EP Equipment CQD16, CQD20RVF, CQD16NRVF, CQD16RVF, CQD16NRV Service Manual
...
Service Manual
Electric Reach Truck
CQD16NRVF/NRV
CQD16/20RVF/RV
Service Manual
Electric Reach Truck
CQD16NRVF/NRV
CQD16/20RVF/RV
Release Date Version No. Changes (Serial number)
2016-07-07 SM-3316 07.16 New Version
This manual applies to:
Model Specifi cations
CQD16RV 1,600 kg Capacity, Full Height Series, Medium Confi guration
CQD16NRV
1,600 kg Capacity, Full Height Series, Medium Confi guration,
Narrow Body
CQD16RVF 1,600 kg Capacity, Full Height Series, Premium Confi guration
CQD16NRVF
1,600 kg Capacity, Full Height Series, Premium Confi guration,
Narrow Body
CQD20RV 2,000 kg Capacity, Full Height Series, Medium Confi guration
CQD20RVF 2,000 kg Capacity, Full Height Series, Premium Confi guration
Some sections of the manual only involve certain model, please refer to the manual
according to the actual confi 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
Tel: 400-0550-205
www.ep-zl.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 affect your normal use because of incomplete information. If the contents of the Manual
have been illegible or damaged, which may affect 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 different from what has been described in this Manual, therefore, we must
reserve the right to modify the appearance, confi guration and technical specifi 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-3316 07.16
REV. 07/2016
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
........................................
21
3.1 Structure & Functions .................................................
23
3.1.1 Travel Switch ...............................................................23
3.1.2 Emergency Stop Switch ..............................................23
3.1.3 Key Switch ...................................................................23
3.1.4 Horn Button .................................................................23
3.1.5 Control Switch (RVF/NRVF) ........................................24
3.1.6 Control Switch (RV/NRV) ............................................24
3.1.7 Instrument....................................................................24
3.1.8 Horn .............................................................................24
3.1.9 Fan ..............................................................................25
3.1.10 Accelerator Pedal ........................................................25
3.1.11 Brake Pedal .................................................................25
3.1.12 Foot Switch ..................................................................25
3.1.13 Warning Light ..............................................................26
3.1.14 Headlight .....................................................................26
3.1.15 Rocker Switch..............................................................26
3.1.16 Stepper Motor ..............................................................26
3.1.17 AC2 Controller(TranceController) ................................27
3.1.18 AC2 Controller (Pump Controller) ................................27
3.1.19 EPS-AC0 Controller ....................................................27
3.1.20 DC-DC Converter ........................................................27
3.1.21 Main Contactor ............................................................28
3.1.22 Solenoid Valve Controller(RVF/NRVF) ........................28
3.1.23 Multi-way Solenoid Valve (RVF/NRVF) .......................28
3.1.24 Multi-way Manual Valve (RV/NRV) ..............................28
3.1.25 Pump Motor ................................................................. 29
3.1.26 Gear Pump ..................................................................29
SECTION
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4. CHASSIS SYSTEM
........................................................
31
4.1 Load Wheel ................................................................
33
4.1.1 Removal and Installation ...............................................33
4.1.2 Faults and Causes.........................................................33
4.2 Caster .........................................................................
34
4.2.1 Removal and Installation ...............................................34
4.3 Brake Pedal ................................................................
35
4.3.1 Removal and Installation ...............................................35
4.3.2 Faults and Causes.........................................................36
4.4 Seat ............................................................................
36
4.4.1 Removal and Installation ...............................................36
4.5 Brakes ........................................................................
37
4.5.1 Removal and Installation ...............................................37
4.5.2 Faults and Causes.........................................................38
5. DRIVE SYSTEM
.............................................................
39
5.1 Drive Wheel ................................................................
42
5.1.1 Removal and Installation ...............................................42
5.1.2 Faults and Causes.........................................................42
5.2 Electromagnetic Brakes..............................................
43
5.2.1 Removal and Installation ...............................................43
5.2.2 Faults and Causes.........................................................44
5.2.3 Checking and Testing ....................................................44
5.2.4 Control Circuit Troubleshooting ..................................... 45
5.3 Drive Motor .................................................................
46
5.3.1 Removal and Installation ...............................................46
5.3.2 Faults and Causes.........................................................46
5.3.3 Checking and Testing ....................................................47
5.3.4 Control Circuit Troubleshooting ..................................... 48
5.4 Gearbox ......................................................................
49
5.4.1 Removal and Installation ...............................................49
5.4.2 Faults and Causes.........................................................49
5.5 Proximity Switch .........................................................
50
5.5.1 Removal and Installation ...............................................50
5.5.2 Faults and Causes.........................................................50
5.5.3 Checking and Testing ....................................................51
5.5.4 Control Circuit Troubleshooting ..................................... 51
5.6 Steering Motor ............................................................
52
5.6.1 Removal and Installation ...............................................52
5.6.2 Faults and Causes.........................................................52
5.6.3 Checking and Testing ....................................................53
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5.6.4 Control Circuit Troubleshooting ..................................... 54
6. OPERATING SYSTEM
...................................................
55
6.1 Control Lever ..............................................................
57
6.2 Control Panel ..............................................................
57
6.3 Horn Button ................................................................
58
6.3.1 Removal and Installation ...............................................58
6.3.2 Faults and Causes.........................................................58
6.3.3 Checking and Testing ....................................................58
6.3.4 Control Circuit Troubleshooting ..................................... 58
6.4 Control Switch (RVF/NRVF) .......................................
59
6.4.1 Removal and Installation ...............................................59
6.4.2 Faults and Causes.........................................................59
6.4.3 Checking and Testing ....................................................59
6.4.4 Control Circuit Troubleshooting ..................................... 60
6.5 Control Switch (RV/NRV) ...........................................
62
6.5.1 Removal and Installation ...............................................62
6.5.2 Faults and Causes.........................................................62
6.5.3 Connection Mode ..........................................................62
6.5.4 Checking and Testing ....................................................62
6.5.5 Control Circuit Troubleshooting ..................................... 63
6.6 Stepper Motor .............................................................
65
6.6.1 Removal and Installation ...............................................65
6.6.2 Faults and Causes.........................................................65
6.6.3 Checking and Testing ....................................................65
6.6.4 Control Circuit Troubleshooting ..................................... 65
6.7 Key Switch ..................................................................
66
6.7.1 Removal and Installation ...............................................66
6.7.2 Faults and Causes.........................................................66
6.7.3 Checking and Testing ....................................................66
6.7.4 Control Circuit Troubleshooting ..................................... 66
6.8 Emergency Switch ......................................................
67
6.8.1 Removal and Installation ...............................................67
6.8.2 Faults and Causes.........................................................67
6.8.3 Checking and Testing ....................................................67
6.8.4 Control Circuit Troubleshooting ..................................... 67
6.9 Rocker Switch.............................................................
68
6.9.1 Removal and Installation ..............................................68
6.9.2 Faults and Causes........................................................68
6.9.3 Checking and Testing ...................................................68
6.9.4 Control Circuit Troubleshooting .................................... 68
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6.10 Travel Switch ............................................................
70
6.10.1 Removal and Installation .............................................70
6.10.2 Faults and Causes.......................................................70
6.10.3 Checking and Testing ..................................................70
6.10.4 Control Circuit Troubleshooting ...................................70
7. HYDRAULIC SYSTEM
...................................................
71
7.1 Overview.....................................................................
73
7.1.1 Hydraulic Schematic Diagram RVF/NRVF ....................74
7.1.2 Hydraulic Schematic Diagram RV/NRV .........................75
7.2 Hydraulic Power Unit ..................................................
76
7.2.1 Removal and Installation ...............................................76
7.3 Pump Motor ................................................................
76
7.3.1 Removal and Installation ...............................................76
7.3.2 Faults and Causes.........................................................76
7.3.3 Checking and Testing ....................................................77
7.3.4 Control Circuit Troubleshooting ..................................... 78
7.4 Multi-way Reversing Solenoid Valve (RVF/NRVF) .....
79
7.4.1 Removal and Installation ...............................................79
7.4.2 Interface Description......................................................79
7.4.3 Faults and Causes.........................................................80
7.4.4 Checking and Testing ....................................................80
7.4.5 Control Circuit Troubleshooting ..................................... 80
7.5 Solenoid Valve (RVF/NRVF).......................................
81
7.5.1 Faults and Causes.........................................................81
7.5.2 Checking and Testing ....................................................81
7.5.3 Control Circuit Troubleshooting ..................................... 82
7.6 Multi-way Reversing Manual Valve (RV/NRV) ............
83
7.6.1 Removal and Installation ...............................................83
7.6.2 Interface Description......................................................84
7.6.3 Faults and Causes.........................................................84
7.6.4 Checking and Testing ....................................................84
7.7 Gear Pump .................................................................
85
7.7.1 Removal and Installation ...............................................85
7.7.2 Faults and Causes.........................................................85
7.7.3 Checking and Testing ....................................................85
7.8 Reach Cylinder ...........................................................
86
7.8.1 Cylinder Removal Precautions ......................................86
7.8.2 Cylinder Installation Precautions ...................................87
7.8.3 Removal and Installation ...............................................88
7.8.4 Cylinder Maintenance ....................................................89
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TABLE OF CONTENTS
7.9 Hydraulic Troubleshooting ..........................................
90
7.10 Hydraulic Symbol......................................................
91
8. ELECTRICAL SYSTEM
.................................................
93
8.1 Controller ....................................................................
95
8.1.1 Removal and Installation ...............................................95
8.1.2 Controller Interface Function .........................................97
8.2 Fuse..........................................................................
107
8.2.1 Location of Fuses ........................................................107
8.2.2 Checking and Testing ..................................................108
8.3 Main Contactor .........................................................
109
8.3.1 Removal and Installation .............................................109
8.3.2 Faults and Causes.......................................................109
8.3.3 Checking and Testing .................................................. 110
8.3.4 Control Circuit Troubleshooting ................................... 110
8.4 Height Display (RVF/NRVF) ......................................
111
8.4.1 Removal and Installation ............................................. 111
8.4.2 Faults and Causes....................................................... 111
8.4.3 Checking and Testing .................................................. 111
8.4.4 Control Circuit Troubleshooting ................................... 112
8.5 Limit Switch ..............................................................
113
8.5.1 Removal and Installation ............................................. 113
8.5.2 Connection Mode ........................................................ 113
8.5.3 Faults and Causes....................................................... 114
8.5.4 Checking and Testing .................................................. 114
8.5.5 Control Circuit Troubleshooting ................................... 114
8.6 Accelerator Pedal .....................................................
116
8.6.1 Removal and Installation ............................................. 116
8.6.2 Faults and Causes....................................................... 116
8.6.3 Checking and Testing .................................................. 116
8.6.4 Control Circuit Troubleshooting ................................... 117
8.7 Foot Switch ...............................................................
118
8.7.1 Removal and Installation ............................................. 118
8.7.2 Faults and Causes....................................................... 118
8.7.3 Checking and Testing .................................................. 118
8.7.4 Control Circuit Troubleshooting .................................. 119
8.8 DC-DC Converter .....................................................
120
8.8.1 Removal and Installation ............................................120
8.8.2 Faults and Causes......................................................120
8.8.3 Checking and Testing .................................................120
8.8.4 Control Circuit Troubleshooting ..................................120
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TABLE OF CONTENTS
8.9 Warning Light / Headlight .........................................
121
8.9.1 Removal and Installation ............................................121
8.9.2 Faults and Causes......................................................121
8.9.3 Checking and Testing .................................................121
8.9.4 Control Circuit Troubleshooting ..................................121
8.10 Cooling Fan ............................................................
122
8.10.1 Removal and Installation ...........................................122
8.10.2 Faults and Causes.....................................................122
8.10.3 Checking and Testing ................................................122
8.10.4 Control Circuit Troubleshooting .................................122
8.11 Seat Switch .............................................................
124
8.11.1 Removal and Installation ...........................................124
8.11.2 Faults and Causes .....................................................124
8.11.3 Checking and Testing ................................................124
8.11.4 Control Circuit Troubleshooting .................................124
8.12 Instrument...............................................................
125
8.12.1 Instrument Operation Schematics .............................125
8.13 Handheld Unit (Optional) ........................................
129
8.13.1 Handheld Unit Connection.........................................129
8.13.2 Handheld Unit Menu Options ....................................129
8.13.3 TESTER Menu ..........................................................131
8.14 Controller Error Message .......................................
133
8.14.1 Tractiong/Pump Controller .........................................133
8.14.2 Steering Controller (EPS-ACO) ................................. 138
8.14.3 SICOS Controller .......................................................147
8.14.4 Solenoid Valve Controller ..........................................148
8.15 Electrical Schematic Diagrams RVF/NRVF ............
149
8.15.1 Electrical Schematic Diagram RVF/NRVF (1/6) ........149
8.15.2 Electrical Schematic Diagram RVF/NRVF (2/6) ........150
8.15.3 Electrical Schematic Diagram RVF/NRVF (3/6) ........151
8.15.4 Electrical Schematic Diagram RVF/NRVF (4/6) ........152
8.15.5 Electrical Schematic Diagram RVF/NRVF (5/6) ........153
8.15.6 Electrical Schematic Diagram RVF/NRVF (6/6) ........154
8.16 Electrical Schematic Diagrams RV/NRV ................
155
8.16.1 Electrical Schematic Diagram RVF/NRVF (1/5) ........155
8.16.2 Electrical Schematic Diagram RVF/NRVF (2/5) ........156
8.16.3 Electrical Schematic Diagram RVF/NRVF (3/5) ........157
8.16.4 Electrical Schematic Diagram RVF/NRVF (4/5) ........158
8.16.5 Electrical Schematic Diagram RVF/NRVF (5/5) ........159
8.17 Cable Wiring Diagrams (RVF/NRVF) .....................
160
8.18 Cable Wiring Diagrams (RV/NRV) ..........................
161
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8.19 Wiring Harness and Connectors (RVF/NRVF) .......
162
8.20 Wiring Harness and Connectors (RV/NRV) ............
163
9. TROUBLESHOOTING
.................................................
165
9.1 Preparation Before Troubleshooting .........................
167
9.1.1 Check the Voltage of Battery .......................................167
9.2 Troubleshooting Solutions of Common Faults ..........
168
APPENDIX
A SERVICE MANUAL - MAST
.......................................
175
A1 Two-stage Mast
.........................................................
177
A1-1 Removal and Installation ........................................
177
A1-2 Lifting Chains .........................................................
178
A1-2.1 Chain Adjustment ......................................................178
A1-2.2 Chain Replacement...................................................179
A1-3 Mast Tubing............................................................
180
A1-4 Lift Cylinder ............................................................
181
A1-4.1 Cylinder Removal (with mast on the vehicle) ............181
A1-4.2 Cylinder Maintenance ...............................................182
A1-4.3 Cylinder Installation ...................................................182
A1-5 Tilt Cylinde..............................................................
183
A1-5.1 Cylinder Removal ......................................................183
A1-5.2 Cylinder Maintenance ...............................................183
A1-5.3 Cylinder Installation ...................................................184
A1-6 Built-in Side Shifter.................................................
184
A1-6.1 Side Shifter Removal ................................................184
A1-6.2 Side Shifter Installation .............................................184
A1-6.3 Side Shifter Maintenance ..........................................185
A2 Three-stage Mast(Lifting Height ≤ 7.5 m)
................
186
A2-1 Removal and Installation ........................................
186
A2-2 Lifting Chains .........................................................
187
A2-2.1 Chain Adjustment ......................................................187
A2-2.2 Chain Replacement...................................................188
A2-2.2.1 Mast Chains ......................................................... 188
A2-2.2.2 Fork Carriage Chains ...........................................188
A2-3 Mast Tubing............................................................
191
A2-4 Lift Cylinder ............................................................
193
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A2-4.1 Cylinder Removal .....................................................193
A2-4.2 Cylinder Maintenance ...............................................194
A2-4.3 Cylinder Installation ...................................................195
A2-5 Tilt Cylinde..............................................................
196
A2-5.1 Cylinder Removal ......................................................196
A2-5.2 Cylinder Maintenance ...............................................196
A2-5.3 Cylinder Installation ...................................................197
A2-6 Built-in Side Shifter.................................................
197
A2-6.1 Side Shifter Removal ................................................197
A2-6.2 Side Shifter Installation .............................................197
A2-6.3 Side Shifter Maintenance ..........................................198
A3 Three-stage Mast (8.0 m≤ Lifting Height ≤ 9.5 m)
199
A3-1 Removal and Installation ........................................
199
A3-2 Lifting Chains .........................................................
200
A3-2.1 Chain Adjustment ......................................................200
A3-2.2 Chain Replacement...................................................201
A3-2.2.1 Mast Chains ......................................................... 201
A3-2.2.2 Fork Carriage Chains ...........................................201
A3-3 Mast Tubing............................................................
204
A3-4 Lift Cylinder ............................................................
206
A3-4.1 Cylinder Removal .....................................................206
A3-4.2 Cylinder Maintenance ...............................................207
A3-4.3 Cylinder Installation ...................................................208
A3-5 Tilt Cylinde..............................................................
209
A3-5.1 Cylinder Removal ......................................................209
A3-5.2 Cylinder Maintenance ...............................................209
A3-5.3 Cylinder Installation ...................................................210
A3-6 Built-in Side Shifter.................................................
210
A3-6.1 Side Shifter Removal ................................................210
A3-6.2 Side Shifter Installation .............................................210
A3-6.3 Side Shifter Maintenance .......................................... 211
A4 Three-stage Mast(10 m≤ Lifting Height ≤ 11 m)
......
212
A4-1 Removal and Installation ........................................
212
A4-2 Lifting Chains .........................................................
213
A4-2.1 Chain Adjustment ......................................................213
A4-2.2 Chain Replacement...................................................214
A4-2.2.1 Mast Chains ......................................................... 214
A4-2.2.2 Fork Carriage Chains ...........................................214
A4-3 Mast Tubing............................................................
217
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A4-4 Lift Cylinder ............................................................
219
A4-4.1 Cylinder Removal .....................................................219
A4-4.2 Cylinder Maintenance ...............................................220
A4-4.3 Cylinder Installation ...................................................221
A4-5 Tilt Cylinde..............................................................
222
A4-5.1 Cylinder Removal ......................................................222
A4-5.2 Cylinder Maintenance ...............................................222
A4-5.3 Cylinder Installation ...................................................223
A4-6 Built-in Side Shifter.................................................223
A4-6.1 Side Shifter Removal ................................................223
A4-6.2 Side Shifter Installation .............................................223
A4-6.3 Side Shifter Maintenance ..........................................224
B SERVICE MANUAL - BATTERY
.................................
225
B1 Lead-acid Battery
......................................................
227
B1-1 Safety and Warnings ..............................................
227
B1-2 Use of Battery ........................................................
227
B1-2.1 Pre-use Checks ........................................................227
B1-2.2 Discharging ............................................................... 227
B1-2.3 Charging ...................................................................228
B1-2.4 Temperature ..............................................................228
B1-3 Maintenance & Care .............................................
228
B1-3.1 Daily Maintenance ....................................................228
B1-3.2 Weekly Maintenance .................................................228
B1-3.3 Monthly Maintenance ................................................229
B1-3.4 Care ..........................................................................229
B1-4 Storage ..................................................................
230
B1-5 Troubleshooting .....................................................
230
B2 Maintenance-free Battery
.........................................
233
B2-1 Safety and Warnings ..............................................
233
B2-2 Use of Battery ........................................................
233
B2-2.1 Pre-use Checks ........................................................233
B2-2.2 Discharging ............................................................... 233
B2-2.3 Charging ...................................................................234
B2-3 Maintenance & Care ..............................................
234
C SCHEDULE
.................................................................
235
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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
certifi cation or evaluation agency.
The following operations shall be performed before you leave the truck:
- No parking on slopes.
- Fully lower the forks.
- Cut off the power supply.
- Turn the switch lock to “STOP” and remove the key.
Prior to truck maintenance:
- Raise the drive wheel off the ground, or cut off the power supply connection.
- Use wooden wedges or other effective fi 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 fl ame to check level of electrolyte, other oils or fl 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 fi 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.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
1
1
1. INFORMATION & SPECIFICATIONS
2
NOTE:
3
REV. 07/2016
INFORMATION & SPECIFICATIONS
1
1.1 After-sales Service Platform
Claims/Replacement Parts Service Platform:
In order to provide you with a fast and effi 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:
i
Customer
nxsp@ep-zl.com
Tel: 400-0550-205
Customer
Components
Warehouse
Customer service to input
into After-sales System.
After-sale Engineer to
call back to confirm the
accuracy of the information
about the components.
Shipped within
24 hours
Claim Form
Customer service to input
into After-sales System.
After-sale Engineer to call
back to confirm about the
specifi c fault information.
Within two business
days after the maintenance, customer service
will call back and close
the claim.
Maintenance service
specialist will provide
on-site service at the
appointed time.
NOTE
Customer
nxsp@ep-zl.com
Tel: 400-0550-205
Claim Form
Customer
REV. 07/2016
INFORMATION & SPECIFICATIONS
1
4
No. Name
1 Lift Mast
2 Overhead Guard
3 Free Lift Cylinder
4 Controller
5 Load Wheel
6 Reach Outrigger
7 Battery
8 Tank
No. Name
9 Drive Wheel
10 Seat
11 Foot Switch
12 Brake Pedal
13 Accelerator Pedal
14 Battery Slider Unlocking Lever
15 Star-shaped Handle
16 Control Panel
1.2 Introduction
5
REV. 07/2016
INFORMATION & SPECIFICATIONS
1
This series are electric reach trucks. Its important structure is as shown in Figure 90001.
-
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
The truck is driven forward or backward by AC
motor. The lifting and lowering of mast can also
drive the truck, while the travel speed will be
limited.
The Electric Power Steering has greatly met the
demand for high mobility of the truck.
The truck is equipped with foot switch, only by
pressing the switch can the truck be operated,
which has greatly reduced the possibility of
misuse by the operator.
Truck can only be operated by single operator;
other personnel is forbidden from riding.
WARNING
1.3 Common Tools
No. Name Remark
1 Hex Wrench 2#~14# One Set
2 Hex Head Socket Wrench 8#~24# One Set
3 Phillips Screwdriver 2# One Piece
4 Slotted Screwdriver 2# One Piece
5 Sockets and Knobs One Set
6 Circlip Pliers One for holes and one for shaft
7 Hammer One Piece
8 Spreader, Crane One Pair
9 Cylinder Wrenches For removal and installation of cylinders
10 Diagonal Pliers One Piece
11 Cylinder Pliers One Piece
12 Grease Gun One Piece
13 Tiger Tooth Wrench 22#/27# One of Each
REV. 07/2016
INFORMATION & SPECIFICATIONS
1
6
Table 1.4.1 Screws/Bolts Performance Levels
Performance Level Material Specifi 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 replacement.
-
-
CAUTION
The performance levels of screws or bolts are
marked on the heads of the screws or bolts.
If you fi nd the screws or bolts used on certain
position are not marked with performance
level, please select spare parts with performance level of at least 8.8 grade or higher level
forreplacement.
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
REV. 07/2016
INFORMATION & SPECIFICATIONS
1
8
9
2
2. MAINTENANCE
10
NOTE:
11
REV. 07/2016
MAINTENANCE
2
-
-
-
Working conditions:
-
-
-
i
2.1 Overview
Only by performing regular vehicle maintenance
and repair, can ensure the continuous and
reliable use of the truck.
Only specially trained and qualified personnel
are capable of maintenance and repair
operations of the equipment. If you want to
perform the maintenance and repair on your
own, it is recommended that on-site training
should be conducted to your maintenance
personnel by the service representative of the
vendor.
When lifting load components or during the
operations under the cabin, sufficiently strong
chains or safety device must be used to secure
the vehicle.
WARNING
Truck must be parked on the level ground
reserved for maintenance (such area needs
to be clean and with less dust), block the
wheels with wooden wedges, disconnect
the key switch and disconnect the battery
connections.
When lifting the truck, the lifting tools can
only be installed on the fixed positions as
specifi ed.
When jacking up the truck, appropriate tools,
such as wedge blocks, wooden blocks, and
so on, must be used to secure the truck to prevent the occurrence of accidental rolling or
tipping over.
Without the supplier's consent, it is strictly
forbidden to make modifi cations to truck, espe-
cially to the safety devices. It is strictly forbidden
to change the various working speeds of the
truck.
CAUTION
Under harsh working conditions: such as, the
external temperature is too high or too low,
dusty, or implementing multiple shifts per day,
the maintenance and care interval should be
shortened.
Prior to lubrications, replacement of fi lters or
operating the hydraulic system, please clean
the external parts carefully and use a clean
container.
Only compliant lubricants can be used See
Table 2.2 Lubricants.
NOTE
12
REV. 07/2016
MAINTENANCE
2
-
-
-
-
2.2 Maintenance
2.2.1 Cleaning
Do not use flammable liquids to clean the
truck.
Before starting to clean, all necessary
security measures must be taken to prevent
sparking (short circuit) during operation. If the
truck is powered by battery, battery plug must
be pulled out.
When cleaning electrical and electronic components, you should use low-intensity suction
gas or compressed dry air. Meanwhile, clean
the dust on the surface of components with
non-conductive and antistatic brush.
Do not use vapor steam to clean the equipment.
2.2.2 Inspection
Regular inspection and maintenance under
normal conditions of use:
Operating
Hours (h)
Requirements
50 At least once per 7 days
150 At least once per 60 days
250 At least once per 90 days
500 At least once every 6 months
1000 At least once per year
When the truck is at running-in phase (after
approximately 100 hours of operation), the
equipment user must check the fastening of
wheel nuts and bolts and re-tighten them if
necessary.
CAUTION
Regular inspection and maintenance under
harsh conditions of use:
Under harsh working conditions, especially:
-
Dusty environment
-
Corrosive environment
-
Cold storage environment
The maintenance intervals should be shortened
by half.
13
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MAINTENANCE
2
Table 2.1 Inspection & Maintenance List
Interval in days/months/years 7 d 60 d 90 d 6 m 1y
Interval in hours 50 150 250 500 1000
Functions and Control
Check the functions of the operation switches and
display
A
Check alarm system functions A
Check foot switch functions A
Check the emergency switch functions A
Check the cables for damage and if the terminals are
secure
A
Check the electronic limit functions A
Check and tighten the controllers and contactors A
Check height display functions A
Check fault information records and operating hours A
Power Supply & Drive System
Check the battery cables for damage and replace if
necessary
A
Check the battery charge connector A
Check if the cable connections between battery monomers are secure, apply some grease to electrodes if
necessary
A
Check electrolyte fl uid level A
Check electrolyte density A
Check battery temperature A
Check battery locking mechanism A
Check and tighten motor mounting bolts A
Check the connections of motor connectors A
Check the position of various bearings for noise A
A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the
vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.
14
REV. 07/2016
MAINTENANCE
2
Table 2.1 Inspection & Maintenance List (Continued)
Interval in days/months/years 7 d 60 d 90 d 6 m 1y
Interval in hours 50 150 250 500 1000
Power Supply & Drive System
Check transmission oil level A
Clean or replace the gear oil
Replace after 100 hours of early operation.
Then replace once every 2000 hours
Check the gearbox for abnormal noise or leaks A
Check and lubricate the bearings between drive motor
and gearbox
A / L
Check and lubricate steering large ring gear A / L
Check the drive wheel and load wheel for worn or
damage
A
Check the wheel bearings and fi xation A
Check the fi xation of drive mounting base A
Check the travel speed A
Hydraulic System
Check the functions of hydraulic system A
Check if the hoses, pipes and interfaces are fastened
or sealed securely, and check if there is damage
A
Check the cylinders for leaks A
Check the cylinders for damages and check the fi xation A
Check the oil tank fi xation and check for leaks A
Check the hydraulic oil level A
Clean or replace the hydraulic oil
Replace after 100 hours of early operation.
Then replace once every 2000 hours
Check and clean oil tank air fi lter A
Replace the oil tank air fi lter and fi lter A
Check the relief pressure A
A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the
vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.
15
REV. 07/2016
MAINTENANCE
2
Table 2.1 Inspection & Maintenance List (Continued)
Interval in days/months/years 7 d 60 d 90 d 6 m 1y
Interval in hours 50 150 250 500 1000
Breking System
Check the braking functions of electromagnetic brake A
Check the air gap of electromagnetic brake A
Check the installation and connection of
electromagnetic brake
A
Check the braking distance of electromagnetic brake A
Check the braking functions of brake A
Check the brake fl uid level A
Check the brake pump and piping connections for leaks A
Check the release of brake pedal is normal A
Check the installation and connection of brake A
Check the braking distance of brake A
Mast System
Check the mast for damages A
Clean and lubricate the rolling surface of lift mast
column with grease
A / L
Check and lubricate mast rollers A / L
Check the fi xation of lift mast A
Check the tubing on mast for connections and leaks A
Check the side shifter functions A
Check the connections of bolts and nuts A
Check and lubricate the chains A / L
Check the lifting chains and chain guides for wear,
adjust and grease
A
Check the fork carriages for wear and damage A
A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the
vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.
16
REV. 07/2016
MAINTENANCE
2
Table 2.1 Inspection & Maintenance List (Continued)
Interval in days/months/years 7 d 60 d 90 d 6 m 1y
Interval in hours 50 150 250 500 1000
Mast System
Visual inspection of rollers, sliders and stoppers A
Check the lifting and lowering speed A
Other
Check if the signs are clear and complete A
Check the chassis for cracks or damages A
Check the engine hood and lubricate the hinges A / L
Lubricate the forward tilting guides and rollers A / L
Check the fi xation of battery and battery tray
A
Check the forward tilting safety blocks
A
Check the seat fi xation and adjustment functions A
Check the seat belt and functions A
Check the overhead guard and cabin A
Checking covering parts for damages A
Check the casters for wear and cracks A
Check if the optional features are functioning properly A
A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the
vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.
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