EP Equipment CPD30L1-B Manuel utilisateur

Service Manual

Electric Forklift Truck

CPD30/35L1-B

CPD30/35L1-S

Service Manual

Electric Forklift Truck

CPD30/35L1-B

CPD30/35L1-S

Release Date Version No. Changes (Serial number)

2020-05-23 SM-3131 05.20 Serial number V1

This manual applies to:

Model Specications

CPD30/35L1-B 3,000/3,500 kg Capacity, Full Height Series, Four-wheel, General

CPD30/35L1-S 3,000/3,500 kg Capacity, Full Height Series, Four-wheel, Deluxe

Some sections of the manual only involve certain model, please refer to the manual

according to the actual conguration of the vehicle.

* If there are any changes, revised version will be published once every 12 months;

if there is no change, please follow the most recent version.

* Please refer to the corresponding version of the service manual against the purchase time

of your vehicle.

* If you need the latest versions of the manual, please contact our service department or

dealer to obtain.

EP Equipment Co., Ltd.

EP Industrial Park, Xiaquan Village,

Dipu Town, Anji County, Zhejiang Province, P.R.China

www.ep-ep.com

Safety signs and instructions:

Please strictly adhere to these safety instructions to avoid personal injury.

Please pay attention to the important safety instructions.

Instructions.

FOREWORD

This Service Manual can help readers learn more about the truck system components,

maintenance and troubleshooting, and other related information. The operation and

maintenance personnel must read this Manual carefully before using the product. And when

vehicle is in use, be sure to follow the complete operation and maintenance information in

this Manual for vehicle maintenance.

Before using, please check if the pages of the Manual are clear and complete, so as not

to a󰀨ect your normal use because of incomplete information. If the contents of the Manual

have been illegible or damaged, which may a󰀨ect reading, please contact our company or

dealer for replacement.

With the constant update and improvement of our products, the equipment you are using

may be slightly di󰀨erent from what has been described in this Manual, therefore, we must

reserve the right to modify the appearance, conguration and technical specications. If you

have any questions, please contact our sales department or dealer.

EP Equipment Co., Ltd.

REV. SM-3131 05.20

REV. 05/2020

TABLE OF CONTENTS

1. INFORMATION & SPECIFICATIONS..............................1

1.1 After-sales Service Platform .........................................3

1.2 Introduction...................................................................4

1.3 Common Tools..............................................................5

1.4 General Tightening Torques .........................................6

2. MAINTENANCE...............................................................9

2.1 Overview..................................................................... 11

2.2 Maintenance...............................................................12

2.2.1 Cleaning ........................................................................12

2.2.2 Inspection ......................................................................12

2.2.3 Lubrication.....................................................................17

3. STRUCTURE & FUNCTIONS........................................19

3.1 Structure & Functions.................................................21

3.1.1 Travel Combination Switch ............................................21

3.1.2 Emergency Stop Switch ................................................21

3.1.3 Warning Light Switch.....................................................21

3.1.4 Horn Button ...................................................................21

3.1.5 Key Switch.....................................................................22

3.1.6 Lighting Combination Switch .........................................22

3.1.7 Reversing Buzzer ..........................................................22

3.1.8 MDI Instrument..............................................................22

3.1.9 Accelerator Pedal ..........................................................23

3.1.10 Brake Pedal.................................................................23

3.1.11 Horn .............................................................................23

3.1.12 Control Switch .............................................................23

3.1.13 Warning Light ..............................................................24

3.1.14 Combination Light........................................................24

3.1.15 Headlight .....................................................................24

3.1.16 Main Contactor ............................................................24

3.1.17 Pump Controller...........................................................25

3.1.18 Traction Controller .......................................................25

3.1.19 Fuse on Controller.......................................................25

3.1.20 DC-DC Converter ........................................................25

3.1.21 Multi-way Manual Valve ..............................................26

3.1.22 Pump Motor ................................................................26

3.1.23 Gear Pump ..................................................................26

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4. CHASSIS SYSTEM........................................................27

4.1 Steering Wheel ..........................................................29

4.1.1 Removal and Installation ...............................................29

4.1.2 Faults and Causes.........................................................30

4.2 Cover..........................................................................30

4.2.1 Removal and Installation ...............................................30

4.3 Seat ............................................................................31

4.3.1 Removal and Installation ...............................................31

4.4 Parking Brake.............................................................31

4.4.1 Removal and Installation ...............................................31

4.5 Parking Brake.............................................................32

4.5.1 Removal and Installation ...............................................32

4.5.2 Faults and Causes.........................................................33

5. DRIVE SYSTEM.............................................................35

5.1 Drive Wheel................................................................38

5.1.1 Removal and Installation ...............................................38

5.1.2 Faults and Causes.........................................................38

5.2 Drive Motor.................................................................39

5.2.1 Removal and Installation ...............................................39

5.2.2 Faults and Causes.........................................................40

5.2.3 Checking and Testing ....................................................41

5.2.4 Control Circuit Troubleshooting .....................................42

5.3 Gearbox......................................................................44

5.3.1 Removal and Installation ...............................................44

5.3.2 Faults and Causes.........................................................44

5.3.3 Component....................................................................45

5.4 Drive Axle ...................................................................46

5.4.1 Removal and Installation ...............................................46

5.4.2 Component....................................................................46

5.4.3 Drive Axle Oil .................................................................48

5.4.4 Faults and Causes.........................................................48

6. OPERATING SYSTEM...................................................49

6.1 Control Lever..............................................................51

6.2 Horn Button ................................................................52

6.2.1 Removal and Installation ...............................................52

6.2.2 Faults and Causes.........................................................52

6.2.3 Checking and Testing ....................................................53

6.2.4 Control Circuit Troubleshooting .....................................53

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6.3 Travel Combination Switch .........................................54

6.3.1 Removal and Installation ...............................................54

6.3.2 Faults and Causes.........................................................54

6.3.3 Checking and Testing ....................................................54

6.3.4 Control Circuit Troubleshooting .....................................55

6.4 Lighting Combination Switch ......................................57

6.4.1 Removal and Installation ...............................................57

6.4.2 Faults and Causes.........................................................57

6.4.3 Checking and Testing ....................................................57

6.4.4 Control Circuit Troubleshooting .....................................58

6.5 Key Switch..................................................................59

6.5.1 Removal and Installation ...............................................59

6.5.2 Faults and Causes.........................................................59

6.5.3 Checking and Testing ....................................................59

6.5.4 Control Circuit Troubleshooting .....................................59

6.6 Warning Light Switch..................................................60

6.6.1 Removal and Installation ...............................................60

6.6.2 Faults and Causes.........................................................60

6.6.3 Checking and Testing ....................................................60

6.6.4 Control Circuit Troubleshooting .....................................60

6.7 Emergency Switch......................................................61

6.7.1 Removal and Installation ...............................................61

6.7.2 Faults and Causes.........................................................61

6.7.3 Checking and Testing ....................................................61

6.7.4 Control Circuit Troubleshooting .....................................61

6.8 Parking Brake Switch .................................................62

6.8.1 Removal and Installation ...............................................62

6.8.2 Faults and Causes.........................................................62

6.8.3 Connection Mode ..........................................................62

6.8.4 Checking and Testing ....................................................62

6.8.5 Control Circuit Troubleshooting .....................................63

6.9 Control Switch ............................................................64

6.9.1 Removal and Installation ...............................................64

6.9.2 Faults and Causes.........................................................64

6.9.3 Checking and Testing ....................................................64

6.9.4 Control Circuit Troubleshooting .....................................65

7. HYDRAULIC SYSTEM...................................................69

7.1 Overview.....................................................................71

7.1.1 Hydraulic Schematic Diagram .......................................72

7.2 Hydraulic Power Unit..................................................73

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7.2.1 Removal and Installation ...............................................73

7.3 Pump Motor................................................................73

7.3.1 Removal and Installation ...............................................73

7.3.2 Faults and Causes.........................................................74

7.3.3 Checking and Testing ....................................................75

7.3.4 Control Circuit Troubleshooting .....................................76

7.4 Multi-way Reversing Manual Valve.............................78

7.4.1 Removal and Installation ...............................................78

7.4.2 Interface Description......................................................79

7.4.3 Faults and Causes.........................................................79

7.4.4 Checking and Testing ....................................................79

7.5 Gear Pump .................................................................80

7.5.1 Removal and Installation ...............................................80

7.5.2 Faults and Causes.........................................................80

7.5.3 Checking and Testing ....................................................80

7.6 Redirector...................................................................81

7.6.1 Removal and Installation ...............................................81

7.6.2 Faults and Causes.........................................................81

7.6.3 Checking and Testing ....................................................81

7.7 Tilt Cylinder.................................................................82

7.7.1 Cylinder Removal Precautions ......................................82

7.7.2 Cylinder Installation Precautions ...................................83

7.7.3 Removal and Installation ...............................................84

7.7.4 Cylinder Maintenance....................................................85

7.8 Hydraulic Troubleshooting ..........................................86

7.9 Hydraulic Symbol........................................................87

8. STEERING SYSTEM .....................................................89

8.1 Steering Bridge ..........................................................92

8.1.1 Removal and Installation ...............................................92

8.1.2 Faults and Causes.........................................................92

8.1.3 Component....................................................................93

8.2 Displacement Sensor .................................................94

8.2.1 Removal and Installation ...............................................94

8.2.2 Faults and Causes.........................................................94

8.2.3 Checking and Testing ....................................................94

8.2.4 Control Circuit Troubleshooting .....................................94

8.3 Steering Cylinder........................................................96

8.3.1 Removal and Installation ...............................................96

8.3.2 Cylinder Maintenance....................................................96

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9. ELECTRICAL SYSTEM .................................................97

9.1 Controller....................................................................99

9.1.1 Removal and Installation ...............................................99

9.1.2 Controller Interface Function (CPD30/35L1-B)............101

9.1.3 Controller Interface Function (CPD30/35L1-S)............104

9.2 Fuse..........................................................................107

9.2.1 Location of Fuses ........................................................107

9.2.2 Checking and Testing ..................................................108

9.3 Main Contactor .........................................................109

9.3.1 Removal and Installation .............................................109

9.3.2 Faults and Causes....................................................... 110

9.3.3 Checking and Testing .................................................. 110

9.3.4 Control Circuit Troubleshooting ................................... 111

9.4 Accelerator Pedal ..................................................... 112

9.4.1 Removal and Installation ............................................. 112

9.4.2 Faults and Causes....................................................... 112

9.4.3 Checking and Testing .................................................. 112

9.4.4 Control Circuit Troubleshooting ................................... 113

9.5 DC-DC Converter ..................................................... 115

9.5.1 Removal and Installation ............................................. 115

9.5.2 Faults and Causes....................................................... 115

9.5.3 Checking and Testing .................................................. 115

9.5.4 Control Circuit Troubleshooting ................................... 115

9.6 Combination Light / Headlight / Warning Light ......... 116

9.6.1 Removal and Installation ............................................. 116

9.6.2 Faults and Causes....................................................... 116

9.6.3 Checking and Testing .................................................. 116

9.6.4 Control Circuit Troubleshooting ................................... 117

9.7 Seat Switch...............................................................118

9.7.1 Removal and Installation ............................................. 118

9.7.2 Faults and Causes....................................................... 118

9.7.3 Checking and Testing .................................................. 118

9.7.4 Control Circuit Troubleshooting ................................... 118

9.8 Handheld Unit-A (Optional).......................................120

9.8.1 Handheld Unit Connection...........................................120

9.8.2 Handheld Unit Menu Options ......................................120

9.9 Handheld Unit-B (Optional) ......................................121

9.9.1 Fault Detection ............................................................120

9.9.2 Testing Truck Operation...............................................122

9.9.3 Settings and Adjustments ............................................122

9.9.4 Adjustments.................................................................123

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9.9.5 Parameter Change ......................................................123

9.10 Parameter Settings.................................................124

9.11 TESTER Menu........................................................126

9.12 Controller Error Message .......................................132

9.12.1 Controller For CPD30/35L1-B(ACE2 master_uc)......132

9.12.2 Controller For CPD30/35L1-B ACE2 supervisor_uc) 151

9.12.3 Controller For CPD30/35L1-S(ACE3 master_uc)......155

9.12.4 Controller For CPD30/35L1-S(ACE3 slave_uc) ........169

9.13 Electrical Schematic Diagrams...............................171

9.14 Cable Wiring Diagrams ..........................................172

9.15 Wiring Harness and Connectors (CPD30/35L1-B) 173

9.15 Wiring Harness and Connectors (CPD30/35L1-S) 174

10. TROUBLESHOOTING...............................................175

10.1 Preparation Before Troubleshooting.......................177

10.1.1 Check the Voltage of Battery .........................................177

10.2 Troubleshooting Solutions of Common Faults......178

APPENDIX .......................................................................183

A SERVICE MANUAL - MAST .......................................185

A1 Wide-View Two-stage Mast ......................................187

A1-1 Removal and Installation........................................187

A1-2 Lifting Chains .........................................................188

A1-2.1 Chain Adjustment......................................................188

A1-2.2 Chain Replacement...................................................189

A1-3 Mast Tubing............................................................190

A1-4 Lift Cylinder ............................................................191

A1-4.1 Cylinder Removal .....................................................191

A1-4.2 Cylinder Maintenance ...............................................192

A1-4.3 Cylinder Installation...................................................192

A1-5 Built-in Side Shifter.................................................193

A1-5.1 Side Shifter Removal ................................................193

A1-5.2 Side Shifter Installation .............................................193

A1-6 External Side Shifter ..............................................194

A1-6.1 Side Shifter Removal ................................................193

A1-6.2 Side Shifter Installation .............................................193

A2 Two-stage Full Free Mast .........................................195

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