5.

Traction, Transmission and Brakes System

Introduction

Module summary
This module covers the Motor, Transmission and Brakes of the new electric forklift.
This training module is there to allow service people to discover the arrangement of
this power train.

Learning Objectives
At the completion of this module, you will be able to do the following
 Identity the functionalities of the various components.
 Diagnose troubleshooting and repair.

Skill Objectives
At the completion of this module, you will be able to do the following:
 Demonstrating proper operation and installation process.
1. General
Two wheel drive axles are installed on the truck. Each one gets an AC motor driving
an individual transaxle (LH & RH). The center of the shortest turning radius is located
between RH and LH drive wheels as shown on figure 1. In this case both motors are
turning opposite directions.

Fig1. Drive axle

This transaxle, which includes speed reducers and wet brakes, supports the
front frame and the mast and wheel hub loads as well.
 2. Specifications of transaxle
As this drive axle is power transmission system that is installed to driving wheel for
electric forklift, it includes hydraulic service brake (dynamic) and mechanical parking
brake system (static).

Fig2. Transaxle
Tab1. Specification
Specification ECB 35 (PMP701) ECB 25/16 (PMP 601)
Max axial load kg 4400 2800
Electric motor power kW 7-8 5
Max input speed rpm 5000 5000
Ratio 17.5-29.5 18.1~26.8
Continuous torque allow at wheel Nm 1900 800
Max motor acceleration at wheel Nm 3000 1300
23x9/10 18x7/8
Tyre dimensions
23x9/12 21x8/9
Gearbox oil type Mobil # 424
Gearbox oil quantity L 1.2~1.3 0.55-0.65
Gearbox oil changing interval Hours 1000 1000
Gearbox weight kg 57 38
Service brake type Wet brake
Brake oil DOT 4
Max dynamic braking pressure bar 85 75
Max dynamic brake pressure allowable bar 150 150
Oil volume for dynamic braking cm 3 3.2 1.8
Chamber volume with worn disks cm 3 5.6 3.1
Lever stroke, never used discs mm 15 5.3
Lever stroke, worn discs mm 21 8
Dynamic braking torque at wheel Nm >3300 1500 at 65 bar
Force on lever/torque at wheel 1000N=1700Nm 1500N=1000N
PMP drive unit is composed of two independent and separated parts:
1) the reduction gear itself
2) the brake cartridge, containing oil lubricated brake discs.

The patented technical solution of the separation between the brake cartridge and
the gearbox allow to optimize the performance of the unit, because the two
chambers are separated and work with the same oil, but with two different oil levels
that automatically compensate it during the working processing.

This system allows an excellent lubrication of the brake discs and the reduction gear,
so optimize:
1) the brake system lift time
2) the thermal exchange
3) the system performance

Attention:
Under normal working conditions the gearbox shall never exceed a temperature of
120℃. If this temperature limit is exceeded it is recommendable to suspend usage
and allow the gearbox to cool down.
 3. Drive motors
The AC induction motors are manufactured by KDS. They supply 5 kW (ECB16) /8
kW(ECB25)/ 10 kW(ECB16) each.
Their speeds (frequency related) are controlled separated by AC controllers according
to steering sensor position creating an electronically differential.

Fig2. Drive motor

Inside the house of each traction motor, a temperature sensor is installed (2 wire
sensor). This sensor provides information to the traction controller about the current
temperature of the motor. When the temperature rises above a set value the
software will react by reducing the performance to prevent overheating and damage
to the motor.
The traction motor is also equipped with another sensor, the speed sensor. This
sensor provides a signal to the traction controller on the current motor speed. This
sensor is used to accurately control the motor and the vehicle speed. It does not only
measure speed but it also detects the direction the motor is running in.
 4. Installation
a. motor installation
Oil-sealing of the inlet shaft is ensure seal (preferably made of FKM) and an O-ring,
housed in the motor flange and on the rear cover of the reduction gear, respectively.
And housing on the motor flange also lodges the stop-ring of the bearing. The inlet
shaft, in fact, is axially blocked in one direction only, and the motor flange stops it on
the opposite direction.

Fig3. Viton seal

The motor flange and the gearbox are coupled by means of 5 M10 screws.

Fig4. Connection of the transaxle and motor

Attention:
1) When securing the screws, secure those two in the diagonal positions first and
apply Lithium-based grease to the connecting part of drive motor and speed
reducer/gearbox;
2) Inject 1.2L gear oil in LH and RH speed reducer/ gearbox separately; Torque on
motor screws: 120Nm;
3) When adding gear oil, two ports needs to be opened; installation drive unit
assembly.
b. Transaxle installation

Fig4. Transaxle installation

Attention: Torque on screws: Torque on screw 180-200Nm

5. Brake discs unit

Left and right brakes use friction plate for braking. Also, driving and parking brakes
share the same brake system.
The brake discs unit is made of 7 steel discs and 6 friction discs, ordered in an
alternate way (the first one and the last one must be smooth). Between every couple
of steel discs four springs are inserted, one spacer on each locking pin.

Fig5. The brake discs unit

 Fig6. Service brake system
1—Brake oil resorvoir 2—Brake oil hose 3—Brake Pedal 4—Master break
cylinder 5—transaxle

Fig7. The module of the mast break cylinder

The mast break cylinder powers the breaking system. The pedal activates the mast
break cylinder providing the pressure requested for the breaking. The break oil type
is DOT 4.
 Fig The model of brake system
The parking brake lever is mounted on the vehicle body and connected by brake
fastener and drive axle. Drive axle parking brake performance should meet full load
braking in slope 15°.

6. Gearbox
The parking brake lever is mounted on the vehicle body and connected by brake
fastener and drive axle. Drive axle parking brake performance should meet full load
braking in slope 15°.