C

Steering Gear

Inspect mounting bolts

C

C

C

C

Inspect whether or not the king pin is loosened or damaged

C

C

C

C

Bend, distortion, crack, or damage condition to be inspected

C

C

C

C

Installation condition to be inspected

C

C

C

C

Steering Knuckle of Rear Axle

Steering Cylinder

Operating condition to be inspected

C

C

C

C

C

Whether or not leaks exists to be inspected

C

C

C

C

C

C

C

C

C

Whether or not loosening exists during installation to be inspected Table 15. Brake System

Item

Inspection Item

Tool

Idle stroke Brake Pedal

Pedal stroke

Diving Ruler

SemiQuarterly annually (600 (1200 Hours Hours)

Daily (8 Hours)

Monthly (200 Hours)

Annually (2400 Hours)

C

C

C

C

C

C

C

C

C

C

125

Daily Checks and Maintenance

8000 YRM 2353

Table 15. Brake System (Continued)

Item

Brake Pedal (continued) Parking Brake Lever Rod, and Guy Cable, etc.

Brake Lines

SemiQuarterly annually (600 (1200 Hours Hours)

Daily (8 Hours)

Monthly (200 Hours)

Operating condition

C

C

C

C

C

Whether or not air present in brake line

C

C

C

C

C

Whether or not brake is safe and reliable

C

C

C

C

C

Control performance

C

C

C

C

C

Control performance

C

C

C

C

C

Whether or not connection is loosened

C

C

C

C

C

Damage, leakage, and cracks

C

C

C

C

Inspect connecting and clamping parts

C

C

C

C

Leakage condition

C

C

C

C

C

C

R

R

Inspection Item

Tool

Oil level to be inspected for oil replacement

C

Annually (2400 Hours)

Inspect master cylinder and Brake Master wheel cylinder condition Cylinder and Wear or damage condition Wheel of master cylinder and Cylinder wheel cylinder

C

Master cylinder and wheel cylinder leakage and damage inspection

R

Whether or not mounting parts of brake drum are loosened Brake Drum and Brake Shoe

126

C

Detection Hammer

C

C

C

C

Wearing condition of friction Vernier plate Calipers

C

Condition of brake show action

C

Whether or not fixed pin is rusted

C

Damage condition of return Ruler spring

C

8000 YRM 2353

Daily Checks and Maintenance

Table 15. Brake System (Continued)

Item

Brake Drum and Brake Shoe (continued)

Inspection Item

Tool

Daily (8 Hours)

Monthly (200 Hours)

SemiQuarterly annually (600 (1200 Hours Hours)

Annually (2400 Hours)

Whether or not operating time interval of automatic regulating device is proper to be inspected

C

Wear and injury condition of brake drum

C

Inspect bottom plate distortion

C

Brake Whether or not cracked Bottom Plate Inspect for loosening exists during installation

C C

Table 16. Lifting System

Item

Inspection Item Damage, distortion, and wear condition of forks

Fork

Mast Fork Carriage

Tool

Daily (8 Hours)

Monthly (200 Hours)

C

C

Damage and wear condition of positioning pin

SemiQuarterly annually (600 (1200 Hours Hours)

Annually (2400 Hours)

C

C

C

C

C

C

Inspect for crack and wear condition of welded parts

C

C

C

C

Whether or not welded place on inside mast/ outside mast and cross beam is cracked or damaged

C

C

C

C

Whether or not welded place of tilting cylinder bracket and mast is under poor connecting condition, cracks, or damaged

C

C

C

C

127

Daily Checks and Maintenance

8000 YRM 2353

Table 16. Lifting System (Continued)

Item

Mast Fork Carriage (continued)

Lift Chain

Attachments

128

Inspection Item

Tool

Daily (8 Hours)

Monthly (200 Hours)

SemiQuarterly annually (600 (1200 Hours Hours)

Annually (2400 Hours)

Whether or not welding of inside/outside mast is under poor connecting condition, cracked or damaged

C

C

C

C

Whether or not welding of forks is under poor connecting condition, cracked or damaged

C

C

C

C

Whether or not roller is loosened

C

C

C

C

Wear and damage condition of bearing brush for mast

C

Whether or not bolts for support cover of mast is loosened

C

C

C

Whether or not bolts for bottom of lifting cylinder, bolts for head of piston rod, u-bolts, and bolts for guide rail of walking beam are loosened

C

C

C

Crack and damage condition of roller and roller shaft

C

C

C

C

C

C

C

C

Oil to be added to chain

C

C

C

C

Riveted pin and loosening condition

C

C

C

C

Whether or not condition is normal to be inspected

C

C

C

C

Tensioning condition, whether or not distorted, damaged, or rusting of chain to be inspected

C

8000 YRM 2353

Daily Checks and Maintenance

Table 16. Lifting System (Continued)

Item

Lifting Cylinder

Monthly (200 Hours)

C

C

C

C

C

Operating condition

C

C

C

C

C

Leakage condition

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

Inspection Item

Tool

Whether or not piston rod, piston rod thread, and connection are loosened, as well as distortion and damage condition

Detection Hammer

Wear and damage condition of pin and cylinder steel-backed bearing

Hydraulic Pump

SemiQuarterly annually (600 (1200 Hours Hours)

Daily (8 Hours)

Whether or not oil leak or noise exists with hydraulic pump

C

Wearing condition of driving gear for hydraulic pump

Annually (2400 Hours)

Table 17. Hydraulic System

Item

Inspection Item Oil quantity to be inspected, or oil to be replaced

Tool

Daily (8 Hours)

Monthly (200 Hours)

C

C

SemiQuarterly annually (600 (1200 Hours Hours) C

C

C

C

C

Foreign substance to be removed

C

C

Return oil filter to be replaced

R

R

Hydraulic Oil Suction oil filter core to be Tank cleaned up

Return Oil Filter

Annually (2400 Hours)

Whether or not connection Control Valve is loosened Rod Operating condition

C

C

C

C

C

C

C

C

C

C

129

Daily Checks and Maintenance

8000 YRM 2353

Table 17. Hydraulic System (Continued)

Item

Inspection Item

Tool

Oil leakage

Monthly (200 Hours)

C

C

C

C

C

C

C

C

C

C

C

C

C

Operating condition of safety valve and tilting autoMain Control locking valve Valve Safety valve pressure to be Oil measured Pressure Gauge Leakage, loosening, crack, distortion, or damage Control Valve condition Lines Line to be replaced

SemiQuarterly annually (600 (1200 Hours Hours)

Daily (8 Hours)

C

C

C

Annually (2400 Hours)

R 1-2 Years Table 18. Electrical System

Item

Inspection Item

DC Motor

Inspect brushes

Battery

Refer to Maintenance manual

Electric Controller

Cleanliness of electric controller box, electric controller

Connection

Inspect connection for battery, electric controller, and motor connecting lines are firm and not damaged

CBU Insulation

Insulation resistance of motor, electric controller, and battery to body not be lower than 0.3 MΩ

130

Tool

Daily (8 Hours)

Monthly (200 Hours) C

500 V Megohm meter

SemiQuarterly annually (600 (1200 Hours Hours)

Annually (2400 Hours)

C

C

C

C

C

C

C

C

C

8000 YRM 2353

Daily Checks and Maintenance

Table 19. Seat, Frame, and Oil

Item

Inspection Item

Seat

Whether or not bolts are damaged or loosened to be inspected

Tool

Daily (8 Hours)

Monthly (200 Hours)

SemiQuarterly annually (600 (1200 Hours Hours) C

Whether or not truck frame and crossbeam are damaged or cracked Frame

Whether or not rivets or bolts are loosened

Detection Hammer

C C

C

C

C

Comprehensive inspection

•

C

C

Repaired place to be inspected, if required Lubricating Lubricating condition of Grease to be underpan to be inspected Added or Oil after cleaning to be Oil in tank to be inspected Replaced

Annually (2400 Hours)

C C

Grease Gun

When oil is different from that specified for this truck, its replacement cycle cannot be the same as that specified in this Manual. In this situation, the time for replacement should be shortened by ½ or 1/4 compared with the time specified in this Manual.

C

C

C

C

C

C •

Though high-viscosity oil has a wide operating temperature range, frequent replacement is still required. The additive will slowly deteriorate, viscosity will be lowered, and it will damage the hydraulic system severely at the time of high temperature.

131

General (CATL-based Lithium-ion Battery)

8000 YRM 2353

General (CATL-based Lithium-ion Battery) DESCRIPTION OF BATTERIES A lithium-ion battery converts chemical energy into electrical energy. Chemical changes within the battery provide the electrical energy. The battery is discharged when the chemical reaction has occurred. When the battery no longer provides its rated voltage and

current, a reverse chemical action must occur so the battery can be used again. The batteries described in this section can be charged again by an outside electric source, so there is a reverse chemical action.

BATTERY TYPES AND OPTIONS

Table 20. Types Battery Type 51.2V 250AH

51.2V 375AH

51.2V 500AH

77.2V 250AH

77.2V 375AH

77.2V 500AH

Table 21. Options Battery Option Working Temperature

Battery Telemetry

Comments

-25°C (-13°F) - 45°C (113°F)

For 375AH and 500AH battery

-10°C (14°F)-45°C (113°F)

For 250AH battery

Battery Management System (BMS) 4G Monitor Vehicle Allocation Matrix (VAM)

Side Charging Door

Standard

Battery Power Key Switch

Standard

Blue Battery Box

Optional

Lifting Tool

Optional

Battery Displayer

Optional

132

Only for ERPUX trucks

8000 YRM 2353

General (CATL-based Lithium-ion Battery)

BATTERY WORKING ENVIRONMENT TEMPERATURE Table 22. Battery Working Environment Temperature Battery Condition

Environment Temperature

Charging

0°C (32°F)-45°C (113°F)

Discharge (For 375AH and 500AH battery)

-25°C (-13°F)-45°C (113°F)

Discharge (For 250AH batter)

-10°C (14°F)-45°C (113°F)

GLOSSARY AND ABBREVIATIONS Table 23. Glossary Terms

Explanation

Battery Cell

The smallest electrochemical energy storage unit consisting of positive electrode, negative electrode, electrolyte, separator, and housing.

Battery Module

An intermediate energy storage unit, which is placed in a mechanical electrical unit. The module is a combination of several cells and circuit devices (for monitoring and protection circuits, electric, and communication ports).

Battery Pack

A power supply system consisting of several battery modules, circuit devices (for protecting circuits, battery management system, electric, and communication ports) and thermal management devices, and so on, to provide energy.

Nominal Voltage

Indicates or identifies an appropriate voltage approximation for a battery.

Nominal Capacity

At the beginning of life (BOL), the minimum capacity provided by the battery when it is fully charged under the specified conditions to discharge at a rate of 1C (Crate).

Capacity

The amount of power that a fully-charged battery can provide under the specified conditions. It is usually indicated by AH.

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Table 24. Abbreviations

134

Abbreviation

Designation

BMS

Battery Management System

VAM

Vehicle Allocation Matrix

BOL

Begin of Life

MSD

Manual Service Disconnect

CAN

Controller Area Network

CMC

Cell Manager Circuit

SOC

State of Charge

SOH

State of Health

DC

Direct Current

OBC

On-board Charger

DCC

Digital Command Control

AC

Alternating Current

CT

Current Transducer

FPC

Flexible Printed Circuit

CSC

Cell Supervision Circuit

PC

Personal Computer

8000 YRM 2353

Warnings and Cautions (CATL-based Lithium-ion Battery)

Warnings and Cautions (CATL-based Lithium-ion Battery) SAFETY

Hazard Pictograms

1. Unauthorized person is strictly prohibited from opening the battery box for repair.

2. DO NOT flush the battery with water.

3. DO NOT disassemble, drop or burn the battery module.

4. Wear insulation gloves, boots and protective glasses before repairing battery. Do not wear metal objects, such as watch.

5. If BMS needs to be powered on for detection, all contactors must be forcedly shut down (MSD)

by PC. 6. DO NOT touch the positive and negative poles and copper bars simultaneously by hands.

7. When opening the battery cover for repair, pay attention not to short-circuit the positive and negative copper bars. The tools must have insulation treatment.

DO NOT touch the positive and negative poles 8. and copper bars simultaneously by both hands.

9. If a fire occurs during discharging, evacuate immediately and then: (1) In case of wire harness fire, use carbon dioxide or dry powder fire extinguisher.

(2) In case of battery fire, use high-pressure water gun to extinguish fire.

10. If a fire occurs during charging, turn off the charger power button immediately before extinguishing.

11. If the battery suffers from water, fire, impact or fall, it must be inspected by professional person before it can be turned on and used.

12. The charger must meet the local standard and be approved by the battery manufacturer.

HAZARDOUS OVERVIEW Table 25. Hazardous Overview CAS-No/EINECS NO. N/A

INCI CTFA-Description Lithium ion polymer rechargeable battery series.

The product is classified and labeled according to Regulation (EC) NO. 1272/2008.

Figure 76. Hazard Pictograms

Signal Word Danger

Hazard Statements H314 Causes severe skin burns and eye injuries.

H317 May cause an allergic skin reaction.

Precautionary Statements P101 If medical advice is needed, have the product container or label at hand.

P102 Keep out of reach of children.

P103 Read label before use.

P260 DO NOT breathe dust/fume/gas/mist/vapors/ spray.

P303+P361+P353 IF ON SKIN (or hair): Take off all contaminated clothing immediately. Rinse skin with water/ take a shower.

P305+P351+P338 IF IN EYES: Rinse cautiously with water for several minutes. Remove contact lenses, if contact lenses are worn and can be easily removed.

Continue rinsing.

P310 Call a detox center/doctor immediately.

P405 Storage must be locked.

P501 Dispose of contents/container in accordance with local/regional/national/international regulations.

Other Hazards Results of PBT and vPvB assessment PBT: N/A vPvB: N/A

135

Warnings and Cautions (CATL-based Lithium-ion Battery)

8000 YRM 2353

COMPOSITION AND INGREDIENT INFORMATION Table 26. Composition and Ingredient Information Material or Ingredient

PEL (OSHA)

TLV (ACGIH)

Approximate Wt%

Graphite

CAS# 7782-42-5 EC#231-955-3

None established

7-25

Lithium iron Phosphate

CAS# 15365-14-7 EC# 476-700-9

None established

15-40

Hexafluoropropylene-vinylidene fluoride Copolymer

CAS# 9011-17-0 EC# 618-470-6

3-15

Hazardous, H411 Lithium Hexafluorophosphate

CAS# 21324-40-3 EC#235-362-0

0-5

Acute Tox. 3, H311

Skin Corr. 1B, H314

Acute Tox. 4, H302 Acetylene Black

CAS# 1333-86-4 EC#215-609-9

Diethyl Carbonate

CAS# 105-58-8 EC#203-311-1

None established

0-2 0-15

Flam. Liq. 3, H226 Dimethyl Carbonate

0-15 CAS# 616-38-6 EC# 210-478-4

Inflammable, H225

Ethyl Methyl Carbonate

0-15 CAS# 623-53-0 EC# 433-480-9

136

Inflammable, H225

8000 YRM 2353

Warnings and Cautions (CATL-based Lithium-ion Battery)

Table 26. Composition and Ingredient Information (Continued) Material or Ingredient

PEL (OSHA)

TLV (ACGIH)

Propylene Carbonate

0-15 CAS# 108-32-7 EC#203-572-1

Eye Irrit. 2, H319

Ethylene Carbonate

0-15 CAS# 96-49-1 EC#202-510-0

HAZARD IDENTIFICATION The materials within the battery may represent a hazard if the structural integrity of the battery is compromised. Damage to the batteries will result in the risk of fire or explosion, which could release dangerous hydrogen fluoride gas. Exposure to the ingredients contained within or their combustion products, could be harmful.

Risk of exposure exists if the battery cell is mechanically, thermally, or electrically damaged and the enclosure is compromised. If this occurs, exposure to electrolyte solutions contained within the battery cell may occur by inhalation, eye contact, skin contact, and ingestion.

The following condition shall be avoided:

•

DO NOT disassemble, puncture, crush, or modify.

DO NOT expose to heat in excess of 60°C (140°F) or incinerate.

DO NOT short circuit.

•

DO NOT expose to water.

• •

Approximate Wt%

Recycle the battery per the appropriate local regulation.

FIRE FIGHTING MEASURES Hazard Analysis (electrical shock, fire, explode, population) There was no electrical shock Hazard for a single cell or a battery module with voltage less than 50V DC (the safety voltage). But if the voltage of pack was greater than 50V DC, the electrical shock shall be avoided.

During the shipment or testing process for LIB Pack or Module, there is danger factors like drop, crush,

Eye Irrit. 2, H319 broken, metal short circuit and liquid immersion, which would lead to the hazard like electrical shock or fire. If pack was in hermetic space, there is a risk of gas exploding hazard; if the pack is well ventilated or in open space, there is no risk of explode Hazard.

Released liquid from a damaged battery or water used in firefighting can pose a health hazard and environment pollution.

Material Preparation and Personnel Trainings 1. Water-based Sprayer Fire Extinguish: 1 set of 9 liter (2 gal) or 2 sets of 6 (1.3 gal) liter water spray fire extinguishers per each 500KWh LIB pack or Modules. The water based spray fire extinguisher could be used for fire type ABCD=solid (A), flash point>60°C (140°F) liquid (B), gas ©), <36Kv electrical (E) fire.

2. Water Protection Sets: raincoat, galoshes, rubber gloves. Plastic rollers. And Rags.

3. PPE: breathing mask, safety glass, face mask, gloves for high temperature.

4. Smoke Extraction Tools: one wall exhaust fan every 20 meters or mobile exhaust fan in rooms.

DO NOT block vents in the lift truck.

5. Gases Explosion-proof Tools: DO NOT charge or service batteries in enclosed spaces.

Some devices like high or low temperature ovens must be sealed. There is one copper foil with the diameter 200mm and thickness 8um as the safety vent. One fan is required every 20m (787 in.) on the wall of the room, and the fan flow rate is at least 5,000 m³ per hour.

6. Neutralized Material: prepare 10kg Ca(OH)2 powder per 500KWh LIB pack or modules. Use Ca(OH)2 to neutralize the Ph of released electrolyte. Electrolyte can react with water to create HF.

137

Warnings and Cautions (CATL-based Lithium-ion Battery) 7. Voltage Measure: Multimeter. Physically block the current measure function. Otherwise, instrument explosion may occur.

8. Personnel Training: a. Turn on fans or portable fans to exhaust smoke. b. Wear the water protection sets, then use water spray fire extinguishers and wipe dry with a cloth or with rubber gloves. Insulate the battery by plastic film. c. Neutralized by Ca(OH)2 or NaOH for released electrolyte. d. Use multimeter to measure voltage. Pay special attention to use the gear correctly (physically close the current block) to prevent instrument explosion.

Fire Extinguisher Instruction 1.

2.

Activate the building fire alarm and evacuate the building if smoking or burning is detected.

Wear personal protection wear (PPE), including a face shield, a self-contained breathing apparatus, and water- and acid-resistant clothing, boots, and gloves.

Unusual Fire and Explosion Hazards Exposing battery cell to excessive heat, fire, or over voltage condition may cause a leak, fire, hazardous vapors, and hazardous decomposition products.

Damaged or opened cells or batteries can result in rapid heating and the release of flammable vapors and potentially dangerous gases. These vapors and gasses, which may be heavier than air, could travel along the ground or be moved by ventilation to an ignition source.

ACCIDENTAL RELEASE MEASURES In the event of an accidental release of vapors or gasses from the battery, or in the event of a fire or explosion, take the following measures: •

Evacuate the area.

•

Trained first responders should wear protective clothing and safety glasses.

Using a shovel or other tool, cover battery with sand or vermiculite.

Dispose of battery in accordance with Disposal Considerations listed below.

• •

LEAK EMERGENCY MEASURES

3.

Turn off the truck, the battery, and any other electrical devices on the truck

•

4.

Use a fire extinguishers rated for solid material fires. The recommended extinguisher sequence is water or mist water, sand, fire extinguisher blanket, carbon dioxide, powder.

•

5.

Open air vents and turn on exhaust fans to exhaust the smoke.

6.

Once the fire is out, dry and neutralize the area.

Dry by fans and neutralize by calcium hydroxide powder.

138

8000 YRM 2353

On Hand: Put the material into suitable containers and call local fire police or department.

In Water: Low electrical shock hazard when battery or module is in water. Hydrogen is generated when electrolyzing water, and ventilation must be maintained to prevent the accumulation of hydrogen and the explosion of hydrogen in confined spaces. If possible, remove the battery or module from the water and report to the local police.

HANDLING AND STORAGE One of the major Hazards when transporting batteries and battery-powered equipment is the short- circuit of the battery caused by the battery terminals coming into contact with other batteries, metal objects, or conductive surfaces. Therefore, packed batteries or cells must be separated in a proper way to prevent short circuits and broken electrode. They must be packed in a strong outer packaging or be contained in equipment.

8000 YRM 2353

Warnings and Cautions (CATL-based Lithium-ion Battery)

Handling

FIRST AID MEASURES

DO NOT expose the battery to excessive physical shock or vibration. Short-circuiting should be avoided; although an accidental short-circuiting in a few seconds will not seriously affect the battery. Prolonged short circuits will cause the battery to rapidly lose energy, could generate enough heat to burn the outer casing. Sources of short circuits include jumbled batteries in bulk containers, coins, metal jewelry, metal covered tables, or metal belts used for assembly of batteries in devices. To minimize Hazard of shortcircuiting, the protective case supplied with the battery should be used to cover the terminals when transporting or storing the battery. DO NOT disassemble or deform the battery. Should an individual cell within a battery become ruptured, DO NOT allow contact with water. When operators handle the battery with voltage more than 50v, they must wear the insulation protection PPE.

WARNING Use the battery under normal conditions, and make sure that the battery is hermetically sealed.

In the event of the following accidents, take the first aid measures as below: •

•

•

Storage The lithium ion battery’s charging capacity should be between 25% and 75% of full charge when stored for a long period of time. Stored in a cool, dry, and well ventilated area. Elevated temperatures can result in loss of battery performance, leakage, or rust. DO NOT expose the battery to open flames.

•

•

Ingestion: Swallowing a battery can be harmful.

Contents of an open battery may cause serious chemical burns of mouth, esophagus, and gastrointestinal tract. If battery or open battery is ingested, DO NOT induce vomiting or eat food or drink. Seek medical attention immediately.

Inhalation: Contents of an open battery can cause respiratory irritation. Inhalation of vapors may cause irritation of the upper respiratory tract and lungs. Provide fresh air and seek medical attention.

Skin Absorption: Ethylene carbonate, diethyl carbonate and dimethyl carbonate may be absorbed through the skin causing localized inflammation.

Skin Contact: Contents of an open battery can cause skin irritation and/or chemical burns.

Remove contaminated clothing and wash skin with soap and water. If a chemical burn occurs or if irritation persists, seek medical attention.

Eye Contact: Contents of an open battery can cause severe irritation and chemical burns.

Immediately flush eyes thoroughly with water for at least 15 minutes, lifting upper and lower lids, until no chemical remains. Seek medical attention immediately.

HANDLING AND STORAGE Table 27. Handling and Storage Handling

DO NOT expose battery or cell to extreme temperatures or fire. DO NOT disassembly, crush, or puncture battery. DO NOT overcharge or over discharge the battery. DO NOT mix batteries of varying types or sizes. DO NOT connect positive and negative terminals or place the batteries on conductive metal.

Storage

Insulate positive and negative terminals to avoid short circuit and ensure sufficient clearance between batteries and other surfaces. Store in a dry, cool and well ventilated area and avoid fire, heat. Elevated temperatures can result in reduced battery life and venting of flammable liquid and gases. Keep batteries away from strong oxidizer and acids.

139

Warnings and Cautions (CATL-based Lithium-ion Battery)

8000 YRM 2353

EXPOSURE CONTROLS AND PERSONAL PROTECTION Table 28. Exposure Controls and Personal Protection Engineering Control

Keep away from heat and open flame. Stored in a cool dry place.

Respiratory Protection

Use a self-contained full face respiratory mask.

Eye Protection Wear safety goggles if handling a ruptured or leaking battery cell.

Hand Protection

Wear viton rubber gloves if handling a ruptured or leaking battery cell.

Skin Protection

Wear rubber apron and viton rubber gloved if handling a ruptured or leaking battery cell.

PHYSICAL AND CHEMICAL PROPERTIES Table 29. Physical and Chemical Properties Physical state

Solid

Color

White

Odor

Odorless

STABILITY AND REACTIVITY Table 30. Stability and Reactivity Stability

Stable under the conditions described in Handling and Storage.

Conditions to Avoid

Temperature that is over 70°C (158°F). Incineration, deformation, mutilation, crush, piercing, short circuit, overcharge, or disassembly. Exposure to humid conditions over a long period.

Hazardous Combustible vapors may be released if exposed to fire.

Decomposition Hydrogen fluoride gas may be present in combustion products.

Products Toxic Fumes may form peroxides.

Possibility of Hazardous Reactions

Hydrogen fluoride gas may be produced in reaction to water.

TOXICOLOGICAL INFORMATION Table 31. Toxicological Information Signs and Symptoms

None, unless battery ruptures. In the event of exposure to internal contents, vapour fumes may be very irritating to the eyes and skin.

Inhalation

Lung irritant.

Skin contact

Skin irritant.

Eye contact

Eye irritant

Ingestion

Poisoning if swallowed.

140

8000 YRM 2353

Warnings and Cautions (CATL-based Lithium-ion Battery)

ECOLOGICAL INFORMATION Table 32. Ecological information Mammalian effects

None at present.

Eco-toxicity

None at present.

Bioaccumulati Slowly bio-degradable. on Potential Environmental None environmental hazards at present.

Fate:

TOXICOLOGICAL INFORMATION Table 33. Toxicological Information Signs and Symptoms

None, unless battery ruptures. In the event of exposure to internal contents, vapour fumes may be very irritating to the eyes and skin.

Inhalation

Lung irritant.

Skin contact

Skin irritant.

Eye contact

Eye irritant

Ingestion

Poisoning if swallowed.

Medical conditions generally aggravated by exposure: In the event of exposure to internal contents, moderate to server irritation, burning and dryness of the skin may occur, and target organs nerves, liver and kidneys.

REGULATORY INFORMATION See ACGIH exposure limits information as noted in Composition and Ingredient Information.

USA This material safety data information meets/exceeds OSHA requirements.

Air Transportation Refer to Civil aviation industry standard MH/ T1020-2018 Lithium Battery Air Transport Standard and IATA DGR and ICAO. This standard is currently used in the international transport and commodity (IMDG CODE).

Ocean Shipping Referring to International Maritime Dangerous Goods Code to transport and According to the requirements of UN NO 3480/3481 to management the goods.

Land Transportation

International

Refer to List of Dangerous Goods(GB12268).

This material safety data information conforms to European Union (UN), the International Standards Organization (ISO) and the International Labor Organization (ILO) and as documental in ANSI (American National Standards Institute) Standard Z400.1-1993.

Avoid Electrical Shock Refer to Standard for Electrical Safety in the Workplace, NFPA-70E.

DISPOSAL CONSIDERATIONS DO NOT incinerate, or subject cells to temperature in excess of 70°C (158°F), and such abuse can result in loss of seal leakage, and/or cell explosion.

Dispose in accordance with local regulations.

141

Warnings and Cautions (CATL-based Lithium-ion Battery)

TRANSPORT INFORMATION Transport Information The lithium ion battery should accord with the International Air Transport Association (IATA DGR 62edition) requirements for transportation. The battery or cell should be packed and signed as following table.

(If the cell’s power less than 20Wh or battery power less than 100Wh and the package according with PI-965 Section, it is not classified as dangerous cargo).

Cells and/or batteries at a SOC of greater than 30% of their rated capacity may only be shipped with the approval of the State of Origin and the State of the Operator under the written conditions established by those authorities.

Packages prepared according to SectionⅡof PI965 must be offered to the operator separately from other cargo and must not be loaded into a unit load device before being offered to the operator.

The lithium core and battery goods required by the packaging specification PI965 and PI968 II shall not be packed in the same outer package as other dangerous goods.

It is NOT allowed to ship the lithium ion battery (UN 3480, PI965 Section IA or IB) or aggregate lithium content (3090, UN PI968 Section IA or IB) with

142

8000 YRM 2353

category 1 explosive material (except ammunition) 1.4, 2.1 flammable gas, flammable liquid, 4.1 3 flammable solid, 5.1 class antioxidant and other dangerous goods.

DO NOT damage or mishandle this package. If package is damaged, batteries must be quarantined, inspected, and repacked. Cells and batteries identified by the manufacturer as being defective for safety reasons, or that have been damaged, that have the potential of producing a dangerous evolution of heat, fire or short circuit are forbidden to transport. Waste lithium ion batteries and lithium ion batteries being shipped for recycling or disposal are prohibited from air transport unless approved by the appropriate national authority of the State of origin and the State of the operator.

The lithium ion battery should pass the UN38.3 test, If the battery can not pass the testing, it should be redesigned. If the batteries pass the test, for the lithium ion battery only, shall follow the UN3480 and the packing requirements for PI965; for the lithium ion battery which installed in equipment, shall follow the UN3481 and the packing requirements for PI967.

The lithium ion battery testing meets all requirements under UN Manual of Tests and Criteria Part III, subsection 38.3.

8000 YRM 2353

Warnings and Cautions (CATL-based Lithium-ion Battery)

Table 34. Transport Information UN NO.

Proper Shipping Name

Power

UN3480

lithium ion batteries

Cell>20Wh Battery>100Wh

Cell≤20Wh Battery≤100Wh

Package Requirements

Label for Pasting

PI965 Section IA Class 9 hazard label Limit per package: Pax A/C = Forbidden CAO = 35 kg (77lb) PI965 Section IB NOTE: Use "IB" if package exceeds Section II Limits or more than 1 package

Class 9 hazard label and lithium ion battery handling label

Limit per package: Pax A/C = Forbidden CAO = 10 kg (7lb) Gross

UN3481

UN3481

lithium ion batteries contained in equipment

lithium ion batteries packed with equipment

Cell≤20Wh Battery≤100Wh

PI965 Section Ⅱ (no more than 1 package) Limit per package: ≤2.7 Wh = 2.5kg; or cells > 2.7 Wh≤20 Wh = 8 cells; or batteries > 2.7 Wh ≤100 Wh = 2 batteries Pax A/C = Forbidden

lithium ion battery handling label

Cell>20Wh Battery>100Wh

PI967 Section I Limit per package: Pax A/C = 5 kg (11 lb) CAO = 35 kg (77lb)

Class 9 hazard label

Cell≤20Wh Battery≤100Wh

PI967 Section Ⅱ Limit per package: Pax A/C = 5 kg (11 lb) CAO = 5 kg (11lb)

lithium ion battery handling label

Cell>20Wh Battery>100Wh

PI966 Section I Limit per package: Pax A/C = 5 kg (11 lb) CAO = 35 kg (77lb)

Class 9 hazard label

Cell≤20Wh Battery≤100Wh

PI966 Section Ⅱ Limit per package: Pax A/C = 5 kg (11 lb) CAO = 5 kg (11 lb)

lithium ion battery handling label

143

Warnings and Cautions (CATL-based Lithium-ion Battery)

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Table 35. Test Information NO.

Items

Result

Remarks

1

Altitude simulation

Pass

2

Thermal test

Pass

3

Vibration

Pass

Test 1 to 5 must be conducted in sequence on the same cell or battery

4

Shock

Pass

5

External short circuit

Pass

6

Impact

Pass

7

Forced Discharge

Pass

Only for Cell

CHARGING AND LABELING

Labeling

Charging

If the battery label or package warnings are not visible, contact relevant personnel to provide a package and/or device label stating.

This battery is made to be charged many times. Use an Energizer approved battery charger. Never use a modified or damaged battery charger. A backup charge termination based on time is recommended to prevent overcharging. The charging temperature should be between 0°C and 45°C (32°F and 113°F).

The battery pack will be normally warm during charging.

Charging Voltages and Currents: Charging voltages are prevented from exceeding the specified limits by an internal battery protection circuit.

Never use a battery that shows signs of a damaged protection circuit or broken case. Adhere to all specified charging and discharging voltages and currents. DO NOT use battery if its voltage drops below the specified minimum voltage.

144

If the lithium ion battery or cell transported by air, the labeling according to the requirement of IATA 60th, the packages is affixed with the Class 9 hazard label or/and lithium ion battery handling label.

If the lithium ion battery or cell transported by sea, the labeling conforms to IMDG, and the requirement are as follows: Package: no need of any indication.

Need all the UN Number.

Subassembly: no need of any indication.

Need the LQ label.

8000 YRM 2353

Warnings and Cautions (CATL-based Lithium-ion Battery)

WARNING CHARGE ONLY WITH SPECIFIED CHARGERS ACCORDING TO DEVICE MANUFACTURER’S INSTRUCTIONS. DO NOT OPEN BATTERY, DISPOSE IN FIRE, OR SHORT CIRCUIT -IT MAY IGNITE, EXPLODE, LEAK, OR GET HOT CAUSING PERSONAL INJURY.

Figure 78. Lithium ion Battery Handling Label

Disposal Dispose in accordance with all applicable federal, state and local regulations.

The information contained herein is furnished without warranty of any kind. Users should consider this data only as a supplement to other information gathered by them and must make independent determinations of the suitability and completeness of information form all sources to assure proper use and disposal of these materials and the safety and health of employees and customers.

Figure 77. Class 9 Hazard Label

145

Component Description (CATL-based Lithium-ion Battery)

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Component Description (CATL-based Lithium-ion Battery) KEY COMPONENTS

DC CONVERTER 600A FUSE PARENT BMS HEATING CONTACTOR CHILD BMS (WHEN CELL QUANTITY IS OVER 48) 6. CHARGING CONTACTOR 7. DISCHARGING CONTACTOR 8. HOLDING RELAY 9. POSITIVE COPPER BARS 10. FLANGED BOLT (THREAD DIMENSION M6X16, CLASS 10.9, TORQUE 12±1 N•M (16±1 LBF FT)) 11. HEAVY BLOCK 12. MODULE 13. NEGATIVE COPPER BARS 14. HALL TRANSDUCER 15. BOLT AND WASHER (THREAD DIMENSION M8, CLASS 8.8, TORQUE 12±1 N•M (16±1 LBF FT))

TOP COVER COMPONENTS

1.

2.

3.

4.

5.

Figure 79. Battery Key Components

1. SAFETY VALVE 2. BUZZER 3. POWER BUTTON 4. FIXED CHARGING CONNECTOR 5. DETECTION COVER 6. P DISCHARGING POLE (+) 7. Q DISCHARGING POLE (-) 8. R CHARGING POLE (+) 9. S CHARGING POLE (-) 10. T TRUCK COMMUNICATION PORT 11. U DISPLAYER AND DEBUG PORT 12. V CHARGING COMMUNICATION PORT 1 13. W CHARGING COMMUNICATION PORT 2 1. FIXED CHARGING CONNECTOR 2. DETECTION COVER 3. SEE FIGURE 81 Figure 80. Top Cover Components

146

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Component Description (CATL-based Lithium-ion Battery)

Tag SV1

Item

Description

1

Safety Valve

2

Antenan

TC1

3

Truck Communication

SD1

4

Display & Debug Port

5

Buzzer

6

Power Button

7

Discharging Pole (+)

8

Discharging Pole (-)

9

Charging Pole (-)

10

Charging Pole (+)

CC1

11

Charging Communication Port

DC1

12

Communication Port for Dual Charging

Discharging Charging

Figure 81. Top Cover Components with Tags

147

Component Description (CATL-based Lithium-ion Battery)

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CONNECTION POINTS

MODULE CONNECTION

1. A: HEATING POWER (-) 2. B: PACK VOLTAGE DETECTION (-); DC INPUT POWER (-) 3. C: CHARGING CABLE (-) 4. D: DISCHARGING CABLE (-) 5. E: DISCHARGING CABLE (+) 6. F: CHARGING CABLE (+) 7. G: HEATING POWER (+); HEATING CONTACTOR ABLATING AND STICKING DETECTION 8. I: CHARGING CONTACTOR ADHESION DETECTION 9. J: DISCHARGING CONTACTOR ADHESION DETECTION 10. K: PACK VOLTAGE DETECTION (+); DC INPUT POWER (+) 11. HALL TRANSDUCER DIRECTION

1.

2.

3.

4.

MODULE PARALLEL CONNECTION MODULE SERIES CONNECTION MODULE (25.8V 125AH) FLANGED BOLT (THREAD DIMENSION M8X16, CLASS 8.8, TORQUE 12±1 N•M (16±1 LBF FT)) Figure 83. Module Connection

Figure 82. Connection Points Table 36. Battery Connection Type

148

Connection Type

Voltage / Capacity

2 Modules Series Connection

25.8 x 2 (V)

3 Modules Series Connection

25.8 x 3 (V)

2 Module Columns Parallel Connection

125 x 2 (AH)

3 Module Columns Parallel Connection

125 x 3 (AH)

4 Module Columns Parallel Connection

125 x 4 (AH)

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Component Description (CATL-based Lithium-ion Battery)

MODULE STRUCTURE

CONNECTION PORTS

1.

2.

3.

4.

X PORT; Y PORT H PORT A PORT; B PORT C PORT; D PORT Figure 85. Parent BMS Ports

1. HEATING CABLES 2. STEEL SHELL Table 37. Voltage and Capacity Single Cell

Single Module

3.22V 125AH

One parallel connection and eight series connection, 25.8V 125AH

Figure 84. Module Structure NOTE: 1. In the module, eight cells are connected in series.

2. In Flexible Printed Circuit (FPC) socket, there are eight voltage collection points (one point for each cell) and two temperature collection points.

3. The heating film is integrated in module and powered by charger when the temperature of any cell is below 0°C (32°F).

1. M PORT 2. A PORT; B PORT 3. C PORT; D PORT Figure 86. Child BMS Ports

Figure 87. DC Converter

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Component Description (CATL-based Lithium-ion Battery)

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Figure 88. Power Button

Figure 89. Holding Relay

CHARGER SPECIFICATION Table 38. Charger Specification Model Model

D48V 100ALi

D48V 150ALi

D48V 200ALi

D80V 100ALi

D80V 150ALi

D80V 200ALi

DC Output Maximum Output Power

6.5kW

9.75kW

13kW

10kW

15KW

20kW

Rated Output Current

100A

150A

200A

100A

150A

200A

Output Voltage Range

18V DC-65V DC

36V DC-100V DC

Current Limit Range

2-100A; 2-150A; 2-200A

Peak-to-peak Noise

≤1%

Stabilization Accuracy

≤±0.5%

Steady Flow Accuracy

≤±0.5%

Current Sharing

≤±5%

Effectiveness

≥94%

Protection

Short circuit, Over Current, Over Voltage, Reverse Connection, Current Backflow Protection

150

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Component Description (CATL-based Lithium-ion Battery)

Table 38. Charger Specification (Continued) AC Input Input Voltage Range

200-220V AC; 320-475V AC; 400-480V AC; 600V AC

Frequency

45-65 Hz

Power Factor (PF)

≥0.99

Current Distortion (THD)

≤5%

Input Protection

Overvoltage; Undervoltage; Phase Loss; Overcurrent Protection Working Environment

Working Temperature

-30-55°C (-22-131°F) (normal operation); 57-75°C (135-167°F) (derating output); 75°C (167°F) or above (shutdown protection)

Storage Temperature

-40-75°C (-40-167°F)

Relative Humidity

0-95%

Altitude

≤2,000 m (78,740 in.) (full load); 2,000-3,000 m (78,740-118,110 in.) (derating) Dimensions and Weight

Dimensions (Host)

481 mm (19 in.) (length) × 430 mm (17 in.) (width) ×731 mm (29 in.) (height)

Protection Level

IP21

Net Weight

51 kg (112 lb)

151

Component Description (CATL-based Lithium-ion Battery)

8000 YRM 2353

CHARGER SELECTION Table 39. Charger Selection Battery/ Charger

48V100A

48V150A

48V200A

80V100A

80V150A

80V200A

Truck Model

51.2V 250AH, Single 160A Charging Connector 2 hr Dual Charging 1 hr

ERP16-20U XT; ERP15-18U X

51.2V 250AH, Single 320A ChargingConnector 2 hr Dual Charging 1 hr

ERP15-18U X

51.2V 375AH, 160A Connector

Single Charging - 2 hr Dual Charging - 1 hr

51.2V 375AH, 320A Connector

Single Charging - 2 hr Dual Charging - 1 hr

51.2V 500AH, 160A Connector

Single Charging - 2 hr Dual Charging - 1 hr

51.2V 500AH, 320A Connector

152

ERP16-20U XT; ERP15-18U X

ERP16-20U XT; ERP15-18U X

Single Charging - 2 hr Dual Charging - 1 hr

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Component Description (CATL-based Lithium-ion Battery)

Table 39. Charger Selection (Continued) 77.2V 250AH, 320A Connector

77.2V 375AH, 320A Connector

77.2V 500AH, 320A Connector

Single Charging - 2 hr Dual Charging - 1 hr

ERP30-35U X

Single Charging - 2 hr Dual Charging - 1 hr

ERP30-35U X

Single ERP30-35U Charging - 2 X hr Dual Charging - 1 hr

153

Software and User Interface (CATL-based Lithium-ion Battery)

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Software and User Interface (CATL-based Lithium-ion Battery) DESCRIPTION OF SOFTWARE TOOLS FOR TECHNICIANS Monitor

Customer

Dealer

Factory

Truck Instrument

Standard

Standard

Standard

Option

Standard

Battery Displayer PC (Version T)

TOOL1

PC (Version R) Charger Displayer

TOOL2 Standard

Standard

Standard

NOTE: 1. Version R software installed in PC can read all real-time data, status, and history data from BMS, which can also update BMS program and forcibly control contactor status to enabled Manual Service Disconnect (MSD).

2. Version T software installed in PC has all functions of version R and other functions like manual modification of most BMS control thresholds.

TRUCK INSTRUMENT

Figure 92. Truck Key Switch Figure 90. Battery Connection

Figure 93. 1309USB OEM Figure 91. Truck CAN Port

154

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Software and User Interface (CATL-based Lithium-ion Battery)

Figure 94. 1314 PC Programming Station - OEM 5.

For ERPUX truck, use Curtis 1309USB OEM (item 6, Figure 93) to connect the drive controller debug port (item 7, Figure 93) and laptop (item 8, Figure 93)

6.

Open the Curtis software 1314 PC Programming Station - OEM (item 9, Figure 94) on the desktop.

NOTE: Curtis 1313-4401 handset can also be used for enabling lithium battery function when connected with truck. a.

Connect Curtis handset 1313-4401 to truck drive controller debug port.

b.

Use four directional buttons for navigation and press the button under Select to enter Parameters category.

Figure 95. Parameter Editor 1.

Connect the battery discharge connector (item 1, Figure 90) to the truck power connector.

c.

Select Customer Settings under Parameter category.

2.

See Schematics and Diagrams for the connection of the battery communication port (item 2, Figure 90) and the truck CAN port (item 3, Figure 91).

d.

Select Advanced Settings under Customer Settings.

e.

Select Lithium Battery under Advanced Settings and enable it to On status.

3.

Switch on the battery power button (item 4, Figure 90) or turn the truck key switch (item 5, Figure 92) to position II.

4.

Turn the truck key switch (item 5, Figure 92) to position I.

155

Software and User Interface (CATL-based Lithium-ion Battery)

Figure 96. Device Connection

Figure 99. Advanced Settings

Figure 97. Handset Displayer

Figure 100. Enable Li-ion Battery Status

Figure 98. Parameters Settings

156

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7.

Click the button (item 10, Figure 95) to read the controller parameters.

8.

Select Lithium Battery (item 11, Figure 95) and set Enable to On.

9.

Restart the truck, then the truck indicates that the battery is OK.

8000 YRM 2353

Software and User Interface (CATL-based Lithium-ion Battery)

1. BATTERY ALARM CODE 2. FAULT WARNING FLAG 3. SOC (STATE OF CHARGE) NOTE: 1. OK INDICATES THAT THE BATTERY IS IN NORMAL CONDITION. 2. SEE TROUBLESHOOTING (CATL-BASED LITHIUM-ION BATTERY) FOR ALARM CODE DETAILS. IF BAT INDICATOR IS NOT DISPLAYED, THE TRUCK IS IN LEAD-ACID MODE. Figure 101. Truck Dashboard For ERPUXT truck, refer to ZAPI instruction for connection device and software setting.

1. SOC 2. ALARM CODE Figure 102. SOC

BATTERY DISPLAYER

Figure 103. Battery Communication Port

157

Software and User Interface (CATL-based Lithium-ion Battery)

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2.

Press the battery power button, the battery displayer is powered on.

3.

Click to (item 3, Figure 105) to select the language.

Figure 104. Battery Displayer Cable Port 1.

See Schematics and Diagrams for cable connection between communication port (item 1, Figure 103) and battery displayer (item 2, Figure 104).

1. ALARM CODE 2. REAL-TIME BATTERY DATA

Figure 105. Batttery Displayer

3. REAL-TIME CELL DATA 4. DETECTION MENU Figure 106. Displayer Main Interface

For alarm code details, see section Troubleshooting (CATL-based Lithium-ion Battery).

158

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Software and User Interface (CATL-based Lithium-ion Battery)

Figure 107. Cell Voltage

Figure 110. Relay Status

Figure 108. Cell Temperature

Figure 111. Charging Information

Figure 109. Heating Temperature

1.

2.

3.

4.

HEATING STATUS AND CURRENT SYSTEM RESISTANCE SYSTEM ALARM CHARGING AND DISCHARGING TIME Figure 112. Others

159

Software and User Interface (CATL-based Lithium-ion Battery)

160

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Figure 113. Heating Status and Current

Figure 115. System Alarm

Figure 114. System Resistance

Figure 116. Charging and Discharge Time

8000 YRM 2353

Software and User Interface (CATL-based Lithium-ion Battery)

CHARGER DISPLAYER

Figure 118. Charger Connection Figure 117. Charger

1. CHARGING INSTRUCTION 2. INDICATOR LIGHT 3. CHARGER MODEL

1.

Connect the power input plug of the charger to the wall socket (item 1, Figure 117).

2.

Connect the output plug of the charger to the charging or (and) discharge connector of the battery. See figure Figure 117. The battery supports dual charging.

4. LCD SCREEN 5. PAUSE BUTTON Figure 119. Charger Panel

161

Software and User Interface (CATL-based Lithium-ion Battery)

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Click (item 1, Figure 120) to go to the setting interface for language selection. Click (item 2, Figure 120) for detailed battery data. Regarding sub-menu and settings, refer to CACTI Charger Service Manual.

Figure 120. Charger Displayer

162

Charger Status

Charger Displayer Background

Battery Icon

Light Status

Standby

Blue

Blue

Flashing Green

Charge

Green

Orange

Red Light On

Time Out

Blue

Orange

Flashing Red

Error

Red

Orange

Fault Information

Completed

Blue

Green

Green Light On

8000 YRM 2353

Software and User Interface (CATL-based Lithium-ion Battery)

BMS INTERFACE See Schematics and Diagrams for cable connection between debug PCAN and communication port. Then connect debug PCAN to PC through USB. Make sure that CAN L and CAN H are connected correctly when connecting debug PCAN.

Figure 121. BMS System

Figure 122. BMS System Interface 1.

Click the Intelligent Battery Management System icon (item 1,Figure 121) on PC.

3.

Click Submit (item 3, Figure 121) to go to the BMS main interface.

2.

Select device type (item 2, Figure 121) according to the debug PCAN type.

NOTE: BMS has 128MB memory and can record history data for three to 12 months as per actual situation.

163

Software and User Interface (CATL-based Lithium-ion Battery)

System Overview

Figure 123. System Overview 1.

Click System overview (item 1, Figure 123), then real time pack data, charger data, key configuration data, and network connection data are displayed.

Real-time Information

Figure 124. Real-time Information-Cell Information 1.

164

Click Real time Info (item 2, Figure 124), then click Cell info (item 3, Figure 124) for real time cell data (voltage and temperature).

8000 YRM 2353

8000 YRM 2353

Software and User Interface (CATL-based Lithium-ion Battery)

Figure 125. Real-time Information-Charging State 2.

Click Charging state (item 4, Figure 125) for real time charging status.

Figure 126. BMS 3.

Click BMS (item 5, Figure 126) for BMS information and real-time BMS status.

165

Software and User Interface (CATL-based Lithium-ion Battery)

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Parameter Calibration

Figure 127. Parameter Calibration 1.

Click Parameter Calibration (item 6, Figure 127), then BMS control thresholds can be modified.

NOTE: Only version T software support this function.

For version R software, this interface is blank.

Force Control

Figure 128. Force Control Click Force control (item 7, Figure 128), discharge contactor, charging contactor and heating contactor can be controlled forcibly to enable MSD.

166

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Software and User Interface (CATL-based Lithium-ion Battery)

Firmware Upgrading

Figure 129. Firmware Upgrading Click Firmware upgrading (item 8, Figure 129), the latest BMS program can be downloaded from the Internet and installed into the BMS.

Select Project name, then click Flash.

NOTE: When upgrading firmware, press the battery power button till the process ends.

History Data

Figure 130. History Data Click History data (item 9, Figure 130), the history data stored in BMS can be exported for analysis.

When exporting the history data, press the battery power button till the process ends.

167

Software and User Interface (CATL-based Lithium-ion Battery)

Real-time Information

Figure 131. Real-time Information

168

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The real time overview (item 10, Figure 131) and alarm code (item 11, Figure 131) are always shown on the right side of any interfaces. For detailed alarm information, see Troubleshooting (CATL-based Lithium-ion Battery).

8000 YRM 2353

Maintenance (CATL-based Lithium-ion Battery)

Maintenance (CATL-based Lithium-ion Battery) BATTERY MAINTENANCE 1. Inspect the battery every three months:

2.

3.

4.

5.

a. Whether the high voltage power cable and connector is scratched or loosened. b. Whether the safety valve of battery case is damaged. c. Whether the battery case swells or deforms. d. Whether abnormal heat occurs during charging and discharging.

In storage status, the battery needs to be fully charged and discharged every month. Besides, SOC should be adjusted to 40%. Otherwise, SOC will drop <1% for each month and SOH will drop <3.5% after three months. SOC can not recover once its value drops.

In operating status, the battery needs to be fully charged and discharged every month for maintaining the original capacity.

If the battery is dropped or heavily impacted, it should be isolated and monitored for 24 hours in case of fire.

DO NOT operate the battery in rain as far as possible. If there is water on the battery top cover, wipe it immediately.

6. Pay attention to the low SOC alarm and charge the battery immediately when the alarm appears.

7. Pay attention to the alarm code and troubleshoot it accordingly. For details, see Troubleshooting (CATL-based Lithium-ion Battery).

8. DO NOT disconnect the charging connector when charging current still exists.

9. DO NOT disconnect the discharge connector or power off the battery when discharging current still exists.

10. It is recommended to charge the battery in the environment where the temperature is 0°C-45°C (32°F)- (113°F). If the environment temperature is below 0°C (32°F), the charger will heat the module to 0°C (32°F) first, then start to charge.

11. The warranty term of battery is 5 years or 1500 cycle life.

12. When the battery is in short term storage (<=1 month), the environment temperature is -40°C (-40°F)-60°C (140°F). When the battery is in long term storage (>1 month), the environment temperature is 0°C (32°F)-25°C (77°F)

169

Battery Repair (CATL-based Lithium-ion Battery)

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Battery Repair (CATL-based Lithium-ion Battery) BATTERY DISASSEMBLY

Figure 134. Remove Bolts on Top Cover Figure 132. Remove the Bolts on Detection Cover

Figure 135. Remove the Top Cover

Figure 133. Power Cable and Buss Bar Connection

Figure 136. Bolts for Electrical Board

170

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Figure 137. Electrical Board and Bolts for Side Cover

1.

2.

Battery Repair (CATL-based Lithium-ion Battery) 5.

If it is needed to replace the modules or the buss bars between modules, remove the bolts (item 3, 4, 5, Figure 136) of electrical board and buss bar.

Then disconnect the heating cables, CSC wires, and buss bars.

6.

Remove the electrical board (item 6, Figure 137).

If needed, remove the bolts (item 7, Figure 137) for side covers and open them.

7.

Remove the bolts (item 8, Figure 138 ) of the module and the bolts (item 9, Figure 138) which connect the buss bars, then remove the module.

Remove the upper modules first, then the lower modules.

CAUTION Use the following insulating tools disassemble or assemble the battery.

•

Ratchet wrench

•

4mm hexagon socket head

•

30mm 6-point socket

•

7mm 6-point socket

•

8mm 6-point socket

•

13mm 6-point socket

•

Long connecting rod

•

10mm 6-point socket

Figure 138. Bolts for Module and Buss Bar

MODULE REPLACEMENT

Clean the top surface. Then remove the bolts (item 1, Figure 132) of the detection cover and open it.

Module Failure

After opening the detection cover. The users can: a. Check the power cable or buss bar connection. b. Detect contactor fault or fuse burnout.

Observe abnormal phenomena, such as overheating. d. Detect cell voltage and module temperature by using wire sequence detector. c.

3.

If the problem can not be solved by opening the detection cover, then remove the bolts (item 2, Figure 134) of the top cover and open it.

4.

Except for the modules and buss bars between modules, other components all can be detected or replaced by opening the top cover.

when

If a module fails, cell voltage or temperature signal is missing or abnormal, FPC circuit is damaged, module is open-circuited or short-circuited, and mechanical damage occurs.

If a module fails when SOH is above 80%, dealer can replace this module with a new one.

If a module fails when SOH is below 80%, dealer needs to consider whether it is cost-efficient to replace this module with a new one.

1.

If a module fails, BMS will cut off all contactors immediately. Leave the battery standing without any actions for at least one hour.

2.

Record the voltage range of all good cells, then power off the battery.

171

Battery Repair (CATL-based Lithium-ion Battery) 3.

Provide the recorded cell voltage range of to SHFL. SHFL will adjust the voltage of new module by special charging and discharging device to the value that is similar to the previous cell voltage.

4.

SHFL delivers the new module to dealer. Then dealer assembles it to battery directly.

8000 YRM 2353 1.

Use the battery until its SOC falls to 40%. Leave the battery standing without any actions for at least one hour.

2.

Record the voltage range of all cells except for the cells of the aged module.

3.

Provide the recorded cell voltage range of to SHFL. SHFL will adjust the voltage of new module by special charging and discharging device to the value that is similar to the previous cell voltage.

4.

SHFL delivers the new module to dealer. Use the battery until its SOC falls to 40%, then dealer assembles it to the battery directly.

NOTE: 1. In this case, new module replacement does not affect SOH. 2. DO NOT power on the battery after providing cell voltage to SHFL. 3. For how to disassemble the module, refer to Battery Disassembly. For how to assemble the module, refer to the Operation Method Sheet.

Module Aging Module aging means the aging rate of a module is obviously faster than others with cell voltage always lower than other cells. The battery SOH reduces rapidly because of this module, but the battery has no alarm and still can be used.

Dealer needs to consider whether it is cost-efficient to replace the aged module with a new one according to the battery service time.

172

NOTE: 1. In this case, module replacement will increase SOH. 2. The battery must be used until its SOC falls to 40% before assembling new module to the battery.

3. For how to disassemble the module, refer to Battery Disassembly. For how to assemble the module, refer to the Operation Method Sheet.

8000 YRM 2353

Principles of Operation (CATL-based Lithium-ion Battery)

Principles of Operation (CATL-based Lithium-ion Battery) FUNCTIONAL DESCRIPTIONS Discharge Power-on Process Power Button Mode 1. Press the battery power button (SW). The DC converter will output 24V power to the BMS (Port X).

2. Press the battery power button for 0.5s, the BMS will close the self-locking relay (KA1) and start initialization and self-test process.

3. If no fault is detected in BMS self-test process, BMS will determine if there are charging connection signals (charger CAN message and On-board Charger (OBC) or (Digital Command Control (DCC) signal).

4. If no charging signal is detected, BMS closes the discharge contactor (KM2) and the battery enters into discharging status.

5. After BMS self-test, the self-locking relay (KA1) will be normally closed if there is no fault. If there is a fault, the self-locking relay (KA1) will also be closed and the fault will be reported by BMS at the same time.

6. After BMS is powered on, the CAN signals for the displayer, PC, and truck controller are output by default. And the red LED lights up.

NOTE: 1. See Figure 140 for the circuit of charger CAN, OBC, DCC, and discharge contactor.

2. See Figure 141 for the circuit of power button, DC converter, self-locking relay and BMS power input.

Discharge Power-off Process Power Button Mode 1. When BMS is in working state, press the power button (SW) for more than 3s.

2. The DIG (port Y on BMS ) detects a +24V signal for more than 3s, then BMS opens the selflocking relay (KA1).

3. After releasing the power button (SW), BMS will be shutdown.

4. After BMS is started for 10s, the DIG (port Y on BMS) just starts to detect +24V signal. This battery power-on delay can prevent BMS shutdown automatically when BMS is just started.

BMS Sleep Mode If the circuit current is less than 5A for above 1 hour, BMS will open the self-locking relay (KA1) and then be shut down automatically.

Fault Mode When there is any serious fault (the fault that needs to end discharging), then the BMS will open the discharging contactor (KM2). The discharging status ends.

Charging Mode If the charging connection signals (charger CAN message and OBC or DCC signal) are detected

by BMS, the BMS will open the self-locking relay (KA1) and the discharge contactor (KM2).

The discharge status ends.

NOTE: 1. See Figure 140 for the circuit of charger CAN, OBC, DCC, and discharge contactor.

2. See Figure 140 for the circuit of power button, DC converter, self-locking relay and BMS power input.

Charging Power-on Process Charger Mode 1. After connecting to the battery and powered on, the charger will immediately supply +24V power and send DCC or OBC signal to BMS (Port X).

Then BMS cuts off the +24V power supply from DC converter and only be powered by charger.

2. If the charger CAN message is detected by BMS and there is no serious charging fault, BMS implements the following actions. If no charger CAN message or any serious charging fault is detected, then the following action will no be implemented.

3. If only OBC signal is detected, BMS closes the charging contactor (KM1) and opens the discharge contactor (KM2) , the battery enters into single charging status. If only DCC signal is detected, BMS closes the discharging contactor (KM2) and opens the charging contactor (KM1), and then battery enters into single charging status. If OBC and DCC signals are detected at the same time, the charging contactor (KM1) and the discharge contactor (KM2) are closed simultaneously, the battery enters into dual charging status.

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Principles of Operation (CATL-based Lithium-ion Battery) 4. The normal charging process begins. The CAN signals for the displayer and PC are output by default.

NOTE: See Charging Schematic for the circuit of charger CAN, OBC, DCC, discharge contactor, and charging contactor.

Charging Power-off Process Charger Mode Power off the charger, then the charger ends +24V power supply to BMS which shuts down immediately. All related contactors (KM1 & KM2) opens. The charging status ends.

NOTE: See Charging Schematic for the circuit of charger CAN, OBC, DCC, discharge contactor, and charging contactor.

SOC Mode 1. When the battery is fully charged (any cell voltage >3.62V), BMS will send CAN message to charger (request 0V, 0A and stop).

After 3s, BMS opens all related contactors (KM1 2. & KM2). The charging status ends.

3. BMS calibrates SOC to 100%.

Fault Mode 1. When there is any serious fault (the fault that needs to end charging), BMS will send CAN message to the charger (request 0V, 0A and stop).

2. After 3s, BMS opens all related contactors (KM1 & KM2). The charging status ends.

Power Button Mode 1. When pressing the power button (SW), the DID_IN1 (BMS port Y) detects an +24V signal.

Then, BMS will send CAN message to the charger (request 0V, 0A & stop).

2. After 3s, BMS opens all related contactors (KM1 & KM2). The charging status ends.

NOTE: See Charging Schematic for the circuit of charger CAN, OBC, DCC, discharge contactor, and charging contactor.

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Module Heating Process 1. Connect the charger to the battery charging port and switch on the charger. Then BMS detects OBC signal and enter into the charging status. If BMS detects any cell temperature that is below 0°C (32°F), the heating process will start.

2. Connect the charger to the battery discharge port and switch on the charger. Then BMS detects DCC signal and enter into the charging status. If BMS detects any cell temperature that is below 0°C (32°F), BMS will report the heating fault and the heating process will not be triggered.

3. Connect the chargers to the battery discharging port and charging port at the same time and switch on the chargers. Then BMS detects DCC and OBC signal and enters into the charging status. If BMS detects any cell temperature that is below 0°C (32°F), BMS will report the heating fault and the heating process will not be triggered.

4. When the heating process starts, BMS closes the charging contactor (KM1) and request the heating current from the charger (8A for each series modules, 250AH-16A, 375AH-24A, 500AH-32A).

5. When BMS detects current on power circuit, the heating contactor (KM3) is closed. After 1s, the charging contactor (KM1) is closed, and the heating current flows into module heating films.

6. When the cell temperature raises to or above 5°C (41°F), then heating and charging works at the same time. The current requested by BMS is the total of the heating current and charging current (see Charging Current Control).

7. When the cell temperature raises to or above 15°C (59°F), the heating ends while the charging continues.

8. If the heating current from charger is ≤ 1A in a minute, then heating fault will be reported.

9. The heating current does not affect SOC calculation.

NOTE: See Module Heating Schematic for the circuit of heating, charger OBC, charging contactor, and heating contactor.

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Principles of Operation (CATL-based Lithium-ion Battery)

Signal Detection Process

CAN Communication

Cell Voltage and Temperature

Charging CAN

1. Connect module FPC port to BMS CSC port (A, B, C, and D), then BMS can detect cell voltage and temperature.

Each FPC port has eight voltage detection 2. points and two temperature detection points.

Each CSC port has 12 voltage collection points and four temperature collection points.

3. For 51.2V battery, one FPC port maps to one CSC. There is no voltage bridge joint. For 77.2V battery, three FPC ports map to two CSC port.

There is a voltage bridge joint between two CSC ports. So after connecting the CSC wire, the wire sequence detector must be used to prevent overvoltage for CSC port. Overvoltage may burn up BMS CSC circuit.

Total Circuit Current and Voltage 1. The current is detected by hall current transducer (CT) which is connected to BMS port Y. Pay attention to the assembly direction.

2. The voltage is detected by BAT + and BAT – which is connected to BMS port H.

Contactor Adhesion 1. Contactor adhesion is detected by DISCHARADH, CHAR-ADH, and HEAT-ADH which are connected to BMS port H. 2. If the voltage at the back end of the contactor exceeds 90% of the voltage at the front end, and the voltage downward trend at the back end is less than 10% of the voltage at the front end within the specified time, then the contactor is considered to be adhered. Otherwise, the contactor is normal.

NOTE: See Single Detection Schematic for the circuit of CSC, total current and voltage, and contactor adhesion detection.

The charging CAN is from pin 25, 26 of BMS port Y to the discharge connector and charging connector.

This CAN links BMS and charger to control charger output parameters (voltage and current) and the battery condition (SOC, failure).

Discharging CAN This CAN is from pin 19, 20 of BMS port Y to connector CC4.

This CAN links BMS and truck controller to control truck current and sends instrument information (SOC, failure).

Battery Displayer (Optional) The battery displayer CAN is from pin 1 and 2 of BMS port Y to the connector CC3. This CAN links BMS and the battery displayer to send information (SOC, voltage, current, temperature, contactor status, charging data, service time, failure and so on.

Personal Computer The personal computer CAN is from pin 1 and 2 of BMS port Y to connector CC3. This CAN links BMS and personnal computer. Users can read real-time data and all information stored in BMS, and can modify BMS control thresholds and contactor status.

Child BMS (When Cell Quantity is over 48) This CAN is transferred from pin 1-3 of BMS port Y to pin 10, 25 of BMS port M. This CAN links parent BMS and child BMS to receive module FPC signal. The child BMS is powered by DC converter and has an enable signal from pin 4 of BMS port Y. NOTE: See CAN Communication Schematic for the circuit of all CAN connections and child BMS.

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Other Functions

MSD

Alarm Buzzer

There is no MSD hardware in battery circuit. Before opening the battery top cover for repairing, firstly use PC to open all contactors to prevent short circuit and personal injuries.

The alarm buzzer (BUZ) is driven by pin 9, 25 of BMS port X according to Discharge Fault Threshold and Charging Fault Threshold.

Key Switch (Optional) The key switch is assembled on truck and the circuit is in parallel with power button (SW) (Com2 & No2).

Turning on the key switch is just like switching on the battery power button, but the key switch can not turn off the battery because it can not create +24V signal for DIG ( port Y on BMS).

NOTE: 1. The total positive and total negative of series modules can not be cut off, so DO NOT link module poles.

2. See Other Functions Schematic for the circuit of alarm buzzer, 4G antenna, and key switch.

Discharge Current Control

Table 40. Discharge Current Control Batt ery Capa city

Cell Temperature

SOC

Conditions

250A H

T<-25°C (-13°F)

N/A

Buzzer alarms continuously Discharge contactor is cutoff

-25°C (-13°F)≤T<-10°C (14°F)

N/A

Buzzer alarms continuous Truck power is reduced to 50%, Travel speed is reduced to 50%, No lifting function

-10°C (-14°F)≤T<10°C (50°F)

SOC≥20%

Normal Discharge

15%≤SOC<2 Buzzer alarms (Interval 2s, 0% Duration 2s) Normal discharge SOC<15%

176

Buzzer alarms continuously Truck power is reduced to 50%, Travel speed is reduced to 50%, No lifting function

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Principles of Operation (CATL-based Lithium-ion Battery)

Table 40. Discharge Current Control (Continued) Batt ery Capa city

Cell Temperature

SOC

Conditions

10°C (50°F)≤T<55°C (131°F)

SOC≥15%

Normal discharge

10%≤SOC<1 Buzzer alarms (Interval 2s, 5% Duration 2s) Normal discharge

55°C (131°F)≤T<60°C (140°F)

SOC<10%

Buzzer alarms continuously Truck power is reduced to 50% Travel speed limited to 50%, No lifting function

SOC≥10%

Buzzer alarms (Interval 2s, Duration 2s) Normal discharge Buzzer alarms continuously Truck power is reduced to 50% Travel speed is limited to 50% No lifting function

375A H 500A H

60°C (140°F)≤T<65°C (149°F)

N/A

Buzzer alarms continuously Truck power is reduced to 50% Travel speed is limited to 50% No lifting function

T≥65°C (149°F)

N/A

Buzzer alarms continuously Discharge contactor is cutoff

T<-30°C (-22°F)

N/A

Buzzer alarms continuously Discharge contactor is cutoff

-30°C (-22°F)≤T<-25°C (-13°F)

N/A

Buzzer alarms continuously Truck power is reduced to 50% Travel speed is limited to 50% No lifting function

-25°C (-13°F)≤T<-10°C (14°F)

SOC≥35%

Normal discharge

30%≤SOC<3 5%

Buzzer alarm (Interval 2s, Duration 2s) Normal discharge

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Table 40. Discharge Current Control (Continued) Batt ery Capa city

Cell Temperature

SOC

Conditions

SOC<30%

Continuous buzzer alarm Truck power is reduced to 50% Travel speed is limited to 50% No lifting function

SOC≥10%

Normal discharge

5%≤SOC<10 %

Buzzer alarm (Interval 2s, Duration 2s) Normal discharge

SOC<5%

Buzzer alarms continuously Truck power is reduced to 50% Travel speed is limited to 50% No lifting function

SOC≥5%

Buzzer alarms (Interval 2s, Duration 2s) Normal discharge

SOC<5%

Buzzer alarms continuously Truck power is reduced to 50% Travel speed is limited to 50% No lifting function

60°C (140°F)≤T<65°C (-149°F)

N/A

Buzzer alarms continuously Truck power is reduced to 50% Travel speed is limited to 50% No lifting function

T≥65°C (149°F)

N/A

Buzzer alarms continuously Discharge contactor is cutoff

-10°C (14°F)≤T<55°C (-67°F)

55°C (131°F)≤T<60°C (-140°F)

NOTE: 1. In normal discharge status, the discharge current is determined by truck load, cell temperature, and SOC.

178

2. If there is any discharge fault, the discharge current will be reduced or cutoff according to Discharge Fault Threshold.

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Principles of Operation (CATL-based Lithium-ion Battery)

Charging Current Control Table 41. Temperature and Current (500AH Battery) Cell ≤0°C Temper (32°F) ature

0°C 5°C 10°C (32°F)-5 (41°F)-1 (50°F)-2 °C 0°C 0°C (41°F) (50°F) (68°F)

20°C (68°F)-50°C (122°F)

50°C 55°C >65°C (149°F) (122°F)-55°C (131°F)-6 (131°F) 5°C (149°F)

Single 0 amps 50 amps 100 amp 200 amps 200 amps Chargin s g Current

200 amps

125 amps 0 amps

Dual 0 amps 50 amps 100 amp 250 amps 400 amps Chargin s g Current

250 amps

125 amps 0 amps

Table 42. Condition and Current (500AH Battery) Condition

Single Current

Dual Current

SOC≥80%

200 amps

250 amps

Vmax≥3500mV

100 amps

100 amps

Vmax≥3580mV

50 amps

50 amps

Vmax≥3620mV

0 amps

0 amps

Table 43. Temperature and Current (375AH Battery) Cell ≤0°C Temper (32°F) ature

0°C (32°F)-5° C (41°F)

5°C 10°C 20°C 50°C 55°C (41°F)-10°C (50°F)-2 (68°F)-50 (122°F)-55° (131°F)-65° (50°F) 0°C °C C (131°F) C (149°F) (68°F) (122°F)

>65°C (149°F)

Single 0 amps Chargi ng Curren t

30 amps

70 amps

150 amps 150 amps 150 amps

100 amps

0 amps

Dual 0 amps Chargi ng Curren t

30 amps

70 amps

150 amps 300 amps 180 amps

100 amps

0 amps

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Principles of Operation (CATL-based Lithium-ion Battery)

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Table 44. Condition and Current (375AH Battery) Condition

Single Current

Dual Current

SOC≥80%

150 amps

180 amps

Vmax≥3500mV

75 amps

75 amps

Vmax≥3580mV

50 amps

50 amps

Vmax≥3620mV

0 amps

0 amps

Table 45. Temperature and Current (250AH Battery) Cell ≤0°C Temper (32°F) ature

0°C 5°C 10°C 20°C 50°C 55°C >65°C (149°F) (32°F)-5° (41°F)-10° (50°F)-20 (68°F)-50 (122°F)-55° (131°F)-65 C (41°F) C (50°F) °C (68°F) °C C (131°F) °C (149°F) (122°F)

Single 0 amps Chargi ng Current

20 amps

45 amps

100 amps 100 amps 100 amps

70 amps

0 amps

Dual 0 amps Chargi ng Current

20 amps

45 amps

100 amps 200 amps 125 amps

70 amps

0 amps

Table 46. Condition and Current (250AH Battery) Condition

Single Current

Dual Current

SOC≥80%

100 amps

125 amps

Vmax≥3500mV

50 amps

50 amps

Vmax≥3580mV

30 amps

30 amps

Vmax≥3620mV

0 amps

0 amps

NOTE: 1. In normal charging status, the charging current is determined by the chager capacity, cell temperature, cell voltage, and SOC. The minimum current value among these conditions is just the actual charging current.

180

2. If there is any charging fault, the charging current will be reduced or cutoff according to Charging Fault Threshold.

If the cell temperature is below 0°C (32°F) , the 3. charger will heat the module automatically with heating rate 0.3°C (32.54°F) per minute.

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Principles of Operation (CATL-based Lithium-ion Battery)

SCHEMATICS AND DIAGRAMS System Electrical Schematic

Figure 139. System Electrical Schematic

181

Principles of Operation (CATL-based Lithium-ion Battery)

Discharge Schematic Part (I)

Figure 140. Discharge Schematic Part (I)

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Principles of Operation (CATL-based Lithium-ion Battery)

Discharge Schematic Part (II)

Figure 141. Discharge Schematic Part (II)

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Principles of Operation (CATL-based Lithium-ion Battery)

Charging Schematic

Figure 142. Charging Schematic

184

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Principles of Operation (CATL-based Lithium-ion Battery)

Module Heating Schematic

Figure 143. Module Heating Schematic

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Principles of Operation (CATL-based Lithium-ion Battery)

Single Detection Schematic

Figure 144. Single Detection Schematic

186

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Principles of Operation (CATL-based Lithium-ion Battery)

CAN Communication Schematic

Figure 145. CAN Communication Schematic

Other Functions Schematic

Figure 146. Other Functions Schematic

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Principles of Operation (CATL-based Lithium-ion Battery)

Main Wire Harness Connection

Figure 147. Main Wire Harness Connection For connection points and BMS ports, see Figure 82 and Connection Ports.

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Principles of Operation (CATL-based Lithium-ion Battery)

Link Wire and H Port Wire Connection

Figure 148. Main Wire Harness Connection For connection points U, W, V, T, K, J, I, G, B, see Figure 80.

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Principles of Operation (CATL-based Lithium-ion Battery)

CAN Wire Connection

Figure 149. CAN Wire Connection For connection points T and U, see Figure 80.

190

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Principles of Operation (CATL-based Lithium-ion Battery)

Power Cable Connection

Figure 150. Power Cable Connection Connect charging positive cable F to R and connect charging negative cable C to S. For R and S connection points, see Figure 80.

Connect discharge positive cable E to P and connect discharge negative cable D To Q. For P and Q connection points. see Figure 80.

Heating Cable Connection

Figure 151. Heating Cable Connection

191

Principles of Operation (CATL-based Lithium-ion Battery) Connect each plug to heating cable of each series modules. For connection points A and G, see Figure 82.

CSC Wire Connection

Figure 152. CSC Wire Connection For 51.2V battery, there are two module FPC sockets.

For 77.2V battery, there are three module FPC sockets.

ALERT 1. In the CSC wire, the connector labels indicate BMS model, BMS port number (A, B, C, D) and module series number (1-12).

2. Connect the CSC wire to BMS according to the model and port number. For the module series number, the module closer to the total negative pole has smaller number and the module closer to the total positive pole has bigger number.

3. One CSC wire must be used for one series modules.

192

Wire Sequence Detector

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Principles of Operation (CATL-based Lithium-ion Battery)

Item

Description

Displayed Information

Correct/ Incorrect/ Invalid Value

1

Cell Voltage

3.XXX

Correct

51.2V Battery

0.000

Invalid Value

77.2V Battery

Other Value

Incorrect

-50°C (-58°F)

Invalid Value

Other Value

Correct

2

Module Temperature

NOTE: THE WIRE SEQUENCE DETECTOR MUST BE USED TO DETECT WHETHER THE MODULE FPC CONNECTION SEQUENCE IS CORRECT BEFORE THE CSC WIRE IS CONNECTED TO BMS. IF

Invalid Value Quantity

51.2V Battery

Comments

Four invalid values

If invalid value (0.000) quantity is No invalid value incorrect, check the wire connection. If an incorrect cell voltage appears individually, check its module voltage. If all cell voltages are incorrect, check FPC connection sequence.

Two invalid values

If invalid value (-50°C (-58°F)) 77.2V Battery One invalid value quantity is incorrect, check the wire connection. If the value is obviously incorrect, check the module sensor.

THE CONNECTION SEQUENCE IS WRONG, BMS CSC CIRCUIT MAY BURN UP AND CAN NOT BE REPAIRED. Figure 153. Wire Sequence Detector

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Troubleshooting (CATL-based Lithium-ion Battery)

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Troubleshooting (CATL-based Lithium-ion Battery) TROUBLESHOOTING Charging Alarm Codes and Solutions Table 47. Charging Alarm Codes and Solutions Fault Description

PC

Battery Displayer

Charger

Solutions 1. Use PC to check the alarm level 2. If the alarm level is class 1 or class 2, there is no need to deal with it while charging the battery.

3. If the alarm level is class 3, check which cell voltage is below 2V. Contact the charger supplier to forcibly charge the battery. If the cell voltage still can not rise to 2.5V, replace the module which includes this cell.

Charging Low Battery Voltage

ChPackUV

lvl x alarm

ChglowTotVolt

Cell-volt lower

Charging Low Cell Voltage

ChgUV

lvl x alarm

ChgLowVolt

Cell-volt lower

Charging Cell Voltage Difference

ChgVdiff

lvl x alarm

ChgDiffVolt

Cell-volt DIFF

1. Use PC to check the alarm level.

2. If the alarm level is class 2, there is no need to deal with it while charging the battery.

3. If the alarm level is class 3, check the cell of which voltage is too low or high.

Replace the module that includes this cell.

NOTE: If the cell voltage of one series module is consistently lower than others, then check whether the copper bar of this series module is loose that makes the charging current can not flow into this series module. Tighten the related copper bar if needed and charge the battery.

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Troubleshooting (CATL-based Lithium-ion Battery)

Table 47. Charging Alarm Codes and Solutions (Continued) Fault Description

PC

Battery Displayer

Charger

Solutions There is no need to deal with it while charging the battery. The BMS will automatically reduce the charging current or order the charger to heat the battery (heating rate: 0.3°C (32.54°F)/min)

Charging High Temperature

ChgOT

lvl x alarm

ChgHighTemp

BAT overtemp

Charging Low Temperature

ChgUT

lvl x alarm

ChgLowTemp

Lower-temp

Charging Temperature Difference

ChgTdiff

lvl x alarm

ChgDiffTemp

Cell-temp DIFF

1. Use PC to check the alarm level.

2. If the alarm level is class 2, there is no need to deal with it while charging the battery.

3. If the alarm level is class 3, check which cell temperature is abnormally low or high. Replace the module that includes this cell.

Charging Overcurrent

AcChgOC

lvl x alarm

AcOverCur

Overcurrent

1. If the alarm level is class 1 or class 2, no need to deal with it when charging the battery.

2. If the alarm level is class 3, contact the charger supplier to solve it.

Charger Input Undervoltage

Input undervolt

Charger Input Overvoltage

Input overvolt

Check the electric power supply. Contact electric power company.

Charger Input Fault

Input fault

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Table 47. Charging Alarm Codes and Solutions (Continued) Fault Description

Charger

Solutions

Charger Overcharge Protection

CH overcharge

Check the charger. Contact charger supplier.

Charger Short Circuit Protection

Short circuit

Charger Overcurrent Protection

CH overcurrent

Charger Overtemperatur e Protection

CH overtemp

Charger One Module Work

One module work

Charger Module Timeout

Module timeout

Charger Fan Fault

Fan fault

BMS Timeout

BMS Timeout

196

PC

Battery Displayer

Check CAN cable connection between charger and battery.

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Troubleshooting (CATL-based Lithium-ion Battery)

Charger Faults and Solutions Table 48. Charger Faults and Solutions Fault Description

Information in LCD Screen

Solutions

LCD screen and LED lights on the panel are off after starting the charger.

LCD screen shows nothing.

1. Check whether the threephase switch on the side of the charger is in the ON position.

2. Check whether the input three-phase power is connected or not and whether is there any lack of phase.

3. Check whether the threephase fuse in the charger is fused.

4. Check whether the 12V+ auxiliary power module in the charger is damaged.

5. Check whether the 5V power on the LCD is normal.

6. Check whether the LCD screen is broken.

The charger can not work after being started. LCD screen is on and LED green light flickers.

Status: standby Error: ok Voltage: 0V SOC: 0.0％

1. Check whether the charging gun and the lift truck is in good connection.

2. Click the battery icon to enter the next interface on LCD screen. If the screen shows that ‘Whether receive the message of the charger: ‘NO’., the control panel of the charger was broken.

3. Check If the screen shows that 'Whether receive the message of the charger: ‘YES’.' or 'Whether receive the message of BMS: ‘NO’., check whether the +12V power of the charging gun A+ and A- is normal or not. If it is normal, the battery is damaged, contact the battery manufacturer.

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Table 48. Charger Faults and Solutions (Continued) Fault Description

Information in LCD Screen

Solutions

The charger can not work charge after being started. LCD screen is on and LED green light flickers.

Status: standby Error: ok Voltage: 0V SOC: 0.0％

1. Check whether the charging gun and the lift truck is in good connection.

2. Click the battery icon to enter the next interface on LCD screen. If the shows that ‘Whether receive the message of the charger: ‘NO’’. Whether receive the message of BMS: ‘NO’. ’ The +12V power is broken.

Replace the +12V auxiliary power.

The charger can not work after being started. LCD screen is on and LED green light flickers.

Status: standby Error: ok Voltage: 0V SOC: **.*％

1. Check whether the charging gun and sockets are in good connection.

2. Open the back door of the charger, measure the voltage between positive and negative terminals with multimeter which connects the charging gun and the charger.

A. If the voltage can not be measured, the battery is damaged.

B. If the voltage can be measured, measure the voltage between OUT+ and OUT- terminals. If voltage still can be measured, the control panel is broken.

Otherwise, check if 300A fuse, pre-charge resistors and diodes between the two ends of the output contactor are broken.

The charger can not work after being started. LCD screen and LED red light are both on.

Status: standby Error: ok SOC: **.*％ Battery Voltage: **.*％ Current: 0A

The output contactor is damaged (charging voltage reaches BMS demand voltage).

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Table 48. Charger Faults and Solutions (Continued) Fault Description

Information in LCD Screen

Solutions

The charger charges after being started. LCD screen and LED red light are both on. Charging current is less than BMS required current.

Status: standby Error: one module work SOC: **.*％ Voltage: **.*V Current: ***A

1. Check whether the input power of the charging module is normal and whether the connector is loose.

2. Check whether the output connector of the charging module is loose. whether CAN 3. Check communication connection line is loose.

4. If the above checks are normal, the charging module is broken.

The charger can not work after being started. LCD screen and LED yellow light are both on.

Status: fault Error: input fault Voltage: **.*V SOC: **.*％

Input lacks phase. Check the fuse in L3 phase and three-phase circuit breaker of the charger.

Electricity connected to the charger lacks L3 phase.

The charger can not work after being started. LCD screen and LED yellow lights are both on.

Meanwhile, charger starts repetitively.

Status: fault Error: input fault Voltage: **.*V SOC: **.*％

Input is lack of phase. Check the fuse in L1 or L2 phase and threephase circuit breaker of the charger.

Electricity connected to the charger is lack of L1or L2 phase.

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Troubleshooting (CATL-based Lithium-ion Battery)

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Discharge Alarm Codes and Solutions Table 49. Discharge Alarm Codes and Solutions Fault Description

PC and Remote Monitor

Battery Displayer

ERPUX Instrument

ERPUXT Instrument

Solutions 1. If low SOC level 3 alarm appears, charge the battery immediately; 2. If there is no low SOC alarm, use PC to check which cell voltage is too low. Replace the module that includes this cell.

Discharge DchgPackUV Low Battery Voltage

lvl x alarm

DchgLowTot Volt

1.7

139

Discharge Low Cell Voltage

lvl x alarm

DchgLowVolt

2.1

127

Discharge DchgPackOV High Battery Voltage

lvl x alarm

DchgHighTot Volt

1.8

140

Discharge High Cell Voltage

DchgOV

lvl x alarm

DchgHighVolt

2.2

128

Discharge Cell Voltage Difference

DchgVdiff

lvl x alarm

DchgDiffVolt

2.7

133

200

DchgUV

Stop driving the truck and wait for 3s to start the truck again. The fault mainly caused by brake current backwash.

1. Use PC to check the cell voltage. one cell's 2. If voltage is abnormally low or high. Replace the module which includes this cell.

3. If the cell voltage of one series module is consistently higher than others, check whether the copper bar of this series module is loose, so that the discharge current can not output from this series module. Tighten the related copper bar if needed.

8000 YRM 2353

Troubleshooting (CATL-based Lithium-ion Battery)

Table 49. Discharge Alarm Codes and Solutions (Continued) Fault Description

PC and Remote Monitor

Battery Displayer

ERPUX Instrument

ERPUXT Instrument

Solutions

Discharge High Temperature

DchgOT

lvl x alarm

DchgHighTe mp

2.3

129

Ignore it when driving the truck. The BMS reduces discharge current automatically.

Discharge Low Temperature

DchgUT

lvl x alarm

DchgLowTem p

2.5

131

1. Use PC to check the alarm level.

2. If the alarm level is class 2, then drive the truck with full load to heat the battery until the alarm disappears.

3. If the alarm level is class 3, use the charger to heat the battery until the alarm disappears (heating rate: 0.3°C (32.5°F) / min).

Discharge Temperature Difference

DchgTdiff

lvl x alarm

DchgDiffTem p

2.8

134

1. Use PC to check the alarm level.

2. If the alarm level is class 2, ignore it when driving the truck.

3. If the alarm level is class 3, check which cell’s temperature is abnormally low or high. Replace the module which includes this cell.

Momentary Discharge Overcurrent

DchgTransO C

lvl x alarm

DchgTransO verCur

1.4

136

Continuously DchgContOC Discharge Overcurrent

lvl x alarm

DchgConOve rCur

1.4

136

Stop driving the truck and wait for 3s to recover. It is mainly caused by longtime extra heavy-duty operation.

201

Troubleshooting (CATL-based Lithium-ion Battery)

8000 YRM 2353

Table 49. Discharge Alarm Codes and Solutions (Continued) Fault Description

PC and Remote Monitor

Battery Displayer

ERPUX Instrument

ERPUXT Instrument

Solutions

Feedback Current

FeedbackOC

lvl 3 alarm

FbOverCur

1.3

135

This fault appears when a lead-acid charger which has no CAN communication is used to charge the battery from the discharge port for five minutes, the fault. So stop the charging immediately.

Low SOC

LowSOC

lvl x alarm

LowSOC

1.5

137

1. If only the buzzer alarms, but no speed limit and lifting prevention, it is recommended to charge the battery.

2. If speed limit and lifting lock happens, charge the battery immediately.

202

8000 YRM 2353

Troubleshooting (CATL-based Lithium-ion Battery)

Battery System Alarm Codes and Solutions Table 50. Battery System Alarm Codes and Solutions Fault Description

PC

Battery Displayer

VoltageDetection Cable Loose

VoltOpenWire

lvl 3 alarm

VoltLine

TemperatureDetection Cable Loose

TempOpenWi re

lvl 3 alarm

TempLine

Contactor Adhesion

RlyFault

lvl 3 alarm

RlyFault

Abnormal Current

CurAbnormal

lvl 3 alarm

CurAbnormal

Charger

Solutions 1. Use PC to check which cell’s voltage or temperature is NC and record its BMS CSC port number.

2. Open the battery service cover and disconnect the CSC wire from this BMS CSC port.

3. Use wire sequence detector to check whether the signal from this CSC wire is normal. If yes, replace the BMS. If no, check whether the module FPC output signal is normal by wire sequence detector.

If yes, replace the CSC wire. If no, replace the module.

the current 1. If exceeds the detection range of hall transducer for five seconds, this alarm appears. In such situation, ignore the alarm. the alarm 2. If continues, check the assembly direction of the halldirection.

If incorrect, reassemble it. If correct, replace it with a new one.

203

Troubleshooting (CATL-based Lithium-ion Battery)

8000 YRM 2353

Table 50. Battery System Alarm Codes and Solutions (Continued) Fault Description

PC

Battery Displayer

Charger

Solutions Replace BMS.

Internal Communication Failure

InterComm

lvl x alarm

InterComm

BMS Fault

BMS SelfDetection Failure

N/A

N/A

N/A

BMS Fault

Heating Failure

HeatFault

lvl 3 alarm

HeatFault

204

1. Check whether the charger is connected to battery discharge port. yes, A. If disconnect it and connect it to battery charging port.

B. If no, then check the charger current.

Please contact charger supplier if there’s no heating current.

8000 YRM 2353

Troubleshooting (CATL-based Lithium-ion Battery)

Other Battery Faults and Solutions Table 51. Other Battery Faults and Solutions Fault Descriptions

Solutions

No LED light and no discharge contactor reactions when pressing the battery button.

1. Open the top cover of the battery and check the wire connection of the battery power button.

A. If the wire is disconnected or loose, connect it firmly.

B. If the wire is connected well, check the input voltage and output voltage of DC converter. a. If there is no input voltage, replace the battery power button. b. If there is input voltage, but no output voltage, replace DC converter.

LED light is on but discharge contactor has no reaction when pressing the battery power button.

1. Open the detection cover and check the wire connection of discharge contactor.

A. If the wire is disconnected or loose, connect it firmly.

B. If the wire is connected well, replace the discharge contactor.

LED light is on and discharge contactor closes when pressing the battery power button. But after releasing the battery power button, LED light is off and discharge contactor opens.

1. Open the service cover and check the wire connection of the holding relay.

A. If the wire is disconnected or loose, connect it firmly.

B. If the wire is connected well, replace the holding relay.

LED light is on and discharge contactor closes when pressing the battery button and then release the button.

But there is no power output from discharge connector.

1. Check the voltage of the discharge connector.

The battery fuse is always fused.

A. If the voltage exists, connect the power cable and CAN cable with the truck firmly.

B. If there is no voltage, check the connection of power cable and buss bar. a. If the power cable and buss bar are disconnected or loose, fasten them. b. If the power cable and buss bar are connected well, disconnect the holding relay and replace it.

1. If the fault appears when the truck and charger is not connected, check the battery insulation.

2. If the fault appears when driving the truck, check the truck insulation.

3. If the fault appears when charging, check the charger insulation.

4. After eliminating insulation errors, replace the battery fuse.

205

Troubleshooting (CATL-based Lithium-ion Battery)

8000 YRM 2353

Table 51. Other Battery Faults and Solutions (Continued) LED light is still on and discharge contactor still closes when pressing the battery button for three seconds and then release.

1. Open the top cover of the battery and check the wire connection of the battery power button.

A. If the wire is disconnected or loose, connect it firmly.

B. If the wire is connected well, disconnect the hlding relay and replace it.

The temperature of the battery case and power cable is much higher than normal during charging or discharging.

1. Check the connection bolts of the power cable and buss bar and tighten the loose bolts.

Battery is dead quickly after discharging and can be fully charged in short time.

1. Use PC to check the capacity setting and SOC.

Charging current is much lower than BMS requested current.

Contact the charger supplier to replace the charger module or replace charger.

The truck still can run when powering off the battery.

Replace the discharge contactor.

The battery fuse is always fused.

1. If the fault appears when the truck and charger is not connected, check the battery insulation.

2. If the fault appears when driving the truck, check the truck insulation.

3. If the fault appears when charging, check the charger insulation.

4. After eliminating insulation errors, replace the battery fuse.

206

A. If the capacity is inconsistent with the actual capacity, correct it.

B. If SOH is below 80%, the battery life ends.

8000 YRM 2353

Troubleshooting (CATL-based Lithium-ion Battery)

Discharge Fault Threshold Table 52. Discharge Fault Threshold Fault Description

Failure Value

Delay

Recovery Value

Delay

Protection Logic

Discharge Low Battery Voltage

77.2V Battery--69.6V 51.2V Battery--46.4V

3s

77.2V Battery--74.4V 51.2V Battery--49.6V

3s

Buzzer alarms (Interval 10s, Duration 2s)

77.2V Battery--64.8V 51.2V Battery--43.2V

3s

77.2V Battery--70.8V 51.2V Battery--47.2V

3s

Buzzer alarms continuously The truck power is reduced to 50%; Travel speed is limited to 50%; No lifting function

77.2V Battery--60V 51.2V Battery--40V

1s

77.2V Battery--81.6V 51.2V Battery--54.4V

3s

Buzzer alarms continuously Discharge contactor is cutoff

2.9V

3s

3.1V

3s

Buzzer alarms (Interval 10s, Duration 2s)

2.7V

3s

2.95V

3s

Buzzer alarms continuously The truck power is reduced to 50%; Travel speed is limited to 50%; No lifting function

2.55V

1s

3.4V

3s

Buzzer alarms continuously Discharge contactor is cutoff

77.2V Battery--87.6V 51.2V Battery--58.4V

5s

77.2V Battery--86.4 51.2V Battery--57.6

3s

Buzzer alarms (Interval 2s, Duration 2s)

77.2V Battery--88.8V 51.2V Battery--59.2V

3s

77.2V Battery--87.6 51.2V Battery--58.4

3s

Buzzer alarms continuously Discharge contactor is cutoff

Discharge Low Cell Voltage

Discharge High Battery Voltage

207

Troubleshooting (CATL-based Lithium-ion Battery)

8000 YRM 2353

Table 52. Discharge Fault Threshold (Continued) Fault Description

Failure Value

Delay

Recovery Value

Delay

Protection Logic

Discharge High Cell Voltage

3.62V

5s

3.6V

3s

Buzzer alarms (Interval 2s, Duration 2s)

3.7V

3s

3.62V

3s

Buzzer alarms continuously Discharge contactor is cutoff

Discharge Cell Voltage Difference

0.5V

3s

0.2V

3s

Buzzer Alarm continuously Discharge contactor is cutoff

Discharge High Temperature

55°C (131°F)

3s

50°C (122°F)

3s

Buzzer alarms (Interval 2s, Duration 2s)

60°C (140°F)

3s

55°C (131°F)

3s

Buzzer alarms continuously The truck power is reduced to 50%; Travel speed is limited to 50%; No lifting function

65°C (149°F)

1s

50°C (122°F)

3s

Buzzer alarms continuously Discharge contactor is cutoff

250AH Battery–10°C (50°F) 375AH Battery–25°C (77°F) 500AH Battery–25°C (77°F)

5s

250AH Battery–5°C (41°F) 375AH Battery–20°C (68°F) 500AH Battery–20°C (68°F)

3s

Buzzer alarms continuously The truck power is reduced to 50%; Travel speed is limited to 50%; No lifting function

250AH Battery–25°C (77°F) 375AH Battery–30°C (86°F) 500AH Battery–25°C (86°F)

5s

-10°C (14°F)

3s

Buzzer alarms continuously Discharge contactor is cutoff

Discharge Low Temperature

208

8000 YRM 2353

Troubleshooting (CATL-based Lithium-ion Battery)

Table 52. Discharge Fault Threshold (Continued) Fault Description

Failure Value

Delay

Recovery Value

Delay

Protection Logic

Discharge Temperature Difference

15

5s

12

3s

Buzzer alarms continuously The truck power is reduced to 50%; Travel speed is limited to 50%; No lifting function

20

5s

5

3s

Buzzer alarms continuously Discharge contactor is cutoff

250AH Battery--300 375AH Battery--400 500AH Battery--400

20s

150

3s

Buzzer alarms (Interval 10s, Duration 2s)

250AH Battery--400 375AH Battery--500 500AH Battery--500

15s

0

3s

Buzzer alarms continuously Discharge contactor is cutoff

250AH Battery--220 375AH Battery--300 500AH Battery--300

5min

250

3s

Buzzer alarms (Interval 2s, Duration 2s)

250AH Battery--250 375AH Battery--350 500AH Battery--350

3min

N/A

N/A

Buzzer alarms continuously Discharge contactor is cutoff

10

5min

N/A

N/A

Buzzer alarms continuously Discharge contactor is cutoff

Momentary Discharge Overcurrent

Continuous Discharge Overcurrent

Feedback Current

209

Troubleshooting (CATL-based Lithium-ion Battery)

8000 YRM 2353

Charging Fault Threshold Table 53. Charging Fault Threshold Fault Description

Failure Value

Delay

Recovery Value

Charging High Battery Voltage

51.2V Battery--58.4V 77.2V Battery--87.6V

3s

51.2V Battery--52.8V 77.2V Battery--79.2V

3s

Charging contactor is cutoff

Charging High Cell Voltage

3.62V

3s

3.3V

3s

Charging contactor is cutoff

Charging Low Battery Voltage

51.2V Battery--40V 77.2V Battery--60V

3s

51.2V Battery--40.8V 77.2V Battery--61.2V

3s

Alarm code appears in battery displayer

51.2V Battery--35.2V 77.2V Battery--52.8V

3s

51.2V Battery--37.6V 77.2V Battery--56.4V

3s

Alarm code appears in battery displayer Reduce charging current to 50% of single charging current

51.2V Battery--32V 77.2V Battery--48V

1s

51.2V Battery--36V 77.2V Battery--54V

3s

Buzzer alarms continuously Charging contactor is cutoff

2.5V

3s

2.55V

3s

Alarm code appears in battery displayer

2.2V

3s

2.35V

3s

Alarm code appears in battery displayer Reduce charging current to 50% of single charging current

2V

1s

2.25V

3s

Continuously Buzzer Alarm Charging contactor is cutoff

Charging Low Cell Voltage

210

Delay Protection Logic

8000 YRM 2353

Troubleshooting (CATL-based Lithium-ion Battery)

Table 53. Charging Fault Threshold (Continued) Fault Description

Failure Value

Delay

Recovery Value

Charging Cell Voltage Difference

0.4V

5s

0.2V

1s

Alarm code appears in battery displayer Charging current is reduced to 50% of the single charging current

0.6V

5s

0.45V

1s

Buzzer alarms continuously Charging contactor is cutoff

60°C (140°F)

3s

48°C (118.4°F)

1s

Alarm code appears in battery displayer

65°C (149°F)

1s

50°C (122°F)

1s

Buzzer alarms continuously Charging contactor is cutoff

5°C (41°F)

5s

(8°F) (46.4°F)

1s

Alarm code appears in battery displayer

3°C (37.4°F)

5s

5°C (41°F)

1s

Alarm code appears in battery displayer Charging current is reduced to 50% of single charging current

0°C (32°F)

5s

5°C (41°F)

1s

Buzzer alarms continuously Charging contactor is cutoff

15°C (59°F)

5s

12°C (53.6°F)

1s

Alarm code appears in battery displayer Charging current is reduced to 50% of single charging current

20°C (68°F)

5s

15°C (59°F)

1s

Buzzer alarms continuously Charging contactor is cutoff

Charging High Temperature

Charging Low Temperature

Charging Temperature Difference

Delay Protection Logic

211

Troubleshooting (CATL-based Lithium-ion Battery)

8000 YRM 2353

Table 53. Charging Fault Threshold (Continued) Fault Description

Failure Value

Delay

Recovery Value

Delay Protection Logic

Charging Overcurrent

250AH Battery–205 amps 375AH Battery–305 amps 500AH Battery–405 amps

10s

250AH Battery–200 amps 375AH Battery–300 amps 500AH Battery–400 amps

1s

Alarm code appears in battery displayer

250AH Battery–210 amps 375AH Battery–310 amps 500AH Battery–410 amps

10s

250AH Battery–200 amps 375AH Battery–300 amps 500AH Battery–400 amps

1s

Alarm code appears in battery displayer Charging current is reduced to 50% of the single charging current

250AH Battery–220 amps 375AH Battery–320 amps 500AH Battery–420 amps

3s

N/A

N/A

Buzzer alarms continuously Charging contactor is cutoff

Other Fault Threshold Table 54. Other Fault Threshold Fault Description

Failure Value

Delay

Recovery Value

BMS SelfDetection Failure

Failure

1s

Restart

Voltage-Detection Cable Loose

Failure

5s

Recover

Delay

Buzzer alarms continuously All contactors are cut off 30s

30s

TemperatureDetection Cable Loose

Contactor Adhesion

212

Failure

Failure

5s

Protection Logic

Buzzer alarms (Interval 10s, Duration 2s) Buzzer alarms continuously All contactors are cutoff

Recover

30s

Buzzer alarms (Interval 10s, Duration 2s)

30s

Buzzer alarm continuously All contactors are cutoff

1s

Buzzer alarms continuously All contactors are cutoff

8000 YRM 2353

List of Wear Parts

Table 54. Other Fault Threshold (Continued) Fault Description

Failure Value

Delay

Recovery Value

Delay

Protection Logic

Abnormal Current

Failure

5s

Recover

5s

Buzzer alarms continuously Discharge contactor is cutoffs

Internal Communication Failure

Failure

30s

Buzzer alarms continuously All contactors are cutoff

Heating Failure

Failure

1s

Buzzer alarms continuously All contactors are cutoff

List of Wear Parts Table 55. Some Wearing Parts S/N

Name

Qty

Installed Position

1

Paper cushion

1

Driving Axle

2

Half shaft pad

2

Driving Axle

3

Main overflow valve

1

Multi-way Valve

4

CDB-F15-2.02 Dust ring

8

Multi-way Valve

5

404-0014-15 Oil seal

1

Gear pump

6

402-12754 Seal ring

2

Gear pump

7

402-12086 3-Shape seal ring

2

Gear pump

8

404-00005-02 Retainer Ring 36

1

Gear pump

9

BZZ1.A401 X-shape seal ring

1

Orbitrol

10

BZZ1.A407 Seal ring

1

Orbitrol

11

BZZ1.A406 Seal ring

2

Orbitrol

12

Piston

1

Lifting Cylinder (Standard)

13

Piston

1

Tilting Cylinder

14

Instrument Left Cover Plate

1

Instrument Rack

15

Instrument Right Cover Plate

1

Instrument Rack

16

Various Hoses

Hydraulic System / Mast Piping System

213

List of Wear Parts

8000 YRM 2353

Table 56. Oil Seal

214

S/N

Standard

Model/Spec

Qty

Installed Position

1

GB/T9877.1-1988

B100×130×12

2

Driving Axle

2

GB/T9877.1-1988

B100×125×12

1

Driving Axle

3

GB/T9877.1-1988

B70×100×10

2

Driving Axle

4

GB/T9877.1-1988

B70×95×10

1

Driving Axle

5

GB/T9877.1-1988

B50×70×12

1

Gearbox

6

GB/T9877.1-1988

B55×72×8

1

Gearbox

7

NOK

Shaft Seal 35×45×6

2

ERP15UX Lifting Cylinder (Standard)

8

NOK

Shaft Seal 40×50×6

2

ERP20UX - ERP25UX Lifting Cylinder (Standard)

9

NOK

Shaft Seal 45×55×6

2

ERP30UX - ERP35UX Lifting Cylinder (Standard)

10

LBH

Dust Ring 35×45×5/6.5

2

ERP15UX Lifting Cylinder (Standard)

11

LBH

Dust Ring 40×48×5/6.5

2

ERP20UX - ERP25UX Lifting Cylinder (Standard)

12

LBH

Dust Ring 45×53×5/6.5

2

ERP30UX - ERP35UX Lifting Cylinder (Standard)

13

NOK

Hole Seal 45×35×6

2

ERP15UX Lifting Cylinder (Standard)

14

NOK

Hole Seal 50×40×3

2

ERP20UX - ERP25UX Lifting Cylinder (Standard)

15

NOK

Hole Seal 56×45×7

2

ERP30UX - ERP35UX Lifting Cylinder (Standard)

16

LBH

Dust Ring 30×38×5/6.5

1

ERP15UX Tilting Cylinder

17

LBH

Dust Ring 32×52×8/11

1

ERP20UX - ERP25UX Tilting Cylinder

18

LBH

Dust Ring 35×43×5/6

1

ERP30UX - ERP35UX Tilting Cylinder

19

NOK

Shaft Seal 30×40×6

1

ERP15UX Tilting Cylinder

20

NOK

Shaft Seal 32×48×10

1

ERP20UX - ERP25UX Tilting Cylinder

21

NOK

Shaft Seal 35×45×6

1

ERP30UX - ERP35UX Tilting Cylinder

22

NOK

Hole Seal D63×53×6

2

ERP15UX Tilting Cylinder

23

NOK

Hole Seal D70×60×6

2

ERP20UX - ERP25UX Tilting Cylinder

24

NOK

Hole Seal D80×70×6

2

ERP30UX - ERP35UX Tilting Cylinder

8000 YRM 2353

List of Wear Parts Table 57. O-Seal Ring

S/N

Standard

Spec

Qty

Installed Position

1

GB3452.1-1992

67×2.65G

2

ERP15UX Driving Axle

2

GB3452.1-1992

71×3.55G

2

ERP20UX - ERP25UX Driving Axle

3

GB1235-76

35×3.1G

2

Gearbox

4

GB1235-76

75×3.1

2

Gearbox

5

GB1235-76

16×2.4

2

Multi-way Valve

6

GB1235-76

63×3.1

5

Multi-way Valve

7

GB1235-76

31×3.5

2

Multi-way Valve

8

ISO6149

15.3×2.2

1

Multi-way Valve

9

P15

14.8×2.4

8

Multi-way Valve

10

GB1235-76

9×1.9

1

Multi-way Valve

11

GB1235-76

22×2.4

1

Multi-way Valve

12

GB3452.1-1992

77.5×2.65

1

Orbitrol

13

GB1235-76

50×3.1

1

15

GB1235-76

22×2.4

1

ERP15UX Lifting Cylinder (Standard)

16

GB1235-76

60×3.1

2

ERP20UX - ERP25UX Lifting Cylinder (Standard)

17

GB1235-76

68×3.1

2

ERP30UX Lifting Cylinder (Standard)

18

GB1235-76

75×3.1

2

ERP35UX Lifting Cylinder (Standard)

19

GB1235-76

63×3.1

1

ERP15UX Tilting Cylinder

20

GB1235-76

22×2.4

1

ERP15UX Tilting Cylinder

21

GB1235-76

70×5.7

1

ERP20UX - ERP25UX Tilting Cylinder

22

GB1235-76

38×3.5

1

ERP20UX - ERP25UX Tilting Cylinder

23

GB1235-76

80×5.7

1

ERP30UX - ERP35UX Tilting Cylinder

24

GB1235-76

41×3.5

1

ERP30UX - ERP35UX Tilting Cylinder

25

GB1235-76

18×2.4

2

Hydraulic System

26

GB1235-76

35×3.5

1

Hydraulic System

27

GB1235-76

22×2.4

13

Hydraulic System

14

215

List of Wear Parts

8000 YRM 2353 Table 58. Combination Seal Ring

S/N

Standard

Spec

QTY

Installed Position

1

JB/T 982-1977

20

1

Driving Axle

2

JB/T 982-1977

18

2

Hinged Bolt

Table 59. Some Electric Appliance Components

216

S/N

Name

Model/Spec

Qty

Remarks

1

Fuse Box

BX2081

1

2

Microswitch

RZ-15GQ22-B3

1

Parking Brake

3

Microswitch

Z-15GW22-B

1

Multi-way Valve

8000 YRM 2353

9/23 (5/23)(2/23)(1/23)(8/22)(4/22)