HANGCHA J Series Service Manual
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HANGCHA J Series Service Manual

Counterbalanced battery forklift truck
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CPD10/15/18/20/25/30J
CPD10/15/18/20/25/30J D1
CPD10/15/18/20/25/30/35J C1
CPD10/15/18/20/25/30/35J C2
CPD40/45/50J D1
CPD40/45/50J C2
1～5t J Series Counterbalanced Battery Forklift Truck
SERVICE MANUAL
Original Instruction
HANGCHA GROUP CO., LTD.
rd
Dec. 2010 3
edition

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  • Page 1 CPD10/15/18/20/25/30J CPD10/15/18/20/25/30J D1 CPD10/15/18/20/25/30/35J C1 CPD10/15/18/20/25/30/35J C2 CPD40/45/50J D1 CPD40/45/50J C2 1～5t J Series Counterbalanced Battery Forklift Truck SERVICE MANUAL Original Instruction HANGCHA GROUP CO., LTD. Dec. 2010 3 edition...
  • Page 3 (CURTIS) (CURTIS) 2.0/500,2.5/500,3/500, 4/500,4.5/500,5/500 CPD10/15/18/20/25/30J D1 (INMOTION) (INMOTION) EVC255 1238 1.0/500,1.5/500,1.8/500, CPD10/15/18/20/25/30/35J C1 (CURTIS) 2.0/500,2.5/500,3/500,3.5/300 (CURTIS) 1236 1.0/500,1.5/500,1.8/500, 1238 CPD10/15/18/20/25/30/35J C2 (CURTIS) (CURTIS) 2.0/500,2.5/500,3/500,3.5/300 1238 1238 4/500,4.5/500,5/500 CPD40/45/50J C2 (CURTIS) (CURTIS) © Dec. 2010 3 edition HANGCHA GROUP CO., LTD.

  • Page 5: Table Of Contents

    CONTENT FOREWORD 1. DRIVING SYSTEM ..........................1 1.1 ENGINE FOR FORKLIFT......................1 1.2 GEAR BOX ............................. 8 1.3 DRIVING AXLE ..........................9 2. STEERING SYSTEM......................... 14 2.1 STEERING DEVICE ........................14 2.2 STEERING AXLE ........................15 3. BRAKE SYSTEM ........................... 19 3.1 MASTER CYLINDER ........................

  • Page 7: Driving System

    1. Driving system Drive system is composed most components such as electrical engineering, gear box, driving axle detent tyre and wheel rim. Gear box is two grades reduce speed gear, one grade straight gear and one grade planet gear. So the gear box is very small.
  • Page 8 CPD10/15/18J C1 Rated Rated Rated Rated Max. Excitations Insulation Cooling Protecting Ration Weight Model Power Voltage Current speed Speed Remark Mode Grade Mode Grade (Kg) ( kw) (r/m) (r/m) YDQ6.8-4HC 1200 2000 IC01 IP20 series XQD –8.2-3D 172.8 1600 3200 IC01 IP20 work...
  • Page 9 CPD30/35J C2 Rated Rated Rated Rated Max. Excitations Insulation Cooling Protecting Ration Weight Model Power Voltage Current speed Speed Remark Mode Grade Mode Grade (Kg) ( kw) (r/m) (r/m) YDQ11.75-4HC 10.6 1200 IC01 IP20 YDQ - 10 161.6 2000 IC01 IP44 work CPD40/45/50J C2...
  • Page 10 CPD40/45/50J-D1 Rated Rated Rated Rated Max. Excitations Insulation Cooling Protecting Ration Weight Model Power Voltage Current speed Speed Remark Mode Grade Mode Grade (Kg) ( kw) (r/m) (r/m) ／ TSP180/4-200 16.6 IC01 IP20 work TSP160/4-250-T 1620 IC01 IP20 Height above sea level No exceed 1200m Remark electromotor...
  • Page 11 1.1.2 Failure diagnosis CPD10-30 Failure phenomenon Possible cause Brush’s pressure is wrong All of sheet copper nigrescence Parts of commutator according to · parts is short circuit a certain order nigrescence · armature coil is short · parts of commutator is not fasten to armature coils open circuit Parts of commutator are ·...
  • Page 12 1.1.3The marker, sign and connecting type of exceed cable or terminal of motor A1 --motor armature's head series A2--motor armature's end excitation D1--shunt excitation's head motor D2--shunt excitation's end A1 --motor armature's head A2--motor armature's end Separated F1—Separated Excitation Excitation excitation's head motor F2-- Separated Excitation excitation's end...
  • Page 13 1.1.4 Use and maintain CPD10-30J The commutator has four check windows, with which you can observe and maintain the commutator and brush. There are four average distributing magnetic poles in seat. The magnetic pole coil is made of F state copper thread, dipping with F state insulating varnish. Parts of stator and neutral position of brush have been adjusted;...

  • Page 14: Gear Box

    CPD10/15/18/20/25/30/35J C1 CPD10/15/18/20/25/30/35J C2、CPD40/45/50J C2 CPD10/15/18/20/25/30J D1、CPD40/45/50J D1 CPD10/15/18/20/25/30/35J C1 、 CPD10/15/18/20/25/30/35J C2 、 CPD40/45/50J C2 、 CPD10/15/18/20/25/30J D1、CPD40/45/50J D1 fork don’t have commutator and brush，not need maintain. You must clear dust everyday. 1.2 Gear box Gear box is two grades reduce speed gear, one grade straight gear and one grade planet gear. So the gear box is very small.

  • Page 15: Driving Axle

    27.right differential 28.left differential 24. Girth gear 25. bolt 26.nut carrier carrier 29. Gear shaft (I) 30. Face gear 31. Gasket 32. Planetary gear 33. Thrust washer 34. Axletree 6211 35. Straight pin 36.Gear shaft (II) 37. Paper gasket 38.pin 39.
  • Page 16 Fig.3-1 Driving axle 1. Rim 2. Brake drum 3. wheel hub 4.Wheel nut 5. Wheel hub bolt 6. Bolt 7.Brake Assembly 8. Wash 9.Bolt 10. Half-axle nut 11. Half axle 12.Bolt 13. Oil seal 14. Taper roller 15. Adjusting nut bearing 16.
  • Page 17 1.3.3Driving axle assemble removal and installation ！ WARNING Be careful when removal and installation driving axle as it is heavy. Raise front end of forklift truck and support frame with wooden blocks. Remove mast assembles. Slightly raise axle with a hoist and place wooden blacks under differential gear carrier and transmission case.
  • Page 18 Vent plug should clear instantly to prevent pressure inside of wheel hub from rising. 1.3.4. Axle shaft and wheel hub Remove 1）Raise the front end of forklift truck and support frame with wooden blocks. 2）Remove front wheel and axle shaft. 3）Remove lock nuts, lock washers, snap ring, felt ring, adjusting nut.
  • Page 19 1.3.5 Bearing adjusting 1）Lubricate on taper roller bearing. 2）Tighten roller bearing lock nut in wheel hub until wheel hub can no longer be rotated with one hand. 3）From that position, turn back lock nut approx. 60 4）Turn back wheel hub two or three rotations so that bearing settles down. 5）Again tighten lock nut until it can no longer be rotated with one hand;...

  • Page 20: Steering System

    2. Steering system Steering system include rear steering axle and steering device. 2.1 Steering device It consists of steering wheel, upside steering column, downside steering column, bearings, steering gear, priority valve, clamp bolt and hydraulic switch etc. You can adjust the steering angle forward and backward by yourself.

  • Page 21: Steering Axle

    2.2 Steering axle 2.2.1 General specifications Axle centre（none for 4-5t） Axle body Center support, swing type type Vertical play（mm） 0～1 Inner 1-1.5t 79.5º wheel 2-3t 80º Turning Adjusting shim for end 1-1.8t 56º angle Outer shaft of axle thickness 0.5, 1.0, 1.6 wheel 2-3t 55.7º...
  • Page 23 2.2.3 Remove Wheel hub Jack up and support forklift truck body with Wooden blocks. Remove tire. Remove hubcap. Remove steering spindle nut. Pull off hub assembles. Remove bearing inner race. Caution：a. Not to drop bearing inner race. b. Be careful not to damage oil seal. 2.2.4 Kingpin and steering spindle Remove rod.
  • Page 24 Installation To install, reverse the order of removal. Careful observes the following. 1）always insert kingpin from lower side. 2）install thrust bearing, set the tighten-ring below the support and loosen-ring. Pack all grease between dust proof inside, loosen-ring, and tighten-ring. 3）adjust axial play to specification with shims. Axial plays less than 0.15mm. 4）the character of seal tape faces outside.

  • Page 25: Brake System

    3. Brake system The brake system is the front two-wheel braking type consisting of a master cylinder, brakes and brake pedal. 3.1 Master cylinder The master cylinder contains a valve seat, check valve, return spring, primary cup, piston and secondary cup, which are kept in place with stop washer and stop wire. The exterior of the cylinder is protected from dust by means of a rubber dust cover.

  • Page 26: Foot Brake

    3.2 Foot brake 3.2.1 Brake The configuration of the 2-3t right detent can refer to fig 3-2. The configuration of 1-1.8t 、4-5t right detent Configuration was similitude to 2-3t. Fig.3-2 2-3t forklift truck right brake assembly 1. Brake mount 2. Wheel cylinder 3.
  • Page 27 3.2.2 Replace brake shoe: Place the forklift truck on level concrete. Start engine and raise carriage about 100mm. Place chocks behind rear wheels to prevent movement of forklift truck. Loosen wheel nuts two or three turns each. Tilt mast fully backward, and place a wooden block under each side of outer mast. ！WARNING：...

  • Page 28: Hand Brake Device

    3.3 Hand brake device The hand brake device adopts a hand-pulling soft brake wire cable device. It makes use of auto-assist pressure linings type brake together with foot brake. Only when parking truck, use the hand brake. If it occurs for foot brake malfunction, use hand brake to stop the truck. condition Probable cause Corrective action...

  • Page 29: Hydraulic System

    4. Hydraulic system The high pressure oil from main pump goes to control valve and divide it to two parts by dividing valve inside control valve: one of them goes to lifting cylinder or tilting cylinder, another part goes to steering gear with invariable flow to control steering cylinder.
  • Page 30 Control valve Trouble Probable cause Corrective action Loose of pressure-adjust screw. Readjusted and retighten. Distorted or damaged pressure-adjust Pressure of relief Replace. spring. valve is not steady Worn or blocked relief valve core. Replace or clean. or too low. Pump abated. Examine and repair pump.
  • Page 31 Adjusting the pressure of the main relieve valve The pressure of the main relieve valve is all ready adjusted in the factory, and it can’t be adjusted generally. The following is an example of 3t truck to specify how to adjust the pressure. (1).
  • Page 32 Hydraulic system principle diagram Tonnage Items 1.3t 1.5t 1.8-3.5t 4-5t The max. input pressure 16MPa 16MPa 16MPa 16MPa of redirector Main safety valve pressure of multi-spool 12 MPa 15 MPa 17.5 MPa 18.5 MPa control valve Rated pressure of gear 20 MPa 20 MPa 20 MPa...

  • Page 33: Lifting System

    5. Lifting system 5.1 Data Inspection and adjustment Assembly clearance （mm） Place Repair clearance（mm） Mast to lift roller 0.1～0.8 0.2～1 Shims 0.5～1 Mast to back up metal 0.1～0.8 0.2～1 Shims 0.5～1 Inner mast to carriage side roller 0.1～0.6 0.2～1 Lift chain deflection 25～30 mm Tightening torque Place...

  • Page 34: Fault

    5.2 Fault Fault Probable cause Corrective action 1.Tilt cylinder and ring abraded Replace piston ring tilt cylinder. excessively Fork arm carrier or mast tilt by itself. 2. The hydraulic control valve spring is Replace it. inoperative. The fork arms 1. Caused by piston jamming or bent Replace the faulty parts.
  • Page 35 Fault Probable cause Corrective action 1. Excessive wear occurs between the oil Replace the worn parts or the oil pump body and gears, causing too much pump. clearance. 2. The lifting jack piston Yx-ring has worn, Replace Yx-ring. resulting in excessive inner leaks. 3.

  • Page 36: Mast

    5.3 mast Basic mast is 3m high, composed of inner and outer mast, fork arm carrier, fork arm, chain and idler wheel, etc. Fig5-1 Double lift mast with wide view 1.Outer mast 2.Inner mast 3.Back rest 4. Fork arm carrier 5.Fork 6.Chain 7.Left lifting...
  • Page 37 Fig 5-3 Container truck mast 1. Outer mast 2.Inner mast 3. Chain 4. Free lifting cylinder 5. Fork arm carrier 6.Fork 7. Sideway cylinder 8. Left rise cylinder 9. Right rise cylinder 10. Fork arms 11.Tilt cylinder Triple full free lift mast Fig 5-4 1.

  • Page 38: Lifting Cylinder

    5.4 Lifting cylinder Plunger feeder lifting cylinder has dash control, configuration see fig 5-5 Fig 5-5 Lifting cylinder 1.LBH dust proof 2. ISI ring 4. O Ring 3. Plug screw 5.Piston 6.Bolt 7. Guide 8.bush 9. Cylinder body 10. Piston 11.

  • Page 39: Electrical System

    6. Electrical system 6.1 CPD10/15/20/25/30J fork 6.1.1summarize Curtis PMC 1244 MultiMode controllers are separately excited motor speed controllers designed for use in a variety of material handling vehicles. These programmable controllers are simple to install, efficient, and cost effective. Typical applications include low lifts, stackers, fork lifts, reach trucks, personnel carriers, counterbalance trucks, order pickers, boom trucks, and other industrial vehicles.
  • Page 40 _ Linear temperature and under voltage cutback on motor currents; no sudden loss of power under any thermal conditions _ High pedal disable (HPD) and static return to off (SRO) interlocks prevent vehicle runaway startup _ Creep speed adjustable from 0% to 25% in each mode _ Continuous diagnostics during operation, with microprocessor power-on self-test _ Internal and external watchdog circuits ensure proper software operation _ Programmable coil drivers provide adjustable contactor pull-in and holding voltages...
  • Page 41 6.1.2 Failure code CPD10-30J Fault table of tow controller LED code PROGRAMMER LCD EXPLANATION POSSIBLE CAUSE DISPLAY HW FAIL SAFE1-2-3 self-test or watchdog fault Controller defective. M-SHORTED internal M- short to B- 1．Controller defective. 1. Motor field wiring loose. FIELD OPEN .Field winding fault 1, 2.
  • Page 42 Fault table of lift (oil pump) controller PROGRAMMER EXPLANATION POSSIBLE CAUSE code LCD DISPLAY NO voltage or controller is not working, error (such as MCII defective) controller work normally, ■ ¤ no error EEPROM miss data EEPROM data check error，use ¤...

  • Page 43: Cpd10/15/20/25/30/35J C1、Cpd10/15/18/20/25/30/35J C2、Cpd40/45/50J C2 Fork

    。 （2）Lift motor Lift motor JC1 is direct current motor, so is the motor of J series truck. Lift motor JC2 adopts three-phase alternating electromotor，increase conversion efficiency，not have commentator brush in order not to maintenance.
  • Page 44 high speed easy control . ② two archives speed and acceleration design ，can apply to most situation. ③ regeneration technology make change direction of fork even smooth。 ④ three regenerative braking mode ： A、acceleration pedal part release appear regenerative braking， B、direction reverse regenerative braking，...
  • Page 45 6.2.2 Error code CPD10-35J C1 EC ERROR CODE TABLE There are two LEDs including a yellow LED and a red LED. The two LEDs have four different display modes, indicating the type of information they are providing. DISPLAY STATUS Controller is not powered on, has a dead Neither LED illuminated battery, or is severely damaged.
  • Page 46 CODE PROGRAMMER POSSIBLE CAUSE LCD DISPLAY 2，2 Controller Overtemp 1. Controller is performance-limited at this temperature. Cutback 2. Controller is operating in an extreme environment. 3. Excessive load on vehicle. 4. Improper mounting of controller. 5. See 1311 menu Monitor » Controller: Temperature. 2，3 Undervoltage Cutback 1.
  • Page 47 CODE PROGRAMMER LCD POSSIBLE CAUSE DISPLAY 3，1 Coil 1 Driver 1. Open or short on driver load. Open/Short 2. Dirty connector pins. 3. Bad crimps or faulty wiring. 3，1 Main Open/Short 1. Open or short on driver load. 2. Dirty connector pins. 3.
  • Page 48 CODE PROGRAMMER LCD POSSIBLE CAUSE DISPLAY 4，1 Throttle Wiper High 1. Throttle pot wiper voltage too high. 2. See 1311 menu Monitor » Inputs: Throttle Pot. 4，2 Throttle Wiper Low 1. Throttle pot wiper voltage too low. 2. See 1311 menu Monitor » Inputs: Throttle Pot. 4，3 Brake Wiper High 1.
  • Page 49 CODE PROGRAMMER POSSIBLE CAUSE LCD DISPLAY 7，1 OS General 1. Internal controller fault. 7，2 PDO Timeout 1. Time between CAN PDO messages received exceeded the PDO Timeout Period. 7，3 Stall Detect 1. Stalled motor. 2. Motor encoder failure. 3. Bad crimps or faulty wiring. 4.

  • Page 50: Cpd10/15/20/25/30J D1 Fork

    6.3 CPD10/15/20/25/30J D1 fork 6.3.1 Summarize INMOTION company procreates controller ，adopt international advanced closed loop system and advanced control technique。 Designing large screen instrument， can clear display ―electric quantity‖、 ―speed‖、―total time of run ‖，―work time of drive ‖，―work time of lift ‖and so on information。 Designation adopt code plus character manner，increase maintain efficiency。It also through meter check periphery component to come true function of handset (1) Actuating motor...
  • Page 51 ④ Three regenerative braking mode ： A、acceleration pedal part release appear regenerative braking， B direction reverse regenerative braking， C、 ramp downslide appear regenerative braking， Except increase security drive，reclaim part of electric energy，prolong work time of every time . ⑤ Control speed during downgrade： speed lie on accelerator 。if speed exceed set point，controller may automatic braking，this give optimal ramp Notice: 1 .Maintain electric control ，...
  • Page 52 6.3.2 Error code (1) Errors detected by VMC20 Code. Source Condition When Tract Main Reset Remark Switch startup error ACCEL switch active at startup ACC SWITCH=OFF Traction setspeed=0 KEY→ON Switch startup error FW|REV switch active at startup FW=REV= OFF Traction setspeed=0 KEY→ON Direction switch...
  • Page 53 (2) Errors detected by drive ACS (EMCY) Code Source Condition When Tract Main Reset Remark Short circuit ACS is shorted or motor terminals KEY=ON ACS may be damaged if short KEY=OFF are shorted circuit is internal. ACS over temperature ACS hs temp > 115 degC KEY=ON KEY=OFF Motor...
  • Page 54 (3)Errors detected by drive ACS (Warning) Code Source Condition When Tract Main Reset Remark ACS heat sink temp < -20 ℃ ACS low temp warning KEY=ON KEY=OFF or Heat Lowest Accel will be used. sink temp normal ACS heat sink temp > 85 ℃ ACS high temp warning KEY=ON KEY=OFF or Heat...
  • Page 55 (4)Errors detected by pump ACS (EMCY) Code Source Condition When Tract Main Reset Remark Short circuit ACS is shorted or motor terminals KEY=ON KEY=OFF ACS may be damaged if short are shorted circuit is internal. ACS hs temp > 115 ℃ over KEY=ON KEY=OFF...
  • Page 56 (5)Errors detected by pump ACS (Warning) Code Source Condition When Tract Main Reset Remark Motor temp > 145 ℃ Motor high temp KEY=ON KEY=OFF See 1.2.2.2 Lowest Accel will warning be used. Heat sink temp sensor ACS heat sink temp sensor KEY=ON KEY=OFF error...
  • Page 58 WIRING DIAGRAM OF CPD10/15/18/20/25/30J...
  • Page 60 ELECTRICAL SYSTEM PRINCIPLE DIAGRAM OF CPD10/15/18/20/25/30/40/45/50J C2...
  • Page 61 ELECTRICAL SYSTEM PRINCIPLE DIAGRAM OF CPD10/15/18/20/25/30/40/45/50J D1...
  • Page 62 WIRING DIAGRAM OF CPD10/15/18/20/25/30/40/45/50/J D1 WIRING DIAGRAM OF CPD10/15/18/20/25/30J D1...

  • Page 63: Maintenance Record

    7. Maintenance record Date Maintain content Maintainer...
  • Page 64 HANGCHA GROUP CO. , LTD. ■ Address for: OVERSEAS USERS ■ Manufacturing site: 88 Donghuan Road, LinAn Econimic Development zone, Zhejiang, P.R.China ■ ZIP:311305 ■ Registered Address：398 Shi Qiao Road, Hangzhou, P.R. China) ■ ZIP :310004 ■ Fax: 0086-571-88926789,0086-571-88132890 ■...

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