HELI CQD16X1 Operation & Service Manual Download

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CONTENTS

I. Safety Instructions of Operation and Driving……………………………………..1

II. External View of Reach Truck……………………………………………………5

III. Main Specifications………………………………………………………………6

IV. Construction and Principle of Reach Truck………………………………………7

4.1 Transmission system………………………………………………………..7

4.2 Rear axle………………………..……………………………………………9

4.3 Steering system……………………….……………………...…………11

4.4 Supporting wheel assembly…………….……………………………..12

4.5 Brake system ……………….…………………………………………14

4.6 Hydraulic system……………….……………………………………...….17

4.7 Body system……………..……………………………………………….29

4.8 Lifting system……………………………………………………….……31

4.9 Electric system………………………………………...……………………53

V. Troubleshooting…………………………………………………………………..93

5.1 Transmission system………………………………………………………93

5.2 Steering system…………………………………………………………….93

5.3 Parking brake system………………………………………………………93

5.4 Hydraulic system…………………………………………………………..94

5.5 Electric system……………………………………………………………95

VI. Maintenance……………………………………………………………………96

VII. Others………………………………………………………………………….99

7.1 The size and weight of the main takedown parts of the truck……………..99

7.2 Mast disassembly…………………………………………………………. 99

7.3 Overhead guard disassembly………………………………………………99

7.4 Vibration specification…………………………………………………...100

Summary of Contents for CQD16X1

Page 1: ......

Page 2: ... of AC motors effectively reduce noise and improve truck comfort and reliability the truck has precise and stable operation through superior motor battery multi function LCD meter and DC DC pressure converter buffers at the upper and lower limit position and during mast lifting and lowering effectively reduce working noise and realize stable moving with CAN bus technology the truck is more reliabl...

Page 3: ...limit of space so you can not get the size and weight accurately from the graphic illustrations which are to describe the correct operation methods of the devices and parts This manual might not correspond with the actual condition because of the improving of our products Our products are subject to improvements and changes without notice ...

Page 4: ...ssembly 12 4 5 Brake system 14 4 6 Hydraulic system 17 4 7 Body system 29 4 8 Lifting system 31 4 9 Electric system 53 V Troubleshooting 93 5 1 Transmission system 93 5 2 Steering system 93 5 3 Parking brake system 93 5 4 Hydraulic system 94 5 5 Electric system 95 VI Maintenance 96 VII Others 99 7 1 The size and weight of the main takedown parts of the truck 99 7 2 Mast disassembly 99 7 3 Overhead...

Page 5: ... into or out the truck directly by platform 2 3 Fix the overhead guard and mast with wire and wedge wheels securely when delivering the forklift 3 Storage 3 1 Lower the forks to the floor 3 2 Turn off the key switch and emergency switch place all operating levers in neutral and pull out the plug from the battery set 3 3 Pull the parking brake 3 4 Put up the wheels and recharge the battery once eve...

Page 6: ...hane solid tyre 4 4 Check all operating switches and pedals 4 5 Check the battery for output voltage specific gravity and state of battery capacity 4 6 Check all of the connectors and plugs in the electric system for reliable contact and accelerator pedal for effectiveness and flexibility 4 7 Check hydraulic oil electrolyte and brake fluid for leakage 4 8 Check main fixing parts for tightness 4 9 ...

Page 7: ...hen lifting the fork 5 8 Do not operate the levers or attachment out of the seat Do not stand on the telescopic working device in case of danger of mis operating the telescopic levers 5 9 Tilt the mast forward or backward completely or ensure the operating levers back to neutral position when the mast is at the highest position 5 10 When releasing operating levers suddenly during mast lowering the...

Page 8: ...ttery when first charging or recharging 6 2 if the output voltage of the battery is reduced to 41V 31V or the voltage of anyone lower than 1 7V or the meter alarms the truck should stop working immediately until the battery is replaced or charged 6 3 When charging often check specific gravity liquid leveL and temperature of the electrolyte 6 4 Charge the battery as soon as possible in 24 hours aft...

Page 9: ...5 II External View of Reach Truck Figure 2 1 External view of reach truck ...

Page 10: ...20x100x35 fork side shift amount mm 50 50 Truck length without fork mm 1815 1865 Truck width mm 1090 1090 Overhead height mm 2320 2320 Min underground clearance at mast mm 60 60 Front overhang mm 318 318 Reaching forward distance mm 600 600 Wheel base mm 1407 1457 Min steering radius mm 1695 1745 Right angle stacking width mm 2817 2832 Performance Travelling speed w o load km h 11 8 10 5 11 8 10 5...

Page 11: ...nd driven gear and the second level deceleration is achieved through gear mesh transmission of the input shaft and spiral bevel tooth The power is transmitted to output shaft after a 90 changing of transmitting direction and thus the drive wheel rotates The steering mode of the whole drive unit is of electric steering That is a meshed gear pair is driven by steering motor The steering mode is simp...

Page 12: ...ut M33 1 5 32 bearing 6207 33 oil seal 34 screw M4 12 35 breather plug 36 tank cover 37 retainer ring 72 38 input shaft 39 lock nut 40 driven gear 41 bearing 30306 42 washer 43 bearing 33206 44 plug 1 2 45 screw 46 washer 12 47 transmission box plate 48 bolt M6 12 49 steering gear 50 induction ring 51 proximity switch bracket 52 bolt B8 26 53 washer 6 54 bolt M8 70 55 washer 8 56 pin B8 26 57 Bolt...

Page 13: ...he drive wheel from idling As a part of rear axle the balance wheel will rotate with the travelling direction of truck when steering The steering knuckle shaft of balance wheel is connected to the steering connecting plate through two tapered roller bearings See figure 4 2 1 When the rear part of the truck is under upwarp condition install the spring between steering connecting plate and frame Whe...

Page 14: ...ring cover plate 4 3 Steering system Steering system type Steering through drive wheel Steering motor 48V 0 6kw 1350rpm Deceleration ratio of steering gear box 1 46 Deceleration ration of gear transmission 1 5 85 Control type AC Steering wheel diameter φ200mm The steering system consists of a steering wheel assembly a electric steering controller a steering motor a steering reduction mechanism and...

Page 15: ...1 consists of a steering wheel a steering bracket a bearing a sensor and so on The function is that it generates a signal of angle and it doesn t overcome the force moment of turning so the turning is easy The install position has a 85 degree with the vertical direction It can not be adjusted after installment Figure 4 3 1 Steering wheel assembly 1 steering wheel 2 steering axle 3 spring 4 Steerin...

Page 16: ...g 6004 2Z 5 shaft sleeve 6 flat key 7 driven gear 8 retainer ring 24 9 bearing 6004 2Z 10 drive gear 11 steering motor 12 shaft sleeve 13 transmission box case cover 14 bolt M8x30 15 washer 8 16 retainer ring 17 screw M10x30 18 washer 10 4 4 Supporting wheel assembly The truck adopts four points supporting structure and the front support is two symmetrically distributed front load wheel assembly S...

Page 17: ... Drive wheel 2 Auxiliary wheel 3 Frame 4 Front load wheel assembly Figure 4 4 2 front load wheel assembly 1 Flange bearing 2 Front leg assembly 3 Pin axle 4 Side plate 1 5 Side plate 2 6 Shim 7 Adjusting shim 8 Load wheel 9 Bolt M12x1 25x25 10 Washer 12 ...

Page 18: ... 2 month 4 5 Brake system 4 5 1 Service brake The truck adopts AC regenerating brake of AC traction motor There are two ways to start service brake one is to release driving operation knob which has weak brake strength and it is suitable for ordinary condition the other way is t release brake pedal which has strong brake strength and it is suitable for emergent condition see figure 4 5 1 Figure 4 ...

Page 19: ... electromagnetic parking brake s electromagnet has no power The armature presses the friction disc tightly the brake hold the traction motor shaft tightly and then the motor shaft can not rotate and thus the truck is parking braked When travelling the electromagnetic parking brake should release the friction disc Release the parking brake and the brake condition shown on the LCD is released Then t...

Page 20: ...ly anaerobic adhesive GY 340 2 Fix the friction disc built in spine sleeve of the electromagnetic parking brake with travelling and traction motor shaft through key 8x25 item 1 Fix the spine sleeve upper end with retainer 25 item 6 Make sure all parts are firmly installed and be sure they can work smoothly Notes when assembling electromagnetic parking brake Make sure the air gap between the basis ...

Page 21: ...elf lock valve With manual lowering function System pressure 21MPa Front lifting cylinder Type Plunger type Piston rod diameter 65mm Additional function Pipe bursting protection end buffering Travel distance 892 1340mm Rear lifting cylinder Type Plunger type Piston rod diameter 45mm Additional function Pipe bursting protection end buffering when lowering Travel distance 1615 2465mm Telescopic cyli...

Page 22: ... tilting cylinder side shifting cylinder pipelines and so on See figure 4 6 1 and 4 6 2 for principle diagram Figure 4 6 1 Comfort type full proportion hydraulic principle diagram Lifting Reaching Side shifting Side shifting Cut off valve Balancing valve Dual direction balance valve ...

Page 23: ...ic oil tank is used to store oil and besides it can dissipate heat in the oil when the environment temperature is low it can be used to keep the heat in the oil dispel the gas in the oil and sediments dirt in the oil Lifting Cut off valve reaching Tilting Side shifting Dual direction balance valve Balancing valve ...

Page 24: ...r 13 oil cover gasket The return oil filter is used to keep the cleanness of the hydraulic oil Change the filter after three months or 600h for the first time In the future change it every six months or every 1200h The filter core code is 936756Q The oil dipstick is used to measure the oil level in the oil tank When checking oil level lower the mast completely and retract mast support If the oil l...

Page 25: ...e through pump oil suction pipe to fill the gears With the rotation of chamber gears bring the oil into the left chamber from right chamber to make the pressure of the left chamber increase and the oil goes out from the oil discharging port Because the gears keep going the oil suction port and oil discharging port keep sucking oil and discharging oil Figure 4 6 4 Gear pump working principle 4 6 3 ...

Page 26: ...8 solenoid valve for lifting control 9 emergent manual lowering valve 1 Lifting 8 solenoid valve for lifting control gets electricity 2 Lowering 1 solenoid valve for lowering control gets electricity 3 Auxiliary functions 6 and 7 get electricity Functions of other valves 4 overflow valve it realizes pressure protection of the hydraulic system 9 emergent manual lowering valve it realizes goods lowe...

Page 27: ...valve 6 Auxiliary valve coil 7 Shuttle valve 8 One way valve 9 System pressure compensated valve 10 Lifting pressure compensated valve 11 Overflow valve 12 Lifting valve core 13 Lowering valve core 4 6 4 Operation of control valve The control valve is operated through integrated knob Different functions can be realized through corresponding buttons See figure 4 6 7 ...

Page 28: ... knob backward the fork will tilt backward the fork will shift left when pushing the left side shifting button to the left and the fork will shift right when pushing the right side shifting button to the right See figure 4 6 8 for the signs of knob operation As you see in Fig 4 6 8 the mast lift up when you push the lift lever forward the mast fall down when you pull the lever forward The mast til...

Page 29: ...nd oil seal are installed on cylinder cover to support plunger rod and to prevent dust getting into it Full free lifting cylinder includes front lifting cylinder and rear lifting cylinder The front lifting cylinder is used to realize the free lifting travel distance of the working device see figure 4 6 9 for its structure The rear lifting cylinder is used to realize non free lifting travel distanc...

Page 30: ...t off valve 19 shim 20 screw Figure 4 6 10 Rear lifting cylinder structure 1 dust proof ring 2 separation blade 3 seal ring for axle 4 separation blade 5 O ring 6 bearing 7 guide sleeve 8 plunger rod 9 cylinder body 10 adjusting sleeve 11 lock screw 12 seal ring 13 support ring 14 sleeve 15 piston 16 retainer ring 17 cut off valve 18 shim 19 screw The pipeline anti bursting valve is used to protec...

Page 31: ...e shaft 3 Spring 4 Seperation blade 4 6 6 Telescopic cylinder The telescopic cylinder is of piston type double acting hydraulic cylinder to realize mast moving backward and forward The front reach cylinder is made up of piston piston rod cylinder body cylinder bottom guide sleeve and sealing parts End clearance buffering technology is applied to reduce the shock when the cylinder moving to the end...

Page 32: ... 5 Support ring 6 Seal ring for axle 7 O ring 8 Dust proof ring 4 6 8 Side shifting cylinder Side shifting cylinder is of plunger type single acting hydraulic cylinder to realize fork left and right shifting See figure 4 6 14 for its structure Figure 4 6 14 Side shifting cylinder structure 1 Cylinder tube assembly 2 O ring 3 Side shifting cylinder cover 4 U ring 5 Separate blade 6 Dust proof ring ...

Page 33: ...ce lower the power device connect battery and ten remove the wedges of wheels 5 Adjust the hinged points according to 4 7 3 in the manual 4 7 2 Check and adjust the fame 1 Disconnect the battery and remove the battery from the truck lift and remove the door 2 Disconnect the connection with drive motors and electric brake device 3 Disconnect the pipelines with steering motor and block the ends of p...

Page 34: ...paint for later hinged points adjusting The trailing edge of supporting wheel shall point at drive wheel as 2 shown in the figure See figure 4 7 1 check spring 8 and supporting wheel 14 Change if necessary At the drive wheel side adjust the hinged distance between adjusting bolt 1 bottom and corresponding drive device 4 to be 1 5mm 0 0 0 5mm tighten the lock nut 2 with a torque of 375 405Nm At the...

Page 35: ...nged points adjusting 4 8 Lifting system 4 8 1 Composition The standard configuration of the truck is three stage full free fork carrier telescopic mast The outer mast and frame are fixed while the fork carrier is retractable The mast is made up of inner mast middle mast outer mast integrated ...

Page 36: ... functions Figure 4 8 1 Structure of lifting system 1 Guard 2 Outer mast assembly 3 Middle mast assembly 4 Inner mast assembly 5 Mast pipeline 6 Rear lifting cylinder and chain for chain wheel 7 Attachment pipeline and control cables 8 Front lifting cylinder chain wheel seat chain wheel chain 9 Pipeline guard 10 Telescopic fork assembly 11 Backrest 12 Fork 13 Mast fixing bolt ...

Page 37: ...ed rollers at top end of outer mast inner mast and middle mast is that the adjusting bolts have different length others are the same Φ119 2 at the lower end of middle mast Φ110 4 out fork plate of attachment Φ78 5 inner fork plate of attachment 4 8 2 Torque requirements 1 Tighten torque of four M20 bolts connecting outer mast cross beam and frame 305 340Nm 2 Tighten torque of four M12 bolts fixing...

Page 38: ...mbined roller structure 1 Main roller 2 Spindle nose 3 Adjusting screw 4 Adjusting screw 5 Elastic washer 6 Side roller 7 Dust proof piece 8 Retainer ring for axle Note a Adjust the side roller clearance to be 0 3mm 0 5mm through rotating screw 3 b Apply lubrication grease on roller surface and mast contacting face c Tighten adjusting screw 4 and rotate screw 3 in anti clockwise direction Make sur...

Page 39: ...nders are synchronized If the two cylinders do not stop at the same time that means the two cylinders travel distances are different Add shims between the plunger rod head which is lower and the middle mast beam to ensure the synchronization of two cylinders The thickness of the adjusting shim is 0 5mm and 1mm 4 8 7 Peeling For new mast peeling of mast surface is not rare The phenomena is normal b...

Page 40: ...lescopic fork on them horizontally 6 Remove the front lifting cylinder 7 Connect a lift equipment on the inner mast Lift the inner mast and make the chain to be loose Remove the chain nuts 8 Remove the control cables hydraulic pipeline chain and pulley from the top of middle mast and lower end of inner mast Mark the positions of all parts The left side is different from the right side 9 Lift the i...

Page 41: ...e frame 10 Put the mast assembly horizontally in a proper place Note when the mast assembly is well placed before removing cylinder and mast assembly please make sure the lifting point of lifting equipment stay as close to the center of mast assembly as possible in order to keep balance 4 8 9 Assembly Note before assembly please refer to the relative requirements such as torque requirements fork a...

Page 42: ... aging 4 8 11 Lifting chain maintenance The lifting chain is very important part of truck it is necessary to maintain the lifting chain in order to truck safety working Improper maintenance period will result poor performance of chain 4 8 12 Cleaning of lifting chain Note when delivery the lubrication grease on the lifting chain is used to protect it from corrosion Please do not remove the lubrica...

Page 43: ... required in table 1 on the chain 6 Measure from the center of first chain pin to the center of last one Note pitch is the distance between the chain pins 7 Calculate the elongation of lifting chain Elongation of lifting chain measured length newly lifting chain length 100 100 Example the lifting chain pitch is 25mm Table 1 shows that newly chain length corresponding lifting chain pitch is 305mm T...

Page 44: ...ic fork rear carrier s low edge of inner mast be 30 35mm b Lower the fork to the ground and tilt back completely Adjust the connector at the top end of chain and nut to make the tensity of two chains the same please be care when maintaining the lifting cylinder 4 8 15 Change the lifting chain 1 Find the part number of lifting chain in parts manual and make sure the lifting chain standby is suitabl...

Page 45: ...e to 80 of rated capacity Use equipments such as vernier caliper 160 scale and so on Be familiar with fork capacity Fork capacity and load center are pasted on the truck Overload may cause permanent deformation or serious fatigue condition Fatigue crack often begins from the hell part of fork Crack can be found during heel check Check if there is any crack within 130mm of the outer diameter of for...

Page 46: ...od and prevent dust from entering The lifting cylinder of the truck includes front lifting cylinder and rear lifting cylinder The front cylinder realizes free lifting of working device See figure 2 for its structure The rear lifting cylinder realizes lifting of inner and middle mast See figure 1 for its structure Figure 4 8 4 Assembly of rear lifting cylinder and its composition 21 Dust proof ring...

Page 47: ...eeve 31 Fixing screw M4 x6 32 SPG0 type sealing parts 55x46 5x3 8 33 Supporting ring 55x50x20 34 Sleeve 35 Piston 36 Retainer ring 37 Safety valve G1 2 38 Shim 39 Screw 5 x5 Figure 4 8 5 Installment of front lifting cylinder and its composition 13 Safety valve 14 Shim 15 Screw M5x8 16 Spring 17 Plunger rod ...

Page 48: ...m The working principle is that the circuits from A chamber to B chamber and from B chamber to A chamber are unlocked normally when the pipeline bursts a great pressure difference is produced between A chamber and B chamber then the shutter 4 locks the flowing hole of the valve body 1 to cut the oil circuit from the cylinder to the outside to ensure the safety of goods and person Figure 4 8 6 Pipe...

Page 49: ...and under the crane Then wedge the wheels and remove the fork 2 Block up the middle mast with two wood batten 3 Turn the key switch off and disconnect the battery 4 Disconnect the pipeline with the cylinder 5 Remove the screw fixing the plunger piston to the install block on top of the middle mast Do not remove the screws on the two cylinders once Remove the one on the cylinder that needs to be re...

Page 50: ... and to protect the connectors from damage Also it is good for oil draining Take care when disassemble and assemble hydraulic oil cylinder and ensure the cleanness of cylinder Before disassembling clean dirt and grease on its surface After the cylinder is disassembled clean all metal parts with solvent and then dry them with compressed air Check the plunger piston assembly and cylinder bore If the...

Page 51: ... bracket assembly the item 5 and 6 in figure 4 8 8 are left and right forward reaching cylinder respectively The forward reaching cylinder also is a double action piston type cylinder Be care when carrying out any repair If there is abnormal leakage on the cylinder cover or the cylinder can not tilt remove the cylinder form truck for repair Figure 4 8 8 Diagram of telescopic fork ...

Page 52: ... Tighten the pipeline connector Air bleeding tilting cylinder 1 Loose the pipeline slowly of part 28 as shown in figure 4 Let the air in the oil cylinder out until there is continuous hydraulic oil flowing out from gap 2 Tighten the pipeline connector 4 8 18 Forward reaching system and attachment 4 8 18 1 Forward reaching assembly When the straddle legs can not enter its inner or lower side the tr...

Page 53: ...om and on top pf the bracket assembly When the forward reaching assembly is drawn back completely The anti motion block can prevent the metal parts from collision Adjust the adjusting shim of anti motion block to make the forward reaching cylinder connect with fork bracket when cylinder is drawn back The anti motion block uses shims to ensure its proper position Tighten the screw to make the screw...

Page 54: ...e fork carrier 3 Extend telescopic fork and then place a wood piece of 50 100 200mm on the right channel steel or left channel steel of item 1 as shown in figure 4 8 10 4 Draw the forward reaching back until the combined roller 11 on scissor plate 4 lay against the wood piece Remove the forward reaching cylinder and the wood piece can prevent the forward reaching assembly from drawing back 5 Remov...

Page 55: ... limit ring 26 and limit pin axle 27 as shown in figure 4 8 10 Remove the lock cover 23 and shim 24 11 Remove the scissor plate assembly 4 as shown in figure 4 8 10 Figure 4 8 11 Structure of side shifter assembly 12 Remove the pin axle 12 as shown in figure 4 8 11 Divide the side shifter assembly into two parts The rear parts of fork carrier 1 tilting cylinder 15 top block of tilting cylinder 21 ...

Page 56: ...cleanness of all contacting surface and make sure there is no furs or fragment that may damage the thrust washer When changing the washer 24 and 25 on two sides of scissor plate assembly as shown in figure 4 8 10 apply a thin layer of grease on all surfaces Please tighten lock cover 23 on the pin axle 17 to lock position Loose the screw nut and then tighten it to a torque of 7 3Nm Then loose it to...

Page 57: ...rocking bar valve control module lifting control module AC pump motor Note The products are subject to improvements and changes If the products are not corresponding with the manual please contact with the manufacturer See attached figure for electric system principle diagram 4 9 2 Detailed description of the electric system 1 CAN bus technology The AC type electric reach truck applies the CAN bus...

Page 58: ...offers truck working mode shifting and set of lifting height pre selector optional B Layout of dash board Figure 4 9 1 meter dash board layout 1 Fork height indicator optional It is used to display the current fork height and the unit is mm 2 Heating in cold environment indicator optional When the electric heating is started in cold storage the indicator shows 3 Hour meter When the hour glass symb...

Page 59: ...lt node and fault code 9 Electricity quantity indicator It shows the current electricity quantity C Meter usage instruction 1 Turn on the key switch and the meter system carries out self checking after it gets electricity Battery electricity quantity truck speed traction hours and wheel angle is shown on the home page Figure 4 9 2 Meter display 2 Safety switch and brake display the truck is braked...

Page 60: ...en the battery electricity quantity is reduced to 15 that means only one LED is on the fault alarm light and undervoltage alarm light will flicker at the same time At this time the truck will slow down and the lifting function is cut off in order to protect the battery At this time charge the battery in time Figure 4 9 4 4 Hour meter when the truck get electricity the hour meter begins to work Use...

Page 61: ...ntroduction Three ZAPI motor controller and one valve controller are installed on the truck to control truck traction lifting system and steering system Figure 4 9 4 controller assembly A Traction and pump motor controller Tractor motor controller type ZAPI ACE2 48V 450A Pump motor controller type ZAPI SCE2 48V 500A Control module code Corresponding control module Control module number HY VCM valv...

Page 62: ...gree IP65 e out of control protection f battery over discharging protection g Mis starting protection The following functions can be realized through controller s hand console a On line inspection and adjusting on traction and lifting control system b On line correction on travelling accelerator and lifting speed adjusting signal c Fault detection and inquiry on traction and lifting control system...

Page 63: ...ing wheel automatic centering through function switch inching And also the function can realized through turning on the electric lock The working environment temperature should be in the range of 30 40 The highest work temperature that is permitted is 85 Protection function of the steering motor controller a Battery polarity protection b Over loaded and short circuit protection c Protection degree...

Page 64: ...on connectors e There are two power output terminals which are 12V and 5V respectively f There are 8 output terminals controlled by current which can control the hydraulic valve accurately and proportionally The terminal can stand a max current of 2A g There is a terminal offering a max current of 4A h There are 3 output terminals controlled by PWM voltage Note Test the truck with four wheels rais...

Page 65: ...phase AC type induction motor free from maintenance Driving motor Pump motor Steering motor Power 7KW 15KW 0 6KW Voltage 36 48V 36 48V 36 48V Rated current 165A 436A 27A Rotation speed 3930rpm 2027rpm 1350rpm Note Cut off the electricity before checking and maintaining the motors to avoid accident 5 Battery A Battery construction and specifications The battery is made up of pole plate pole plate s...

Page 66: ...he battery clean and dry Take care of the bolts poles and connectors it there is a loose or poor contact adjust it 2 Do not put any conductor on the battery set to avoid a short circuit 3 The first charging of the battery is called first charging while the other charging is called common charging The charging time varies with the battery capacity and using degree In normal conditions if the usage ...

Page 67: ...entilated warehouse Keep the temperature in a range of 5 40 2 Avoid exposing under the sunshine and drenching in the rain Keep the battery more than 2M away from the heat source 3 Do not keep the battery upside down or side or tossed or rolled nor pressed heavily 4 Keep the poisonous and corrosive goods away from the battery No metal and substance should be dropped into the battery 5 Do not store ...

Page 68: ...de The characteristics of faults causation and repair measure are bellowed fault Characteristics Causation Repair measure Pole plate sulfide 1 decrease of the battery capacity 2 low density of the electrolytic below the normal lever 3 High battery voltage when beginning or finishing the charging 4 high rising of the electrolytic temperature when charging 5 air bubble in the early time of charging ...

Page 69: ...plate 2 Clean the precipitate and conductor 3 Replace the plate Shedding off of the reactive matter 1 Decrease of the battery capacity 2 Turbid electrolytic 3 Much precipitate 1 Being unsuitable to the electrolytic quality standard 2 Frequent discharging and charging or over charging or discharging 3 High electrolytic temperature when charging 4 Outside short circuit when discharging 1 Clean the p...

Page 70: ...ollowing point 1 diagnosis when the electric lock being off the circuit of the watching dog current censor charging of the capacity phase voltage driving of the connector can bus connector the order of the switch operation the output of the acceleration the synchronism of the two micro processor the input of the hardware that having something to do with the safety 2 The alternate check The circuit...

Page 71: ...t in electric system such as DC DC brake coil or check if the controller input power to earth is well connected 2 Over low or over high of battery voltage 3 Check if the cables on binding post such as B B and main contactor are firmly connected 4 Check if the calibration parameter of the controller voltage agrees with the actual voltage 5 Fault of logic board hardware electric circuit on over volt...

Page 72: ...current sensor tested by micro control system exceeds the allowable range of the non running current Change the controller 6 60 CAPACITOR CHARGE Incorrect capacitor charging When the key is switched ON the inverter tries to charge the capacitor through a power resistance and check if the capacitor is charged within a timeout If this is not true and capacitor voltage is less than 20 of the battery ...

Page 73: ...s no LED bar meter fault alarms and the lifting function is locked Charge the battery then If the battery has electricity check if the value of ADJUST BATTERY agrees with the battery voltage 7 74 DRIVER SHORTED Driver short circuit When the key is turned off the microprocessor will check if the driver of the main contactor has short circuit if there is short circuit it alarms Check if the main con...

Page 74: ...or the alarm Man made operation can also cause the fault so restart the truck for example for the following operations 1 Truck runs into barriers suddenly and the truck can not travel 2 Brake suddenly when travelling with high speed 2 220 PROG VACC NOT OK Accelerator programming fault If the 2 5 POT is programmed to be ON the controller will check the recorded maximum value and minimum value of th...

Page 75: ...fety input fault When the safety input switch is open the main contactor opens and electromagnetic or auxiliary output coil is driven Check if the connection of A11 is correct If all outskirt is all right change the controller 2 230 COIL SHORTED MC Main contactor coil short circuit Reason when short circuit coil of the main contactor is connected to can 16 output terminal the fault occurs The faul...

Page 76: ...ke is ON all the time change the controller 2 236 CURRENT GAIN Current gain fault The max current gain parameter is factory setting value It means the max current adjusting parameter program is not yet operated Remedy HELI technician set the correct program on current gain parameter 2 237 ANALOG INPUT Analog signal input fault When A D input by all analog signal is converted into a fixed value the...

Page 77: ...ll are right change controller 2 243 SENS MOT TEMP KO Temperature sensor fault Phenomenon motor temperature sensor output signal exceeds range Remedy check sensor value and wiring condition If all is right the interior of the controller has fault 2 244 SOFTWARE ERROR Software fault Causes of this fault are many such as CAN bus fault EEPROM FAULT and so on check the DEBUG MODE it should be OFF 2 24...

Page 78: ...ourages output Logic card s driver electric circuit has fault change the controller 3 Pump control system common fault PU node displayed on meter Fault code Meaning explanation Remedy 1 13 EEPROM KO Damage of programmable memorizer Fault in the area of memory in which the adjustment parameters are stored this alarm inhibits machine operation If the defect persists when the key is switched OFF and ...

Page 79: ...controller 3 31 VMN HIGH VMN HIGH When turning on the key switch MOS lower end voltage is higher than 10 of the normal battery voltage or phase voltage higher than 1 2 of the battery voltage Possible causes 1 incorrect wiring or fault of motor circuit check if the three phase connecting of the motor is correct check if the motor to earth leaks check if the motor coil has broken circuit 2 Change co...

Page 80: ...occurs when the motor temperature digital switch turns on or analog signal exceeds cut off value When the motor temperature reaches to 120 the truck still can travel but truck performance degrades because the max current is reduced when the temperature reaches to 125 the motor stops working At this time cool the motor If the fault still occurs when the motor is cold check the wirings If all are ok...

Page 81: ... the pump controller switch signal the fault alarms Check the seat switch wiring 2 222 WAITING FOR NODE Wait for node signal One controller receives a signal that the other signal can no t work normally and the controller is under waiting condition until all CAN bus are ok Check the unable communicating module wiring check its software edition and programming 2 223 WATCHDOG 1 Watchdog fault 1 The ...

Page 82: ...e the controller 2 237 ANALOG INPUT Analog signal input fault When A D input by all analog signal is converted into a fixed value the fault occurs Delayed time exceeds 400 millisecond The fault is used to detect A D converter fault or analog signal conversion Fault analysis if fault exists all the time change the controller 2 238 WRONG ZERO VOLTAGE Zero voltage fault VAM high terminal voltage feed...

Page 83: ...are fault Causes of this fault are many such as CAN bus fault EEPROM FAULT and so on check the DEBUG MODE it should be OFF 2 245 WRONG RAM MEMORY Dynamic memory fault Fault is detected when checking the main memory The resisted address is DIRTY The fault will limit the operation of truck Remedy turn off the key switch and turn it on again if fault still occurs change the controller 2 247 DATA ACQU...

Page 84: ...on location in EEPROM fails The SW expects to read the written value It occurs also when the hour counter gives different values between the three redundant locations in which it is recorded It occurs also when the busy bit of the EEPROM does not rise within 12s Change the controller 16 LOGIC FAILURE 4 This alarm occurs in the rest state if the output of the voltage amplifilter of the phase Vw Vv ...

Page 85: ... of the current amplifilter are not comprissed in the window 2 2 to 2 8v 2 after the initial diagnosis this alarm occurs when the outputs of the current amplifilter at rest have a drift larger than 0 15v Change the controller 61 HIGH TEMPERATURE This alarm occurs if the temperature of the controller base plate overtakes 75 Improve cooling or change the controller 65 MOTOR TEMPERATURE When DIAG MOT...

Page 86: ...POC2 connected to CNA 8 bigger than MAX SP SLOPE it alarms Change the double potentionmeter 85 STEER HAZARD It warns operator Steering controller limits steering angle but does not lower travelling speed 99 INPUT ERROR 1 Safety switch CAN 4 terminal voltage is higher than 12V before safety switch connects 212 CLOCK PAL NOT OK The main Uc encoder disagrees with slave uC encoder Change the controlle...

Page 87: ...controller power unit is damaged 2 check if the steering motor winding is damaged Set DEBUG OUTPUT as LEVEL 11 for convenient of finding fault 223 JERKING FB POT Feed back potentionmeter Voltage is discontinuous Feedback potentionmeter conneted to CNB 6 s COPT changes in 16 MS exceed 0 3V and it alarms Change the feedback potentionmeter 225 CURRENT GAIN The parameter is used to compensate current ...

Page 88: ...rough CAN bus from sending the request to receiving it alarms all the time At this time steering is invalid and the safety relay is disconnected 238 EPS NOT ALIGNED This is a real alarm that cut off the traction It occurs at the initial alignment if the straight ahead condition is not matched within 6s throughout this 6s delay the steer is not activated yet the safety relays are open and the tract...

Page 89: ... line of stepper motor 2 Check the resistance between the battery negative pole and terminal 2A9 It should be lower than 30ohm 3 Change the stepper motor 245 DATA ACQUISITION The alarm occurs when the acquiring the motor resistance or when adjusting the parameters to compensate for the gain of the current amplifilter max current factory adjusted Recycle the key 246 MICRO SLAVE KO In stepper motor ...

Page 90: ...arm occurs when one connection of feedback potentiometer is broken 250 MICRO SLAVE It occurs when the information on the status bus between the main uC and the slave uC is frozen to the 0xFF value the slave uC does not update the status bus configuration Change the controller 251 KM OPEN This alarm occurs if the slave uC detects the safety contact of the main uC open when expected being closed Cha...

Page 91: ...t the key switch change the intelligent display If the fault EEPROM KO disappears the factory settings will replace the parameters memorized before CANBUS KO Intelligent display can not receive message from can bus line Troubleshooting If the fault code is displayed together with other alarm information the fault is probably to be looked for in the display CAN interface since the display seens to ...

Page 92: ...TRAC 209 PARAM RESTORE 241 M S PAR CHK MISM 210 WRONG RAM MEM 242 PARAM TRANSFER 211 PUMP INC START 244 CHECK UP 213 ENCODER LOCKED 1 246 NO CAN MSG C 214 ENCODER LOCKED 2 247 NO CAN MSG 6 215 OUT PORT PULL UP 248 NO CAN MSG 10 217 ANALOG INPUT 249 CAN BUS DISPLAY 219 VALVE ENABLE 223 NO CAN MSG 5 Subordinate controller code Code Fault Explanation Remedy 08 WATCHDOG Watchdog fault 19 LOGIC FAILURE...

Page 93: ...change the controller 215 OUT PORT PULL UP Incorrect hardware configuration Change controller 217 ANALOG INPUT Incorrect transition of controller A D Change controller 218 IN MISM D Mismatch of main controller s digital quantity and subordinate controller s digital quantity Change controller 219 IN MISM A E mismatch of main controller s analog quantity and subordinate quantity or encode signal Cha...

Page 94: ... circuit of front wheel electromagnetic brake s drive terminal Check if the resistance between front wheel electromagnetic drive terminal B23 and B is small or if there is short circuit change controller 247 DRV OPEN EVP9 Open circuit of front wheel electromagnetic brake s drive terminal Change controller 4 9 4 Routine maintenance Check the wear and connect condition of the contactor point Check i...

Page 95: ... skilled person only All spare pats should be original The installation of the controller should be done according to the manual strictly Any change or special requirements can be done only after consulting our company We will take no responsibility on the fault caused by the disparity between the dealer and the content of this manual Any cause which is visible or reliable by an ordinary technicia...

Page 96: ...T GRAPHIC 代号名称英文名称代号名称英文名称代号名称英文名称 C0 代号名称英文名称 OPT OPT 36V 48V 36V 48V 蓄电池牵引电机温度传感器速度传感器主接触器脚踏安全开关 K1 主接触器 Y1 电磁制动器牵引控制器泵控制器泵电机温度传感器速度传感器电控风扇继电器高度编码器自由起升高度开关零位开关 VCM阀控制器下降限速开关起升限速开关起升电磁阀比例阀下降电磁阀比例阀后倾电磁阀比例阀前倾电磁阀比例阀前移后移电磁阀开关阀左移右移电磁阀开关阀电转向控制器温度传感器电机编码器自动对中开关1 自动对中开关2 转向电机起升下降前移后移前倾后倾左移右移脚制动开关 k3 风扇继电器电控风扇接转向接近开关后移缓冲 ...

Page 97: ... system problem Possible cause Remedies No steering no working of the steering motor Check and replace the power supply line no working of the turn angle sensor Check and replace the power supply line damage of the proximity switch Check if the clearance between proximity switch and sensing plate is smaller than 5mm or change the proximity switch no working of the steering controller Check the har...

Page 98: ...e connector Check and repair low oil level in the oil tank Add oil too much impurity in the oil and the filter being blocked Chang oil or oil filter much wear of the gears Change oil leakage of the gears Check the o ring or replace Low pressure of system safety valve Adjust safety valve pressure Inner leakage of control valve s lifting piece Change the control valve Inner leakage of lifting cylind...

Page 99: ...on switch Check and change a fault of the driving controller Check and change a fault of the steering controller Check and change No working of the lifting motor a short circuit in the contactor coil Change the connector abnormal working of the lifting switch Check and change broken wire Connect again poor contact of the connector Check and repair a fault of the lifting controller Check and repair...

Page 100: ...nd battery set should be maintained and serviced according to the manual 4 All electric connectors should be check once a month 5 Prevent water from entering the truck prohibit cleaning the truck with water gun and working outside on rainy day 6 Keep the surface of the battery set clean and dry 7 Periodically maintain the truck from the following list Number Item Mode Cycle Remarks 1 Drive gear bo...

Page 101: ...place it at once when damaged 6 2 Oil for forklift truck Name Trademark code name home Trademark code name abroad Hydraulic oil N40 ISOVG30 Gear oil 85W 90 SAE90 SAE80W Lubricating grease 3 lithium base grease dropping point 170 JISK 2220 1 2 ...

Page 102: ...98 6 3 Lubricating chart ...

Page 103: ...dimensions mm 3321 645 926 Weight kg 1325 Battery 775Ah for CQD16X1 Max dimensions mm 985 788 365 Weight kg 800 Battery 930Ah for CQD18X1 Max dimensions mm 1985 788 415 Weight kg 935 7 2 Mast disassembly Draw the telescopic bracket back completely and tilt backward Hook the hole for hoist on the top beam of mast with rope Disassemble the high pressure pipeline at the lower end of mast Disconnect t...

Page 104: ...100 7 4 Vibration specification Item Type Value Vibration acceleration Travelling work 900m s Lifting work 300m s ...

Page 105: ......

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