BigBattery TITANGREEN EP18K-Li Manual de usuario

 Table of Contents 
 External  view  and  technical  parameter  .....................................................................................  4 
 Safe  driving,  operation  and  maintenance  of  forklift  .................................................................  6 
1  Transportation,loading,unloading  and  lifting  of  forklifts  ...................................................  7 
1.1  Forklift  transportation  ......................................................................................................  7 
1.2  Forklift  loading  and  unloading  .........................................................................................  7 
1.3  Lifting  of  forklifts  ............................................................................................................  7 
2  Parking  of  forklifts  ..............................................................................................................  8 
3  Preparation  before  use  .........................................................................................................  8 
4  Precautions  for  safe  operation  .............................................................................................  9 
5  Maintenance  of  lithium  battery  forklift  .............................................................................  13 
5.1  New  forklift  maintenance  ..............................................................................................  13 
5.2  Starting  essentials  ...........................................................................................................  13 
5.3  Maintenance  Summary  ..................................................................................................  13 
5.4  Forklift  oil  and  grease  ....................................................................................................  15 
6   Brief  operating  instructions  ..............................................................................................  16 
6.1  Control  mechanism  and  instrument  ...............................................................................  16 
6.2  Brief  description  of  operation  ........................................................................................  17 
6.3  Maintenance  of  control  system  ......................................................................................  18 
6.4  Special  reminder  ............................................................................................................  19 
7  Warning  sign  .....................................................................................................................  19 
 Structure,  principle,  adjustment  and  maintenance  of  lithium  battery  forklift  .........................  25 
1  drive  system  ......................................................................................................................  25 
1.1  Summary  ........................................................................................................................  25 
1.2  Removal  of  drive  system  ...............................................................................................  27 
1.3  Installation  of  transmission  system  ................................................................................  28 
1.4  Addition  of  gear  oil  ........................................................................................................  30 
2  braking  system  ..................................................................................................................  31 
2.1  Summary  ........................................................................................................................  31 
2.2  Maintenance  and  adjustment  essentials  of  brake  system  ...............................................  34 
3  steering  system  ..................................................................................................................  35 
3.1  Summary  ........................................................................................................................  35 
3.2  Adjustment  and  maintenance  essentials.  ........................................................................  39 
 Electrical  system  .....................................................................................................................  41 
1  Summary  ...........................................................................................................................  41 
2  Instrument  .........................................................................................................................  44 
2.1  Summary  ........................................................................................................................  44 
2.2  Instrument  interface  .......................................................................................................  44 
2.3  Instrument  instructions  ...................................................................................................  45 
2.4  Instrument  working  process  and  instructions  ................................................................  47 
2.5  Instrument  main  menu  and  instructions  .........................................................................  49 
2.6  matters  needing  attention  ...............................................................................................  54 
3   Inmotion  AC  electric  control  assembly  ...........................................................................  55 
3.1  summary  .........................................................................................................................  55 
3.2  Controller  structure  ........................................................................................................  55 
3.3  Controller  fault  code  ......................................................................................................  56 
4  AC  electron  accelerator  .....................................................................................................  60 
4.1  Appearance  and  port  function  ........................................................................................  60 
4.2  Wiring  and  port  diagram  ................................................................................................  61 
 Inmotion  three-phase  AC  motor  ..............................................................................................  61 


1  Summary  ...........................................................................................................................  61 
2  Operating  environmental  conditions  .................................................................................  62 
3  Routine  inspection  and  maintenance  of  AC  motor  ...........................................................  62 
 Lithium  battery  and  charger  ....................................................................................................  62 
1  Use  and  maintenance  of  lithium  battery  ............................................................................  62 
1.1  Instructions  for  use  of  lithium  battery  ............................................................................  62 
1.2  Charging  steps  and  precautions  of  lithium  battery  .........................................................  63 
1.3  Lithium  battery  storage  ...................................................................................................  65 
1.4  Treatment  of  lithium  battery  ...........................................................................................  65 
1.5  Lithium  battery  safety  precautions  .................................................................................  65 
1.6  Lithium  battery  maintenance  ..........................................................................................  66 
2  Charger  ..............................................................................................................................  67 
2.1  Use  of  charger  and  charging  method  ..............................................................................  67 
 Hydraulic  system  .....................................................................................................................  68 
1  Summary  ...........................................................................................................................  68 
1.1  Oil  pump  ........................................................................................................................  69 
1.2  Multiway  valve  ..............................................................................................................  69 
1.3  Lifting  cylinder  ..............................................................................................................  76 
1.4  Speed  limiting  valve  ......................................................................................................  79 
1.5  Tilt  cylinder  (Fig.  7-17)  .................................................................................................  80 
1.6  Hydraulic  oil  tank  ..........................................................................................................  81 
1.7  Hydraulic  system  schematic  diagram  ............................................................................  82 
2  Maintenance  and  adjustment  of  hydraulic  system  ............................................................  82 
2.1  Maintenance  of  hydraulic  oil  pump  ...............................................................................  82 
2.2  fault  diagnosis  ................................................................................................................  86 
Mast  system  ..............................................................................................................................  87 
1  Summary  ...........................................................................................................................  87 
1.1  Internal  and  external  mast(Fig.  8-1)  ...............................................................................  88 
1.2  Fork  carriage  ..................................................................................................................  89 
1.3  Fork  locating  pin  ............................................................................................................  90 
1.4  Roller  position  ................................................................................................................  90 
2  Maintenance  and  adjustment  of  gantry  system  .................................................................  90 
2.1  Lifting  cylinder  adjustment  ............................................................................................  90 
2.2  Height  adjustment  of  fork  rack  ......................................................................................  91 
2.3  Replace  the  fork  carrier  roller  ........................................................................................  91 
2.4  Replace  the  gantry  roller  (Fig.  8-8)  ................................................................................  92 


1. External view and technical parameter

Outline drawing of three-wheel lithium battery forklift

Performance parameters of three-wheel lithium battery forklift

Manufacturer

TITANGREEN

Model designation

1.8T

Power

Electric

Operation

Sit

Rated capacity

lb(kg)

3968(1800)

Load center

in(mm)

24(610)

Tire type－cushion, solid, pneumatic, etc.

Drive/steer

solid/solid

Tire size

Drive/steer

18X7-8/15×4.5-8

Wheels - number

X=driven

Drive/steer

2X/2

Tread

Tires Std dr/steer

in(mm)

37.8/7(960/178)

Mast tilt

Std

degrees

3.5F/5B

Mast - lowered height

Std mast

in(mm)

87(2220)

Free lift - top of fork

Std 2 stg limited free lift mast

in(mm)

5(140)

Opt 2 stg full free lift mast with/without LBR

in(mm)

39/58(990/1475)

Lift height - top of fork

Std 2 stg limited free lift mast

in(mm)

118(3000)

Mast - extended height

Std mast with / without LBR

in(mm)

157/137(3995/3490)

Overhead guard height

Std/drive in rack/opt/opt flat plate

in(mm)

81.4(2070)

Sip to bottom std ohg

Susp at mid-point

Std/susp/swivel

in(mm)

39.4(1000)

Tow pin height

Vertical center of pin

in(mm)

19.9(505)

Overall width

Standard tread

in(mm)

44.4(1130)

Forks

Thickness x width x length

in(mm)

1.6x3.9x42(40×100×1

070)

Standard carriage width

Class II

in(mm)

39.7(1008)

Ground clearance

Lowest point

NL/RL

in(mm)

3.3/3.1(85/80)

Ground clearance

Center of truck

NL/RL

in(mm)

4.3/3.9(110/100)

Load distance

Center of wheel to face of forks

in(mm)

15.1(384)

Battery compartment

Height

in(mm)

22(560)

Width

in(mm)

31.5(800)

Length

in(mm)

16.5(420)

Length to face of forks

Chassis length

in(mm)

75.9(1927)

Wheelbase

in(mm)

53.5(1360)

Right angle stack

in(mm)

125.9(3197)

Equal aisle

90˚ Intersecting aisle

in(mm)

73.6(1870）

Outside turning radius

in(mm)

61.4(1560）

Truck weight

Without battery (NL)

lb(kg)

6797(3083)

Axle loading－drive

Static with max. wt. battery

NL/RL

lb(kg)

3284/10141

(1490/4600)

Axle loading－steer

Static with max. wt. battery

NL/RL

lb(kg)

3836/948 (1740/430)

Voltage

51.2

Travel speed

Extended shift off

NL/RL

mph(km/h)

9.32/8.39(15/13.5)

Lift speed

Std 3 stg FFL mast

NL/RL

ft/min(m/sec)

83/69(0.42/0.35)

Lower speed

Std 3 stg FFL mast

NL/RL

ft/min(m/sec)

69/79(0.35/0.40)

Gradeability

5 Minute rating

NL/RL

ft/min(m/sec)

24/18

Brake

Method of control

Service/parking

ft/min(m/sec)

Hydraulic/mechanical

Method of operation

Service/parking

ft/min(m/sec)

Foot/foot

Battery

Type

lithium-ion

Traction motor

60 Minute rating

hp(kW)

8.8(6.5)

Pump motor

15% Rating

hp(kW)

20(15)

Traction motor

Type/control method

AC/transistor

Pump motor

Type/control method

AC/transistor

Number of speeds

Traction/pump

Infinitely variable

/ infinitely variable

Step height

in(mm)

15.2(386)

Floor height

Lowest point

in(mm)

22.8(580)

Attachment relief pressure(mech levers/mini-levers)

psi(bar)

2540/2320(175/160)

Sound level

Measured per ANSI B56.11.5

dB(A)

2. Safe driving, operation and maintenance of forklift

Forklift drivers and managers must remember "safety first". Before the first operation, please

carefully read the Operation and Maintenance Manual, which will enable you to fully

understand our forklift and operate it correctly and safely.

2.1 Transportation,loading,unloading and lifting of forklifts

2.1.1 Forklift transportation

（1）When the forklift is transported by container or truck, the parking brake pedal shall

be pressed after the forklift is parked in place

（ 2 ） Fix the mast and the balance weight with steel wire and use jacks to prevent the

forklift trucks from moving in the container.

（3）Pay attention to the overall length, width, height when loading, unloading and shipping

and conforming the regulations is necessary.

（4）If necessary, the working device can be disassembled and transported separately.

2.1.2 Forklift loading and unloading

（1）Use the plate with enough length, width and strength.

（2）Pull the parking brake and use jacks to stop the wheel.

（3）Fasten the plate on the center of the cabin, there must be no grease on the plate.

（ 4 ） The left and right height of the plate must be equal to make the loading and

unloading smooth.

（5）Don’t change the direction on the plate to prevent the danger.

（6）Reverse the forklift slowly when loading it on the freight car.

2.1.3 Lifting of forklifts

（1）Only the specially trained personnel can sling the truck.

（2）Sling points should always be at the positions specified in sling nameplate.

（3）The slinging cable must be enough to hang the forklift truck.

（4）Disassembled parts of the forklift truck must be slung in the appointed position.

Model

Mast

Dimensions(mm)

Weight(kg)

1.8T

2100×1088×393

700

Notice:

Dismantling and slinging the component shall not be performed without the

approval of our company. Under special circumstances, the appointed sling

position should be used. The balance weight, fork and mast of the forklift

truck all have their appointed sling position.The above weights are for

reference only and may be adjusted due to different counterweights or

technical optimization.

2.2 Parking of forklifts

（1）The mast is lowered to the lowest position.

（ 2 ） Turn left the key switch and press the emergency stop switch, place all control

levers in the empty position, and unplug the power plug.

（3）Tighten the handbrake lever.

（4）Chock the front and rear tires.

（ 5 ） When the forklift is out of service for a long time, the wheels should be overhead.

Before long-term storage, confirm that the power of the battery system is not less than 50% and

not more than 80%, and charge and maintain it every two months. After storage for more than

two months, please confirm whether the power battery system has a fault alarm before reuse).

（ 6 ） Forklifts shall be stored in a dry and ventilated environment away from heat sources as

far as possible after long-term shutdown.

2.3 Preparation before use

（

1）Check whether all instruments are normal.

（2）Check tire wear.

（3）Check all handles and pedals.

（ 4 ） (Before using the vehicle for the first time, it needs to be charged to 100% before

use. After the vehicle is powered on, confirm that there is no battery system alarm message on

the instrument panel. Please check the remaining power before use. It is recommended that the

SOC be used between 50% and 100%. If the SOC is less than 15%, it is not recommended to

continue to use. Please charge as soon as possible.).

(5)Check whether the battery and vehicle power line connectors and signal line connectors

are reliable.

（6）Check the hydraulic oil and brake fluid for leakage.

（7）Check the tightness of the main fasteners.

（8）Check whether the lighting and signal are normal.

（9）Release the parking brake.

（ 10 ） Carry out the trial operation of mast lifting, forward and backward tilting, forklift

steering and braking.

（11）The contamination degree of hydraulic oil is not greater than Grade 12.

2.4 Precautions for safe operation

（ 1 ） Forklift belongs to special equipment. Only drivers who have passed the training

and examination and hold the driving license can drive; The maintenance of the forklift should

also be carried out by trained and qualified personnel to ensure the normal use of the forklift.

（2）Wear the safety guards, such as clothing, shoes, helmet and gloves while

operating the truck.

（ 3 ） When the center of gravity of the goods is 600mm from the front wall of the vertical

section of the fork, the maximum load is the rated lifting weight, and the load should not

exceed the specified value during handling. If the center of gravity of the goods is more than

600mm from the front wall of the vertical section of the fork, the lifting capacity shall be

reduced according to the value specified in the load curve, and overloading is strictly

prohibited.

（

4）Operate your forklift truck on hard ground. Operate on other ground, the lift

capacity and travel speed must be decreased. Wipe off the oil and grease from the floor.

（ 5 ） Daily maintenance should be done before or after using the truck. Anytime you find

that the truck is not functioning normally, operation of the truck should be halted and checked

or repaired at once.

（6）When operating one lever, pay attention not to shift another lever. Don’t operate

the lever at any position out of the driver’s seat.

（7）Don’t handle unfixed or loose goods. Be careful to handle bulky goods. To

prevent the collapse of stacked goods, tighten them. Forbid loading loose or little

volume goods without pallets.

（ 8 ） Forklifts with accessories specially ordered by users can make their use more

extensive. However, the forklift with attachments will reduce the payload and stability of the

forklift. Do not use the accessories and special devices for other purposes. Please read the

additional instructions we provide for you and use them strictly according to the requirements.

Users are not allowed to modify without permission.

（ 9 ） Do not use a fork to pull the embedded object (if necessary, the pulling force shall

be calculated first).

（

）

When loading goods, the distance between forks shall be adjusted according to the

size of the goods, and the weight of the goods shall be equally shared by the two forks, so as to

prevent the goods from slipping to one side during eccentric loading or driving; It is prohibited

to pick up goods with a single fork.

（ 11 ） When carrying large volume goods, the goods block the driver's sight, and the

forklift should be driven in reverse.

（ 12 ） When loading goods, put the fork to the bottom. After the fork is inserted into the

cargo pile, the front wall of the vertical section of the fork should be in contact with the goods,

and then the gantry should be tilted back to the limit position, and the fork should be lifted 200

mm - 300 mm from the ground before driving

（ 13 ） When lifting or lowering goods, no one is allowed under the lifting frame; It is

forbidden to lift people with a fork.

（14）When loading and unloading goods, keep the mast vertical and the truck is in

braking state.

（15）Because the forklift truck turns by the rear wheels, the end counterweight may

swing widely when turning. Use care in narrow aisles and other workplaces.

（ 16 ） During operation, pay attention to the performance and condition of the system of

machinery, hydraulic, electric and speed-adjuster etc.

（

17 ） Turn on the power, step on the brake, press the one-button start switch, select the

position of the direction switch, turn the steering wheel to see if the vehicle turns normally, and

slowly step on the accelerator pedal to maintain the proper starting acceleration.

（

18 ） Pay attention to observe the SOC. When the forklift is working, if the SOC power

is lower than 15%, it is recommended to stop the operation as soon as possible, charge the

lithium battery or replace the lithium battery with sufficient power. If the SOC power is lower

than 10%, the forklift will be forced to operate with reduced power for the protection of the

battery. At this time, it is necessary to go to the charger immediately for charging.

（

19) The speed of cargo lifting or lowering can be controlled by the number of

movements of the operating handle of the multi way directional valve. The initial speed of

cargo lifting or lowering should not be too fast.

（ 20 ） Before tilting the mast forward and backward, the forklift shall be braked, and

shall tilt slowly when tilting forward to prevent the goods from slipping out suddenly.

（

21 ） Tilt the mast of the high lift forklift truck as backward as possible when operating

the truck. Use minimum forward and backward tilt when loading and unloading. It is dangerous

to travel or turn when lifting the goods at high levels.

（22） It is noted that the goods will fall down when the forks of the truck with lifting

height more than 3m lift, take the protection measures if necessary.

（ 23 ） The overhead guard is the main part which is strong enough to meet safety

standards, and protect the operator from falling materials. It’s very dangerous to dismantle or

rebuild the overhead guard, because these conditions could lead to an accident.

（24） The shelf is a safety part. When the goods are stacked high on the fork and the

gantry is tilted backward, the goods shall be prevented from sliding backward to avoid personal

injury to the driver.

（25） The height of loading and unloading shall be limited to the height of the shelf. If

the height of the goods exceeds the shelf, it is easy to cause the goods to slide to the operator,

which will lead to serious accidents.

（ 26 ） During outdoor operation, the wind has a great impact on the stability of the

forklift, so please pay special attention.

（27）When driving on the wharf or temporary planking, be careful and drive slowly.

（ 28 ） When carrying goods, do not tilt the mast forward, do not load or unload, and do

not brake to prevent the goods from slipping out.

（ 29 ） Forklifts should drive into the cargo pile at a low speed, and pay attention to

whether there are protruding hard objects near the cargo to avoid puncturing the tires.

（ 30 ） When driving, pay attention to pedestrians, obstacles and potholes, and pay

attention to the clearance above the forklift.

（ 31 ） When the forklift is running, the handle, foot and other parts of the body are not

allowed to extend out of the cab, and the vehicle is not allowed to carry people.

（ 32 ） Drive carefully on the ramp, and do not turn, drive laterally or diagonally,

otherwise the forklift may roll over; When carrying goods on a large ramp, drive forward when

going uphill and backward when going downhill; Please use foot brake when going downhill

and drive carefully; When driving on the ramp, it is prohibited to slide in neutral gear and use

the emergency stop button carefully.

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