ep CQD12R Operation Manual Download Page 7

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5.Truck Maintenance

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5.1 Operational safety and environmental protection

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5.2 Maintenance Safety Regulations

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5.3 Servicing and inspection

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5.3.1 Maintenance Checklist

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5.3.2 Lubrication Schedule

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5.3.3 Maintenance Instructions

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5.4 Decommissioning the truck

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5.4.1 Prior to decommissioning

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5.4.2 Restoring the truck to operation after decommissioning

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5.5 Safety checks to be performed at regular intervals and following

any unusual incidents

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5.6 Final de-commissioning, disposal

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6.Troubleshooting

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Summary of Contents for CQD12R

Page 1: ...I ...

Page 2: ... ordered Through our online after sales service system customers can process their warranty claims order spare parts and consult the operation manuals maintenance materials and spare parts catalogs With business all over the world EP has thousands of employees and hundreds of agents worldwide to provide our global customers with prompt local service Based on the concept of sharing economy EP also ...

Page 3: ...ifferences between your product and the description in this manual And the operator manual details will be different because of customer s special requirements If you have any questions please keep in touch with the sales department of E P Equipment or let the dealer know Notes 1 This manual is used for operation and maintenance the detail parameters size and specifications in context is only for ...

Page 4: ...sition and remove the key 4 Before starting to operate truck Be in operating position Place directional control in neutral Before operating truck check functions of lift systems directional control speed control steering warning devices and brakes 5 Do not use open flame to check lever or for leakage of electrolyte and fluids or oil Do not use open pans of fuel or flammable cleaning fluids for cle...

Page 5: ...n to minimize fire hazards facilitate detection of loose or detective parts 11 Modifications and additions which affect capacity and safe truck operation shall not be performed by the customer or user without manufacturers prior written approval Capacity operation and maintenance plates or decals shall be changed accordingly ...

Page 6: ... 1 Control panel controls and displays 15 3 2 2 Display unit controls and displays 17 3 3 Run the truck 18 3 3 1 Checking and Preparing 18 3 3 2 Adjusting the driver s seat 18 3 3 3 Adjusting the steering wheel 19 3 3 4 To prepare the truck for operation 19 3 4 Industrial Truck Operation 20 3 4 1 Safety regulations for truck operation 20 3 4 2 Travel Steering Braking 21 3 4 3 Lifting and depositin...

Page 7: ...ance Checklist 31 5 3 2 Lubrication Schedule 33 5 3 3 Maintenance Instructions 34 5 4 Decommissioning the truck 36 5 4 1 Prior to decommissioning 36 5 4 2 Restoring the truck to operation after decommissioning 36 5 5 Safety checks to be performed at regular intervals and following any unusual incidents 37 5 6 Final de commissioning disposal 37 6 Troubleshooting 38 ...

Page 8: ...roprietor is considered the person who in accordance with existing contractual agreements between the owner and user of the truck is charged with operational duties The proprietor must ensure that the truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded Furthermore accident prevention regulations safety regulations and op...

Page 9: ...is designed for internal and external use to lift and transport goods Open bottom pallets or pallets with transverse boards can be lifted inside or outside the area of the load wheels or roll cage Loads can be stacked unstacked and transported over long distances The capacity can be obtained from the data plate ...

Page 10: ...omponent Item Component 1 Mast 8 Tank 2 Overhead guard 9 Drive wheel 3 Free lift cylinder 10 Driver s seat 4 Controller 11 Drive pedal 5 Load wheel 12 Accelerator pedal 6 Outriggers 13 Star shaped handle 7 Battery 14 Control panel ...

Page 11: ...n the control panel The position of the steered drive wheel is shown in the control panel display unit The maximum steer angle is 90 Operator position The driver s position is ergonomically designed with ample legroom The driver s seat and steering arm can be adjusted to suit the driver Controls and Displays The functions are activated via ergonomic thumb movement to ensure fatigue free operation ...

Page 12: ... gradeability laden unladen 8 10 Service weight include battery SEE Form 2 lb Axle loading fork advanced unladen driving side loading side 2264 2171 lb Axle loading fork retracted unladen driving side loading side 2828 1020 lb Axle loading fork advanced laden driving side loading side 862 6333 lb Axle loading fork retracted laden driving side loading side 2590 4605 lb Drive motor rating S2 60 min ...

Page 13: ...Form1 in l7 Length across wheel arms exclusive fork See Form1 in b3 Fork carriage width 37 7 in b4 Distance between wheel arms loading surfaces 27 5 in b5 Distance between fork arms 7 9 25 6 in s e l Fork dimensions 1 6 4 42 in m1 Ground clearance laden below mast 2 75 in m2 Ground clearance center of wheelbase 2 36 in Wa 最小转弯半径 61 8 in Ast Aisle width for pallets 1000 1200 crossways See Form1 in ...

Page 14: ... 12 105 51 106 1 Aisle width for pallets 800 1200 lengthways Ast 106 5 107 28 107 87 108 66 Aisle width for pallets 1000 1200 lengthways Ast 108 46 109 25 109 65 110 43 Aisle width for pallets 800 1200 crossways Ast 100 2 100 98 101 38 102 17 Form 2 Mast Type Lift height in Service weight without battery lb CQD12R RF 2 stage 98 43 4345 106 3 4389 118 11 4433 129 92 4477 141 73 4521 157 48 4576 169...

Page 15: ...0 28 152 56 141 73 93 11 182 09 164 37 157 48 100 98 197 83 180 12 169 29 106 89 209 65 191 93 3 stage 137 8 68 31 29 13 45 87 177 17 160 43 157 48 74 8 35 63 52 36 196 85 180 12 177 17 81 3 42 13 58 86 216 54 199 8 188 98 85 24 46 06 62 8 228 35 211 61 196 85 87 8 48 62 65 35 236 22 219 49 216 54 94 29 55 12 71 85 255 91 239 17 3 stage Side sway 137 8 68 31 28 15 45 87 178 15 160 43 157 48 74 8 3...

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Page 17: ...10 1 4 Identification points and data plates ...

Page 18: ...ng 2 Warning decal 3 Don t drive in rain warning 4 Operator warning 5 Operator decal 6 Operator warning decal 7 Truck data plate 8 Security mark 9 Hydraulic pressure decal 10 Model decal 11 Capacity chart 12 Never stand warning 13 CE decal 14 Strap points for crane lifting ...

Page 19: ...ax Battery Mass 4 Production Date 11 Min Battery Mass 5 Battery Voltage 12 Lifting Height 6 Capacity 13 Load weight 7 Lifting height max 14 Load center For queries regarding the truck or ordering spare parts please quote the truck serial number 2 1 4 2 Capacity chart The chart given above shows the relation between the load center and the weight of loads ...

Page 20: ...ten The flattening will disappear after a short period of operation 2 2 During brake in We recommended operating the machine under light load conditions for the first stage of operation to get the most from it Especially the requirements given below should be observed while the machine is in a stage of 100 hours of operation Must prevent the new battery from over discharging when early used Please...

Page 21: ... e g wheel or brake problems must not be used until they have been rectified Repairs The driver must not carry out any repairs or alterations to the truck without the necessary training and authorisation to do so The driver must never disable or adjust safety mechanisms or switches Hazardous area A hazardous area is defined as the area in which a person is at risk due to truck movement lifting ope...

Page 22: ...15 3 2 Controls and Displays 3 2 1 Control panel controls and displays ...

Page 23: ... Select the required driving direction 5 Horn button Activates the horn 6 Control panel lock Sets control panel distance and height 7 Driver s seat lock The driver s seat can be horizontally adjusted 8 Weight adjustment driver s seat Adjusts driver s weight for optimal seat cushioning 9 Backrest adjustment The backrest on the driver s seat can be adjusted 10 Accelerator pedal Provides infinite con...

Page 24: ...17 3 2 2 Display unit controls and displays 1 Switch Set the controller parameter of truck used by authorised service personnel 2 Display ...

Page 25: ...pear 3 3 Run the truck 3 3 1 Checking and Preparing Checks and operations to be performed before starting daily work Visually inspect the entire truck in particular wheels and load handler for obvious damage Visually inspect the battery attachment and cable connections Check the load handler for visible damage such as cracks bent or severely worn load forks Test the warning device Make sure the lo...

Page 26: ...ds to the desired position Engage locking lever 2 in position again 3 Adjusting the backrest Lift up the locking lever 3 and adjust the incline of the backrest Release locking lever 3 to lock the backrest in position 3 3 3 Adjusting the steering wheel Adjust the control pane 1 vertically and horizontally to the required position 3 3 4 To prepare the truck for operation Insert the key in the key sw...

Page 27: ...ck as a lookout Negotiating slopes and inclines Negotiating slopes or inclines is only permitted if such roads are clean and have a non slip surface and providing such journeys are safely undertaken in accordance with the technical specifications for the truck in question The truck must always be driven with the load unit facing uphill The industrial truck must not be turned operated at an angle o...

Page 28: ...to select the required driving direction Forward the drive direction V the main travel direction Back the load direction R apply the drive pedal 6 The travel speed is governed by the accelerator 5 Use steering wheel 1 to steer the truck in the required direction Warning The truck can only be moved with or without a load when the mast support is retracted the mast tilted back and the load handler l...

Page 29: ... with the coasting brake with the emergency brake with the service brake With the reversing brake While the truck is travelling press the travel switch 4 It switches to the opposite travel direction and the truck decelerates through the traction current controller until it starts to move in the opposite direction With the coasting brake Not apply the drive pedal 6 Travel inhibited truck decelerate...

Page 30: ...switch lever Lowering Pull the control switch lever 1 towards direction S until you reach the desired height The lowering speed is determined by the inclination of the control switch lever 2 Extending Retracting Do not reach between the mast and the battery cover Extending Move the control switch lever 2 in direction T to extend the mast support forward Retracting Move the control switch lever 2 i...

Page 31: ...l switch lever 4 in direction Y 3 5 Parking the truck securely When you leave the truck it must be securely parked even if you only intend to leave it for a short time Lower the load completely and position it horizontally Retract the mast support fully Set the emergency brake switch 2 OFF Turn off the key switch and remove the key 1 Warning Do not park the truck on a slope The load must always be...

Page 32: ...sparks within 2 metres around the truck The area must be well ventilated Fire protection equipment must be provided Battery Disposal Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws The manufacturer s disposal instructions must be followed 4 2 Battery type dimension Battery type dimension as follow form Form 4 1 Tuck type CQD12R CQ...

Page 33: ...ver 2 the mast is now in its limit position Insert the battery lock shaft Lift up the battery trolley unlatch rod 1 Move the control switch lever 2 towards arrow T and extend the mast holder with the coupled battery trolley until the battery is exposed for maintenance Release the battery lock shaft Turn the emergency brake switch and key switch off Warning Before starting up the truck again the ba...

Page 34: ...n manufacturers 4 5 Battery removal and installation Expose the battery See 4 3 Expose the battery Place the battery plug or the battery cable in such a way that they will not get caught on the truck when the battery is removed The hooks 1 must be attached to the eyes of the battery in such a way Lift the battery clear and move out to the side Installation is in the reverse order of operations War...

Page 35: ...attery appears need for charge please charge it quickly Battery maintenance The battery cell covers must be kept dry and clean The terminals and cable shoes must be clean secure and have a light coating of dielectric grease Batteries with non insulated terminals must be covered with a non slip insulation mat Battery storage If batteries are taken out of service for a lengthy period they should be ...

Page 36: ...er s service department has field technicians specially trained for these tasks We therefore recommend a maintenance contract with the manufacturer s local service centre Lifting and jacking up When a truck is to be lifted the lifting gear must only be secured to the points specially provided for this purpose When jacking up the truck take appropriate measures to prevent the truck from slipping or...

Page 37: ...st be replaced every six years When replacing hydraulic components also replace the hoses in the hydraulic system 5 3 Servicing and inspection Thorough and expert servicing is one of the most important requirements for the safe operation of the truck Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment The service intervals stated a...

Page 38: ...Travel Check transmission for noise and leakage Check travel mechanism adjust and lubricate if necessary Check wheels for wear and damage Check wheel suspension and attachments Check drive support plate Change transmission oil Truck frame Check chassis for damage Check labels Check mast attachment Make sure overhead guard is secure and check for damage Check moving mast holder and wear rails Check...

Page 39: ...djust and grease Check fork tines and fork carrier for wear and damage Perform sight check of rollers sliding elements and stops Steering system Test electric steering Check steering toothing for wear and lubricate Lubrication Grease the vehicle in accordance with the lubrication schedule ...

Page 40: ...33 5 3 2 Lubrication Schedule ...

Page 41: ...onding agent consumable mixture must be disposed of in accordance with regulations Code Description Used for A L HM46 Hydraulic oil C 85W 90GL 5 Gear oil B Polylub GA352P Lubrication grease D ZSM207DOT3 Brake fluid 5 3 3 Maintenance Instructions Prepare the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs The...

Page 42: ...airs See 5 3 3 Maintenance Instructions Open the cover See 5 3 3 Maintenance Instructions Check the transmission oil level it should be at the control plug level See 5 3 2 Lubrication Schedule If necessary add transmission oil of the correct grade See 5 3 2 Lubrication Schedule Installation is the reverse order Recommissioning The truck may only be recommissioned after cleaning or repair work once...

Page 43: ...ge the battery See 4 4Charging the battery Disconnect the battery clean it and apply grease to the terminals In addition follow the battery manufacturer s instructions Spay all exposed electrical contacts with a suitable contact spray 5 4 2 Restoring the truck to operation after decommissioning Thoroughly clean the truck Lubricate the truck in accordance with the maintenance schedule See 5 3 2 Lub...

Page 44: ...on the technical regulations and principles governing the inspection of trucks A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect The truck must also be examined for damage caused by possible improper use A test report shall be provided The test results must be kept for at least the next 2 inspections The owner is responsible for ensuring th...

Page 45: ...fuse truck in charge mode Check the battery connector and connect if necessary Set key switch to I Check battery charge charge battery if Necessary Test fuses Interrupt charging Load can not be lifted Hydraulic oil level too low Excessive load Check the hydraulic oil level Note maximum capacity see data plate If the fault cannot be rectified after carrying out the remedial procedure notify the man...

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