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EP Equipment CPD30L1-S User Manual

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Service Manual
Electric Forklift Truck
CPD30/35L1-B
CPD30/35L1-S

Table of Contents

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EP Equipment CPD30L1-S Specifications

General IconGeneral
Load Capacity3000 kg
Lift Height3000 mm
Power SourceElectric
Overall Width1250 mm
Load Center Distance500 mm
Fork Length1070 mm
Battery Voltage48 V

Summary

SAFETY WARNING

1. INFORMATION & SPECIFICATIONS

1.1 After-sales Service Platform

Describes the process for claims and maintenance service requests.

1.2 Introduction

Provides a general overview of the electric forklift truck series.

1.3 Common Tools

Lists the common tools required for maintenance and repair.

1.4 General Tightening Torques

Provides tables for screw/bolt performance levels and tightening torques.

2. MAINTENANCE

2.1 Overview

Introduces the importance of regular maintenance and qualified personnel.

2.2 Maintenance

Outlines general maintenance tasks including cleaning, inspection, and lubrication.

3. STRUCTURE & FUNCTIONS

3.1 Structure & Functions

Describes the various structural components and their functions on the forklift.

4. CHASSIS SYSTEM

4.1 Steering Wheel

Details the removal, installation, and checks for the steering wheel assembly.

4.2 Cover

Explains the procedure for removing and installing battery and floorboard covers.

4.3 Seat

Covers the removal, installation, and adjustment of the operator's seat.

4.4 Parking Brake

Outlines the removal and installation process for the parking brake mechanism.

4.5 Brake Pedal

Details the removal, installation, and troubleshooting of the brake pedal system.

5. DRIVE SYSTEM

5.1 Drive Wheel

Covers the removal, installation, faults, and causes related to the drive wheel.

5.2 Drive Motor

Details the AC drive motor, its removal, installation, faults, and troubleshooting.

5.3 Gearbox

Explains the gearbox removal, installation, faults, and components.

5.4 Drive Axle

Covers the drive axle's removal, installation, components, oil, and faults.

6. OPERATING SYSTEM

6.1 Control Lever

Describes the removal and installation of the control lever assembly.

6.2 Horn Button

Details the function, removal, installation, and troubleshooting of the horn button.

6.3 Travel Combination Switch

Explains the switch for forward, reverse, and neutral travel direction control.

6.4 Lighting Combination Switch

Covers the switch for turn signals, headlights, and marker lights.

6.5 Key Switch

Describes the key switch for starting and stopping the truck.

6.6 Warning Light Switch

Details the switch for controlling the warning light ON/OFF.

6.7 Emergency Switch

Explains the emergency power cut-off switch function and procedures.

6.8 Parking Brake Switch

Covers the parking brake switch operation, faults, and testing.

6.9 Control Switch

Describes the control switch for starting the pump motor.

7. HYDRAULIC SYSTEM

7.1 Overview

Provides a general introduction to the hydraulic system's pressure and components.

7.1.1 Hydraulic Schematic Diagram

Presents the schematic diagram of the hydraulic system.

7.2 Hydraulic Power Unit

Details the removal and installation of the hydraulic power unit.

7.3 Pump Motor

Explains the AC pump motor and its removal/installation procedures.

7.4 Multi-way Reversing Manual Valve

Covers the valve for controlling various functions like lifting and tilting.

7.5 Gear Pump

Details the gear pump's function, faults, and maintenance.

7.6 Redirector

Describes the redirector's function, faults, and checking procedures.

7.7 Tilt Cylinder

Covers tilt cylinder removal, maintenance, and installation precautions.

7.8 Hydraulic Troubleshooting

Lists common hydraulic system faults and their troubleshooting measures.

7.9 Hydraulic Symbol

Provides a reference for hydraulic system symbols used in diagrams.

8. STEERING SYSTEM

8.1 Steering Bridge

Details the steering bridge's removal, installation, faults, and components.

8.2 Displacement Sensor

Covers the displacement sensor's function, removal, installation, and troubleshooting.

8.3 Steering Cylinder

Explains the steering cylinder's removal, installation, and maintenance.

9. ELECTRICAL SYSTEM

9.1 Controller

Discusses the controller functions and their removal/installation.

9.2 Fuse

Details the vehicle's fuses, their locations, and checking procedures.

9.3 Main Contactor

Explains the main contactor's function and removal/installation.

9.4 Accelerator Pedal

Covers the accelerator pedal's removal, installation, faults, and testing.

9.5 DC-DC Converter

Describes the DC-DC converter for voltage conversion and its troubleshooting.

9.6 Combination Light / Headlight / Warning Light

Details the removal, installation, and testing of the vehicle's lights.

9.7 Seat Switch

Covers the seat switch's function, removal, installation, and troubleshooting.

9.8 Handheld Unit-A (Optional)

Explains the connection and menu options for the handheld diagnostic unit.

9.9 Handheld Unit-B (Optional)

Describes the Zapi Handset for diagnostics, operation, and settings.

9.10 Parameter Settings

Provides a list of parameters that can be adjusted for controller settings.

9.11 TESTER Menu

Lists parameters available for real-time status presentation in the TESTER menu.

9.12 Controller Error Message

Lists controller error codes, possible causes, and fault elimination steps.

9.13 Electrical Schematic Diagrams

Presents the electrical schematic diagrams for the forklift model.

9.14 Cable Wiring Diagrams

Shows the cable wiring diagrams for the forklift's electrical system.

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

Illustrates the wiring harness and connectors for the CPD30/35L1-B model.

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

Illustrates the wiring harness and connectors for the CPD30/35L1-S model.

10. TROUBLESHOOTING

10.1 Preparation Before Troubleshooting

Details essential preparation steps before starting troubleshooting.

10.2 Troubleshooting Solutions of Common Faults

Provides a list of common faults and their corresponding troubleshooting measures.

APPENDIX

A SERVICE MANUAL - MAST

Contains detailed service information related to the forklift mast.

A1 Wide-View Two-stage Mast

Details the removal, installation, and maintenance of the two-stage mast.

A1-1 Removal and Installation

Provides steps for removing and installing the two-stage mast assembly.

A1-2 Lifting Chains

Covers the adjustment and replacement of the mast lifting chains.

A1-2.1 Chain Adjustment

Explains how to adjust the tension of the mast lifting chains.

A1-2.2 Chain Replacement

Details the procedure for replacing worn or damaged mast lifting chains.

A1-3 Mast Tubing

Identifies and describes the mast tubing components.

A1-4 Lift Cylinder

Covers the removal, maintenance, and installation of the lift cylinders.

A1-4.1 Cylinder Removal

Provides steps for removing lift cylinders with the mast on the vehicle.

A1-4.2 Cylinder Maintenance

Explains the maintenance procedures for the lift cylinder components.

A1-4.3 Cylinder Installation

Details the installation process for the lift cylinder.

A1-5 Built-in Side Shifter

Covers the removal and installation of the built-in side shifter.

A1-5.1 Side Shifter Removal

Provides steps for removing the built-in side shifter.

A1-5.2 Side Shifter Installation

Details the installation of the built-in side shifter.

A1-6 External Side Shifter

Covers the removal and installation of the external side shifter.

A1-6.1 Side Shifter Removal

Provides steps for removing the external side shifter.

A1-6.2 Side Shifter Installation

Details the installation of the external side shifter.

A2 Two-stage Full Free Mast

Details the removal, installation, and maintenance of the two-stage full free mast.

A2-1 Removal and Installation

Provides steps for removing and installing the two-stage full free mast.

A2-2 Lifting Chains

Covers the adjustment and replacement of the two-stage full free mast lifting chains.

A2-2.1 Chain Adjustment

Explains how to adjust the tension of the mast lifting chains.

A2-2.2 Chain Replacement

Details the procedure for replacing mast lifting chains.

A2-3 Mast Tubing

Identifies and describes the mast tubing components.

A2-4 Lift Cylinder

Covers the removal, maintenance, and installation of lift cylinders for the two-stage mast.

A2-4.1 Cylinder Removal

Provides steps for removing lift cylinders for the two-stage mast.

A2-4.2 Cylinder Maintenance

Explains the maintenance procedures for the lift cylinder components.

A2-4.3 Cylinder Installation

Details the installation process for the lift cylinder.

A2-5 Built-in Side Shifter

References the procedure for the built-in side shifter.

A2-6 External Side Shifter

References the procedure for the external side shifter.

A3 Three-stage Full Free Mast

Details the removal, installation, and maintenance of the three-stage full free mast.

A3-1 Removal and Installation

Provides steps for removing and installing the three-stage full free mast.

A3-2 Lifting Chains

Covers the adjustment and replacement of the three-stage full free mast lifting chains.

A3-2.1 Chain Adjustment

Explains how to adjust the tension of the mast lifting chains.

A3-2.2 Chain Replacement

Details the procedure for replacing mast lifting chains.

A3-3 Mast Tubing

Identifies and describes the mast tubing components.

A3-4 Lift Cylinder

Covers the removal, maintenance, and installation of lift cylinders for the three-stage mast.

A3-4.1 Cylinder Removal

Provides steps for removing lift cylinders for the three-stage mast.

A3-4.2 Cylinder Maintenance

Explains the maintenance procedures for the lift cylinder components.

A3-4.3 Cylinder Installation

Details the installation process for the lift cylinder.

A3-5 Built-in Side Shifter

References the procedure for the built-in side shifter.

A3-6 External Side Shifter

References the procedure for the external side shifter.

B SERVICE MANUAL - BATTERY

Contains information on lithium-ion battery safety, usage, and maintenance.

B1 Lithium-ion Battery

Details safety, usage, charging, and maintenance for lithium-ion batteries.

B1-1 Safety and Warnings

Lists crucial safety precautions and warnings for handling lithium-ion batteries.

B1-2 Use of Battery

Covers pre-use checks, discharging procedures, and temperature guidelines.

B1-2.1 Pre-use Checks

Outlines checks before using the battery, including plug, meter, and connections.

B1-2.2 Discharging

Explains procedures related to battery discharging and recharging.

B1-2.3 Charging

Details the correct procedures and precautions for charging the lithium-ion battery.

B1-3 Maintenance & Care

Covers daily maintenance, battery storage, and supplementary charging.

C SCHEDULE

Provides a schedule for maintenance or other operational tasks.

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