EP Equipment CPD30L1-B User manual

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.
i
Copyright
Copyright of Service Manual belongs to
EP Equipment Co., Ltd.
REV. SM-3131 05.20

REV. 05/2020
TABLE OF CONTENTS
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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A2-1 Removal and Installation........................................195
A2-2 Lifting Chains .........................................................196
A2-2.1 Chain Adjustment......................................................196
A2-2.2 Chain Replacement...................................................197
A2-3 Mast Tubing............................................................198
A2-4 Lift Cylinder ............................................................200
A2-4.1 Cylinder Removal .....................................................200
A2-4.2 Cylinder Maintenance ...............................................202
A2-4.3 Cylinder Installation...................................................204
A2-5 Built-in Side Shifter.................................................204
A2-6 External Side Shifter ..............................................204
A3 Three-stage Full Free Mast ......................................205
A3-1 Removal and Installation........................................205
A3-2 Lifting Chains .........................................................206
A3-2.1 Chain Adjustment......................................................206
A3-2.2 Chain Replacement...................................................207
A3-2.2.1 Mast Chains .........................................................207
A3-2.2.2 Fork Carriage Chains...........................................207
A3-3 Mast Tubing............................................................209
A3-4 Lift Cylinder ............................................................ 211
A3-4.1 Cylinder Removal ..................................................... 211
A3-4.2 Cylinder Maintenance ...............................................212
A3-4.3 Cylinder Installation...................................................213
A3-5 Built-in Side Shifter.................................................213
A3-6 External Side Shifter ..............................................213
B SERVICE MANUAL - BATTERY.................................215
B1 Lithium-ion Battery...................................................217
B1-1 Safety and Warnings..............................................217
B1-2 Use of Battery ........................................................217
B1-2.1 Pre-use Checks ........................................................217
B1-2.2 Discharging...............................................................217
B1-2.3 Charging ...................................................................218
B1-3 Maintenance & Care ..............................................218
C SCHEDULE .................................................................220
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SAFETY WARNING
For your own safety and that of others, please observe the following safety instructions:
Thorough and normative maintenance is one of the most important prerequisites to ensure
stable and reliable operation of truck. Neglecting regular maintenance could easily lead
to the truck malfunction and failure, and potential threats to staff and operational safety.
Therefore, there must be adequate maintenance equipment, professional maintenance
personnel and a comprehensive maintenance plan in place.
Please perform the maintenance and inspections according to the following provisions:
To strictly enforce the truck maintenance, lubrication and inspection plans.
Truck maintenance, lubrication and inspection personnel must be approved by accredited
certication or evaluation agency.
The following operations shall be performed before you leave the truck:
- No parking on slopes.
- Fully lower the forks.
- Cut o󰀨 the power supply.
- Turn the switch lock to “STOP” and remove the key.
Prior to truck maintenance:
- Raise the drive wheel o󰀨 the ground, or cut o󰀨 the power supply connection.
- Use wooden wedges or other e󰀨ective xtures.
- When performing maintenance underneath the vehicle, make sure that the lifting device
or jack leg is secure.
- Park your vehicle in a safe and secure area.
Never use an open ame to check level of electrolyte, other oils or uids for leaks.
Keep the parking lot clean, well-ventilated and dry.
Regular checks and maintenance should be conducted to braking, steering, control, warning
and safety devices to keep them in good condition.
All nameplates and safety signs on the truck should be cleaned regularly to make them
clearly visible.
Regular checks and maintenance should be conducted to all the devices of lifting system to
ensure them to be safe for use.
The hydraulic system should be checked regularly based on usage. Hydraulic cylinders,
hydraulic valves and other hydraulic components should be ensured to be without leakage.
Regular checks and maintenance should be conducted to batteries, motors, controllers,
limit switches, protective devices, wires and connectors, and so on. Please pay particular
attention to the electrical insulation.
Park the truck in a clean environment to minimize the risk of re.
Without the permission of the manufacturer, users are not allowed to change or increase
the capacity of the truck. After having been changed under permission, the nameplates and
safety signs on the truck should also be changed accordingly.
The eld modication and installation of electrial accessories shall be carried out by trained
personal only.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

1
1
1. INFORMATION & SPECIFICATIONS

2
NOTE:

3
REV. 05/2020
INFORMATION & SPECIFICATIONS
1
1.1 After-sales Service Platform
Claims/Replacement Parts Service Platform:
In order to provide you with a fast and ecient
after-sales service, when you claim / order spare
parts or after-sales service upon maintenance,
please provide accurate truck model, vehicle
body serial number and part number.
After-sales Maintenance Service Platform:
iNOTE

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INFORMATION & SPECIFICATIONS
1
4
No. Name
1 Drive wheel
2 Battery Cover
3 Chassis
4 Steering wheel
5 Counterweight
6 Rear Combination Lights
No. Name
7 Driver Seat
8 Warning Light
9 Overhead Guard
10 Headlight
11 Mast
12 Operate Lever
13 Forks
1.2 Introduction

5
REV. 05/2020
INFORMATION & SPECIFICATIONS
1
This series are electric forklift trucks. Its impor-
tant structure is as shown in Fig3131-00003SM.
-Please refer to the nameplate for rated load
capacity of the vehicle.
- The vehicle can only be used on the level gro-
und indoors, never use it on mezzanine or
balcony area.
WARNING
Truck can only be operated by single operator;
other personnel is forbidden from riding.
1.3 Common Tools
No. Name Remark
1 Hex Head Socket Wrench 8#~27# One Set
2 Phillips Screwdriver 2# One Piece
3 Slotted Screwdriver 2# One Piece
4 Sockets and Knobs One Set
5 Circlip Pliers One for holes and one for shaft
6 Hammer One Piece
7 Spreader, Crane One Pair
8 Cylinder Wrenches For removal and installation of cylinders
9 Diagonal Pliers One Piece
10 Cylinder Pliers One Piece
11 Grease Gun One Piece
12 Tiger Tooth Wrench 22#/27# One of Each
WARNING

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INFORMATION & SPECIFICATIONS
1
6
Table 1.4.1 Screws/Bolts Performance Levels
Performance Level Material Specication (mm)
5.8 grade Low carbon steel M6 ~ M48
8.8 grade Quenched and tempered medium
carbon steel M6 ~ M48
10.9 grade Quenched and tempered medium
carbon alloy steel M6 ~ M48
12.9 grade Quenched and tempered medium
carbon alloy steel M6 ~ M48
12.9
10.9
8.8
5.8
1.4 General Tightening Torques
Screws or bolts used on the truck are of 8.8
grade or higher performance level.
When you are conducting truck maintenance,
you can refer to Table 1.4.1 and Table 1.4.2 to
select the suitable screws or bolts for replace-
ment.
-
-
CAUTION
The performance levels of screws or bolts are
marked on the heads of the screws or bolts.
If you nd the screws or bolts used on certain
position are not marked with performance
level, please select spare parts with perform-
ance level of at least 8.8 grade or higher level
for replacement.

7
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INFORMATION & SPECIFICATIONS
1
Table 1.4.2 Metric Screws/Bolts Tightening Torque Table (n•m)
Nominal Diameter
(mm)
Performance Level
5.8 8.8 10.9 12.9
Proof Stress (MPa)
380 600 830 970
M6 7~8 10~12 14~17 17~20
M8 16~18 25~30 34~41 41~48
M8×1 17~20 27~32 37~43 43~52
M10 31~36 49~59 68~81 81~96
M10×1 35~41 55~66 76~90 90~106
M12 55~64 86~103 119~141 141~167
M12×1.5 57~67 90~108 124~147 147~174
M14 87~103 137~164 189~224 224~265
M14×1.5 144~170 149~179 206~243 243~289
M16 136~160 214~256 295~350 350~414
M16×1.5 144~170 228~273 314~372 372~441
M18 186~219 294~353 406~481 481~570
M18×1.5 210~247 331~397 457~541 541~641
M20 264~312 417~500 576~683 683~808
M20×1.5 294~345 463~555 640~758 758~897
M22 360~431 568~680 786~941 918~1099
M22×1.5 395~473 624~747 803~1034 1009~1208
M24 457~547 722~864 998~1195 1167~1397
M24×2 497~595 785~940 1086~1300 1269~1520
M27 669~801 1056~1264 1461~1749 1707~2044
M27×2 723~865 1141~1366 1578~1890 1845~2208
M30 908~1087 1437~1717 1984~2375 2318~2775
M30×2 1005~1203 1587~1900 2196~2629 2566~3072
M36 1587~1900 2506~3000 3466~4150 4051~4850
M36×3 1680~2011 2653~3176 3670~4394 4289~5135
M42 2538~3039 4088~4798 5544~6637 6479~7757
M42×3 2731~3269 4312~5162 5965~7141 6921~8345
M48 3813~4564 6020~7207 8327~9969 9732~11651
M48×3 4152~4970 6556~7848 9069~10857 10598~12688

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INFORMATION & SPECIFICATIONS
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8