EP CPD15/18/20TV8 CPD15/18/20TW8 CPD15/18/20FVD8 Electric Forklift Truck Service Manual

EP CPD15/18/20TV8 CPD15/18/20TW8 CPD15/18/20FVD8 Electric Forklift Truck Service Manual – PDF DOWNLOAD

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EP CPD15/18/20TV8 CPD15/18/20TW8 CPD15/18/20FVD8 Electric Forklift Truck Service Manual – PDF DOWNLOAD

Language : English
Pages : 216
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

EP CPD15/18/20TV8 CPD15/18/20TW8 CPD15/18/20FVD8 Electric Forklift Truck Service Manual – PDF DOWNLOAD

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 21
3 1 Structure & Functions 23
3 1 1 Travel Combination Switch 23
3 1 2 Emergency Stop Switch 23
3 1 3 Key Switch 23
3 1 4 Horn Button 23
3 1 5 Lighting Combination Switch 24
3 1 6 Reversing Buzzer 24
3 1 7 MDI Instrument 24
3 1 8 Horn 24
3 1 9 Control Switch (TW Series) 25
3 1 10 Control Switch (TV Series) 25
3 1 11 Accelerator Pedal 25
3 1 12 Brake Pedal 25
3 1 13 Warning Light 26
3 1 14 Combination Light 26
3 1 15 Headlight 26
3 1 16 Warning Light Switch 26
3 1 17 Traction Controller 27
3 1 18 Pump Controller 27
3 1 19 Main Contactor 27
3 1 20 DC-DC Converter 27
3 1 21 Multi-way Solenoid Valve 28
3 1 22 Multi-way Manual Valve 28
3 1 23 Pump Motor 28
3 1 24 Gear Pump 28
4 CHASSIS SYSTEM 29
4 1 Load Wheel(TV/TW Series) 31
4 1 1 Removal and Installation 31
4 1 2 Faults and Causes 32
4 2 Parking Brake 32
4 2 1 Removal and Installation 32
4 3 Brake Pedal 33
4 3 1 Removal and Installation 33
4 3 2 Faults and Causes 34
4 4 Seat 34
4 4 1 Removal and Installation 34
4 5 Load Wheel(FVD Series) 34
4 5 1 Removal and Installation 34
4 5 2 Faults and Causes 35
5 DRIVE SYSTEM 37
5 1 Drive Wheel 40
5 1 1 Removal and Installation 40
5 1 2 Faults and Causes 40
5 2 Drive Motor 41
5 2 1 Removal and Installation 41
5 2 2 Faults and Causes 43
5 2 3 Checking and Testing 43
5 2 4 Control Circuit Troubleshooting 45
5 3 Gearbox 46
5 3 1 Removal and Installation 46
5 3 2 Component 46
5 3 3 Gear Oil 47
5 3 4 Faults and Causes 47
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
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 56
6 4 1 Removal and Installation 56
6 4 2 Faults and Causes 56
6 4 3 Checking and Testing 56
6 4 4 Control Circuit Troubleshooting 57
6 5 Key Switch 58
6 5 1 Removal and Installation 58
6 5 2 Faults and Causes 58
6 5 3 Checking and Testing 58
6 5 4 Control Circuit Troubleshooting 58
6 6 Warning Light Switch 59
6 6 1 Removal and Installation 59
6 6 2 Faults and Causes 59
6 6 3 Checking and Testing 59
6 6 4 Control Circuit Troubleshooting 59
6 7 Parking Brake Switch 60
6 7 1 Removal and Installation 60
6 7 2 Faults and Causes 60
6 7 3 Connection Mode 60
6 7 4 Checking and Testing 60
6 7 5 Control Circuit Troubleshooting 61
6 8 Emergency Switch 62
6 8 1 Removal and Installation 62
6 8 2 Faults and Causes 62
6 8 3 Checking and Testing 62
6 8 4 Control Circuit Troubleshooting 62
6 9 Control Switch (TV Series) 63
6 9 1 Removal and Installation 63
6 9 2 Faults and Causes 63
6 9 3 Connection Mode 63
6 9 4 Checking and Testing 63
6 9 5 Control Circuit Troubleshooting 64
6 10 Control Switch (TW Series) 65
6 10 1 Removal and Installation 65
6 10 2 Faults and Causes 65
6 10 3 Checking and Testing 65
6 10 4 Control Circuit Troubleshooting 66
7 HYDRAULIC SYSTEM 69
7 1 Overview 71
7 1 1 Hydraulic Schematic Diagram (TV Series) 72
7 1 2 Hydraulic Schematic Diagram (TW Series) 73
7 2 Hydraulic Power Unit 74
7 2 1 Removal and Installation 74
7 3 Pump Motor 74
7 3 1 Removal and Installation 74
7 3 2 Faults and Causes 75
7 3 3 Checking and Testing 75
7 3 4 Control Circuit Troubleshooting 76
7 4 Multi-way Reversing Solenoid Valve (TW Series) 78
7 4 1 Removal and Installation 78
7 4 2 Interface Description 78
7 4 3 Faults and Causes 79
7 4 4 Checking and Testing 79
7 4 5 Control Circuit Troubleshooting 79
7 5 Solenoid Valve (TW Series) 80
7 5 1 Faults and Causes 80
7 5 2 Checking and Testing 81
7 5 3 Control Circuit Troubleshooting 81
7 6 Multi-way Reversing Manual Valve (TV Series) 82
7 6 1 Removal and Installation 82
7 6 2 Interface Description 83
7 6 3 Faults and Causes 83
7 6 4 Checking and Testing 83
7 7 Gear Pump 84
7 7 1 Removal and Installation 84
7 7 2 Faults and Causes 84
7 7 3 Checking and Testing 84
7 8 Redirector 85
7 8 1 Removal and Installation 85
7 8 2 Faults and Causes 85
7 8 3 Checking and Testing 85
7 9 Tilt Cylinder 86
7 9 1 Cylinder Removal Precautions 86
7 9 2 Cylinder Installation Precautions 87
7 9 3 Removal and Installation 88
7 9 4 Cylinder Maintenance 89
7 9 Hydraulic Troubleshooting 90
7 10 Hydraulic Symbol 91
8 STEERING SYSTEM 93
8 1 Steering Bridge (TV/TW Series) 97
8 1 1 Removal and Installation 97
8 1 2 Faults and Causes 97
8 1 3 Component 98
8 1a Steering Bridge (FVD Series) 99
8 1 1a Removal and Installation 99
8 1 2a Faults and Causes 99
8 1 3a Component 100
8 2 Steering Potentiometer 101
8 2 1 Removal and Installation 101
8 2 2 Faults and Causes 101
8 2 3 Checking and Testing 102
8 2 4 Control Circuit Troubleshooting 102
9 ELECTRICAL SYSTEM 103
9 1 Controller 105
9 1 1 Removal and Installation 105
9 1 2 Controller Interface Function 107
9 2 Fuse 117
9 2 1 Location of Fuses 117
9 2 2 Checking and Testing 118
9 3 Main Contactor 119
9 3 1 Removal and Installation 119
9 3 2 Faults and Causes 119
9 3 3 Checking and Testing 120
9 3 4 Control Circuit Troubleshooting 120
9 4 Accelerator Pedal 121
9 4 1 Removal and Installation 121
9 4 2 Faults and Causes 121
9 4 3 Checking and Testing 121
9 4 4 Control Circuit Troubleshooting 122
9 5 DC-DC Converter 124
9 5 1 Removal and Installation 124
9 5 2 Faults and Causes 124
9 5 3 Checking and Testing 124
9 5 4 Control Circuit Troubleshooting 124
9 6 Combination Light / Headlight 125
9 6 1 Removal and Installation 125
9 6 2 Faults and Causes 125
9 6 3 Checking and Testing 125
9 6 4 Control Circuit Troubleshooting 125
9 7 Seat Switch 127
9 7 1 Removal and Installation 127
9 7 2 Faults and Causes 127
9 7 3 Checking and Testing 127
9 7 4 Control Circuit Troubleshooting 127
9 8 Instrument 128
9 8 1 Instrument Operation Schematics 129
9 8 2 TESTER Menu 130
9 9 Controller Error Message 132
9 9 1 Traction Controller (DUALAC2) 132
9 9 2 Pump Controller (AC2) 138
9 9 3 Solenoid Valve Controller 143
9 10 Electrical Schematic Diagrams (TV Series) 144
9 10 1 Electrical Schematic Diagram (TV Series) (1/2) 144
9 10 2 Electrical Schematic Diagram (TV Series) (2/2) 145
9 11 Electrical Schematic Diagrams (TW Series) 146
9 11 1 Electrical Schematic Diagram (TW Series) (1/4) 146
9 11 2 Electrical Schematic Diagram (TW Series) (2/4) 147
9 11 3 Electrical Schematic Diagram (TW Series) (3/4) 148
9 11 4 Electrical Schematic Diagram (TW Series) (4/4) 149
9 12 Cable Wiring Diagrams 150
9 13 Wiring Harness and Connectors (TV Series) 151
9 14 Wiring Harness and Connectors (TW Series) 152
10 TROUBLESHOOTING 153
10 1 Preparation Before Troubleshooting 155
10 1 1 Check the Voltage of Battery 155
10 2 Troubleshooting Solutions of Common Faults 156
APPENDIX 161
A SERVICE MANUAL – MAST 163
A1 Two-stage Mast 165
A1-1 Removal and Installation 165
A1-2 Lifting Chains 166
A1-2 1 Chain Adjustment 166
A1-2 2 Chain Replacement 167
A1-3 Mast Tubing 168
A1-4 Lift Cylinder 169
A1-4 1 Cylinder Removal 169
A1-4 2 Cylinder Maintenance 170
A1-4 3 Cylinder Installation 170
A1-5 Built-in Side Shifter 171
A1-5 1 Side Shifter Removal 171
A1-5 2 Side Shifter Installation 171
A1-6 External Side Shifter 172
A1-6 1 Side Shifter Removal 172
A1-6 2 Side Shifter Installation 172
A2 Two-stage Full Free Mast 173
A2-1 Removal and Installation 173
A2-2 Lifting Chains 174
A2-2 1 Chain Adjustment 174
A2-2 2 Chain Replacement 174
A2-3 Mast Tubing 175
A2-4 Lift Cylinder 177
A2-4 1 Cylinder Removal 177
A2-4 2 Cylinder Maintenance 179
A2-4 3 Cylinder Installation 181
A2-5 Built-in Side Shifter 181
A2-6 External Side Shifter 181
A3 Three-stage Full Free Mast 182
A3-1 Removal and Installation 182
A3-2 Lifting Chains 183
A3-2 1 Chain Adjustment 183
A3-2 2 Chain Replacement 184
A3-2 2 1 Mast Chains 184
A3-2 2 2 Fork Carriage Chains 184
A3-3 Mast Tubing 186
A3-4 Lift Cylinder 188
A3-4 1 Cylinder Removal 188
A-4 2 Cylinder Maintenance 189
A3-4 3 Cylinder Installation 190
A3-5 Built-in Side Shifter 190
A3-6 External Side Shifter 190
B SERVICE MANUAL – BATTERY 191
B1 Lead-acid Battery 193
B1-1 Safety and Warnings 193
B1-2 Use of Battery 193
B1-2 1 Pre-use Checks 193
B1-2 2 Discharging 193
B1-2 3 Charging 194
B1-2 4 Temperature 194
B1-3 Maintenance & Care 194
B1-3 1 Daily Maintenance 194
B1-3 2 Weekly Maintenance 194
B1-3 3 Monthly Maintenance 195
B1-3 4 Care 195
B1-4 Storage 196
B1-5 Troubleshooting 196
B2 Maintenance-free Battery 199
B2-1 Safety and Warnings 199
B2-2 Use of Battery 199
B2-2 1 Pre-use Checks 199
B2-2 2 Discharging 199
B2-2 3 Charging 200
B2-3 Maintenance & Care 200
C SCHEDULE 201