Xilin CBD15W-LiX User manual

OPERATION MANUAL &
PARTS CATALOGUE
CBD15W-LiX
Pallet Truck with Lithium Battery

WARNING
Only drivers who have received formal training or
are authorized can be allowed to drive the truck.
When operating the truck, please always wear safe
shoes. When assembling or disassembling the
truck, please always wear safety goggles.
When running, please watch out your feet to avoid
injury crushed by drive wheel. Please do not use
this product to carry people. Please do not use this
truck on a slippery surface, such as grease, ice or
snow.
Do not travel on too steep slopes to prevent cargo
from slipping. Operators should not leave the truck
in an active state to avoid accidents.
When using this truc k , pl e ase ob s er ve t he
surroundings, do not distract.
Operation in refrigerating warehouse or some low
temperature, salt containing or other corrosive
environments shall be strictly forbidden. No
operation in raining outdoor environment. This
electric truck is only limited to utilization indoor
with a hard flat floor.
Overloading operation is forbidden.
The piling of goods should be controlled to avoid
sight blocking, goods falling-down or truck
tipping-over
No sharp turn on narrow aisle. When turning, slow
down the truck so as to ensure the safety of
personnel and goods.
01

TABLE OF CONTENTS
4
5
6
7
Truck Description
Truck Parameters
Truck Layout
Assembly of handle
11
12
13
14
15
Driving and Stopping
Lifting and Lowering
Braking
Emergency Reverse
Safe Parking
17
18
19
20
21
25
27
Routine Checks
Electrical schematic diagram
Adding hydraulic oil
Truck hoisting
Battery Charging and Replacing
Trouble Shooting
Packing list
01/ DESCRIPTION
02/ OPERATION
03/ MAINTENANCE
02
04/ PARTS CATALOGUE
28
Parts Catalogue

01/
DESCRIPTION
03

TRUCK DESCRIPTION
Tapered forktip
Tandem PU rollers
(OPTION)
Driving wheel
Lithium battery
Multi-function
controller handle
04
01/ DESCRIPTION

TRUCK PARAMETERS
Manual Model
Model Name
CBD15W-Li
Load Capacity
1500 kg
Chassis
Dimensions
Forks
Lowered Height
80 mm
Fork Length
1150/1220 mm
Overall Fork Widths
550/685 mm
Maximum lifted height
190 mm
Service Weight
135 kg
Battery
Battery type
lithium
Rated Voltage
48V/20Ah
Turning Radius
1424/1494
Overall length
1623/1693
01/ DESCRIPTION
05
•The ambient air temperature does not exceed +40℃ or below -10℃.
•For hard and flat ground only.
•It is forbidden to use this truck in flammable, explosive, acid-base or other corrosive
environment.
•The loaded maximum gradeability is 5%.

TRUCK LAYOUT
01/ DESCRIPTION
06

HANDLE ASSEMBLY
01/ DESCRIPTION
07
1. Remove the pin 1 from pin 2, then pull
out the pin 2.
2. Loose the screw 3, remove the cover
plate 4 from handle assembly 5.
The handle has been removed before leaving the factory for the safe transportation and packaging, so the
user has to install the handle before use, the installation steps are as follows
Fig. 1 Fig. 2

ASSEMBLY OF HANDLE
01/ DESCRIPTION
08
3. Insert handle assembly 5 (Fig. 2) into A (Fig. 1), connect handle assembly 5 to pump body 10 by
pin 2. Thread the rod chain 8 through the hole of pin 2. Pull the handle to horizontal position, take
out pin 9 and save it for next time use.
Connect the wire of handle assembly 5 to the truck body through connector 6, tighten it with a
harness for a reliable connection (see Fig.5). After that, fix it to handle assembly 5 by line card 7
according to Fig. 4.
Fig. 3 Fig. 4 Fig. 5

ASSEMBLY OF HANDLE
01/ DESCRIPTION
09
4. See Fig. 4&6, fix the screw and nut at the end of chain 8 into the groove of lever plate 11.
5. Pass the pin 2 through pin 2 and fix, install the cover plate 4 onto handle assembly 5.
Fig. 6
Fig. 4

02/
OPERATION
10

DRIVING AND STOPPING
02/ OPERATION
Plug in the battery connector. Turn on the key switch. Pull the handle to section B.
A and C are breaking section.
Rotate the accelerator to start the truck slowly (for safety,
reason no abrupt acceleration).
Return the accelerator to neutral position to stop the truck.
11

LIFTING AND LOWERING
02/ OPERATION
Press the lifting button on the
handle to lift the forks. Pull the
lever toward the operator to lower
the forks.
Plug in the battery connector. Turn on the key switch.
12
Lifting button
Lowering lever

BRAKING
02/ OPERATION
Turn the handle to A or C quickly for
emergency braking, the brake will lock
the wheel to achieve the emergency
braking.
Release the accelerator for normal
braking, the truck stops slowly by the
regenerative brake of the motor until the
brake lock the wheels.
13

EMERGENCY REVERSE
02/ OPERATION
14
THE EMERGENCY REVERSE BUTTON minimizes the possibility of the driver being
pressed by the steering arm while driving the truck in slow speed.
If the switch presses against the operator while the truck is driving toward the
operator, the switch changes the direction of the truck.
It is a safety button which avoids the extrusion of the truck to protect the operator
from injured when he meets the obstacles.
Emergency reverse button

SAFE PARKING
02/ OPERATION
15
Release speed control button to stop the truck.
Lower the fork to the lowest position.
Turn off the key switch.
Disconnect the battery connector if park for a long time.

03/
MAINTENANCE
16

ROUTINE CHECKS
03/ MAINTENANCE
17
Daily Maintenance: To keep the surface clean and examine if the power supply cable is damaged.
Weekly Maintenance: To check the condition of the operational components, all fastening items, if oil leakage,
if abnormal wearing in mechanical components exists, if abnormal temperature rises or sparks in electric
equipment, etc.
Periodic Maintenance
(Pls refer to the following table)
Electrical System
Hydraulic system
Mechanical system
Every three months check
Yearly check
Every half a year check
□ Check the reliability of electric
connectors
□ Check the function of switches
□ Check the insulation of electric
parts
□ The insulation resistance of electric
equipment and the forklift body
≥0.5MΩ
□ Check the sealing of hydraulic
components and check for
damage
□ Check the oil level
□ Check the state of oil cylinders
□ Check the condition of load
limit valve
□ Oil to be replaced yearly
□ Check the gearbox for abnormal
noise or leaks
□ Check the bearing and rotating
flexibility of the drive wheel
□ Apply lubricant to rotating joints
□ Check fastening items for fixation,
retighten, if necessary
□ Check the condition of the fork

ELECTRICAL SCHEMATIC DIAGRAM
03/ MAINTENANCE
18

03/ MAINTENANCE ERROR CODE
Code
Description
Possible causes and trouble shooting
1
Feedback overspeed
Controller fails, contact the manufacturer.
2
Kernel running error
Controller fails, contact the manufacturer.
8
Speed sensor missing
No speed feedback detected. To solve the problem as following:
1. Check the connection between speed sensor and controller;
2. Check whether the signal of speed sensor is normal;
3. Check the detection circuit of the controller.
9
Direction of speed sensor is
wrong.
The direction or phase of Hall sensor ABC and motor UVW are inconsistent.
To solve the problem as following:
1. Adjust the Hall phase through the controller parameter P47; increase
by 300 each time until the motor rotates normally. Then adjust 50 every
time to find out the normal rotation range of the motor. Finally, the
midpoint of the range is set as the parameter value.
2. If the method of 1 cannot solve the problem, repeat step 1 after
changing parameter P3.0 (feedback commutation).
11
2-minute maximum current
protection of motor
The motor current lasts for more than 2 minutes and the maximum current
lasts for more than 2 minutes.
1. The motor is locked; check whether the brake is open and whether
there is any foreign matter stuck in the driving mechanism.
2. The controller parameters are not set properly, see motor parameter
adjustment for details.
12
Over current of controller
Possible causes:
1. The motor is short circuited.
2. The direction or phase of Hall sensor ABC and motor UVW are
inconsistent.
3. Motor parameter p15 weak magnetic base speed setting error.
4. In case of controller failure, contact the manufacturer.