FORWARD

CQD AC type electric reach truck is the new offering of HELI to meet the needs
of the market. The new series is designed on the base of the advantages of some reach
trucks made by domestic and foreign manufacturers and developed by introduced
technology from abroad. The electric truck is environment-friendly and it is suited for
handing and stacking packed goods in stations, ports, and warehouse. It is used widely
in food processing, light and textile and other factories. With a function of mast
moving backward and forward and small turning radius design, it is suit to work in
narrow aisle space such as supermarket and other enterprises which have high
standard in utilization rate of land.
These trucks feature a wide-visible lifting system, EPS electronic powered
steering uniting, continuous speed control, three sorts of separated braking system,
assembled with high quality motor, battery, MOSFET driving and lifting controller,
multifunction liquid crystal display meter and DC-DC commutator. So they have a lot
of advantages such as good performance, easy operation, wide visibility of operator,
flexible steering, reliable braking, powerful and smooth power, low noise, no
contamination to environment and great shape.
This manual states the trucks’ specification, operation, maintenance, service, main
assemblies’ constructions and working principles so as to help operators to use the
truck correctly and attain the highest function. It is necessary to read over the manual
before operating the trucks.
The rules and notices in the manual should be abided seriously by all of the
relative people to enable these trucks in optimized working state for long period and
bring the highest efficiency.
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.

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 CONTENTS
FORWARD
I. Safety Instructions of Operation and Driving ................................................................................ 3
II. External View of Reach Truck...................................................................................................... 7
III. Main Specifications..................................................................................................................... 8
IV. Construction and Principle of Reach Truck................................................................................. 9
4.1 Transmission system ........................................................................................................... 9
4.1.1 Drive motor shaft ..................................................................................................... 9
4.1.2 Input shaft ................................................................................................................ 9
4.1.3 Drive shaft ................................................................................................................ 9
4.1.4 Drive wheel installation……………………..…………………………………….10
4.2 Steering system ................................................................................................................. 12
4.2.1 Steering column assembly...................................................................................... 12
4.2.2 Steering gearbox..................................................................................................... 14
4.2.3 Spare steering system ............................................................................................. 15
4.3 Braking system.................................................................................................................. 15
4.3.1 Wheel Braking ....................................................................................................... 15
4.3.2 Parking brake ......................................................................................................... 19
4.4 Hydraulic system............................................................................................................... 20
4.4.1 Lift pump................................................................................................................ 21
4.4.2 Control valve .......................................................................................................... 21
4.4.3 Operation of control valve ..................................................................................... 22
4.4.4 Hydraulic pipeline system ...................................................................................... 24
4.4.5 Rear lifting cylinder ............................................................................................... 26
4.4.6 Front lift cylinder (fig. 4-4-6) ................................................................................. 27
4.4.7 Tilt cylinder (fig. 4-4-7) ......................................................................................... 29
4.4.8 Reach cylinder........................................................................................................ 30
4.5 Loading system ................................................................................................................. 31
4.5.1 Inner, middle, outer mast........................................................................................ 31
4.5.2 Side shifter (fig. 4-5-2) ........................................................................................... 33
4.5.3 The adjustment of loading system .......................................................................... 35
4.6 Electric System ................................................................................................................. 35
4.6.1 General description ................................................................................................ 35
4.6.2 Detail description of electric system ...................................................................... 38
4.6.3 Diagnosis ................................................................................................................ 49
4.6.4 Routine maintenance .............................................................................................. 62
4.6.5 Battery moving ....................................................................................................... 63
4.7 Supporting wheel .............................................................................................................. 65
V. Troubleshooting .......................................................................................................................... 70
VI. Maintenance .............................................................................................................................. 73
VII. Others ...................................................................................................................................... 76

2
I. Safety Instructions of Operation and Driving
1. Drivers and equipment keepers should keep “safety first” in mind and

operate according to the operation and service manual.

2. Transporting

Pay attention to the following instructions before transporting the forklift with

containers or trucks:

2.1 Take the mast backward, turn off the battery and pull the parking brake;

2.2 Hang up the forklift according to the decal. It is not allowed to hang the mast

or get 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 every month when the

forklift is lying by for a long time.

4. Preparations for start

4.1 Read the manual carefully to get familiar with the meters, operating levers,

construction and functions of the forklift before driving. The drivers must have

license.

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 Fig. 1-1
1. LCD 2. Key switch 3. Lifting and lowering lever 4. Reach lever

5. Tilting lever 6. Side shifter lever 7. Direction switch 8. Horn

9. Emergency switch 10. Hand wheel 11. Electric pedal 12. Brake pedal

4.2 Check all the instruments for normal function;

4.3 Check the polyurethane solid tyre;

4.4 Check all operating levers 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;

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 4.9 Make the trial of the mast for lifting, lowering, forward and backward tilting

and the truck for steering and braking.

5. Precaution in driving

5.1 Grasp the handle on the left side of the forklift when getting on the forklift

truck. Do not grasp the hand wheel.

5.2 Pay attention to the state of mechanical, electrical, hydraulic system and

MOSFET speed adjuster.

5.3 Turn on the key switch and pull up the emergency switch, set the direction to

the desired position, depress the accelerator pedal gradually and keep suitable

acceleration.

5.4 Read the electric energy on the meter and charge the battery or change a full

one when the capacity of the battery is less than one LED.

5.5 Do not over load. Insert the forks to pallet correctly and do not hand

off-center loads.

5.6 Starting, steering, driving, braking and stopping should go well. Slow down

when steering.

5.7 Do not stand under the fork and on the fork when lifting the fork.

5.8 Do not operate the levers or attachment out of the seat. Do dot stand between

the mast and the battery in case of danger of operating the backward or forward lever.

5.9 Once the mast is tilted backward or forward to respective terminal position or

the fork reach the highest position, the tilt lever or life lever should return to

respective neutral position.

5.10 When the truck travels with loads, place the load as low as possible and tilt

back the mast. Do not drive or steering with fork lifting up.

5.11 When driving, be careful of the passersby, obstacles and rough road, and

make sure there is enough clearance between the mast and the entrance.

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 5.12 Do not brake suddenly.

5.13 Before leaving the forklift truck, lower the fork fully, place levers in neutral,

turn off the battery and pull the hand brake.

5.14 Do not adjust the pressure of the control valve which has been adjusted well

in our company as will.

5.15 Check the chain regularly.

5.16 According to the measurement method specified in JB/T3300, the maximize

noise at the outboard of the truck should be no more than 80dB (A).

6. Charging

6.1 Obey the stipulations strictly in operation instruction for battery when first

charging or recharging.

6.2 if the output voltage of the battery is reduced to 41V 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 lever and temperature of

the electrolyte.

6.4 Charge the battery as soon as possible (in 24 hours) after working. Do not

undercharge or overcharge in case of a damage to the battery.

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II. External View of Reach Truck

Fig. 2-1 External View of Reach Truck

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III. Main Specifications
Item parameter
characteristics Rated capacity kg 1600 2000
Load center mm 600 600
Lifting height mm 4250 4250
Free lifting height mm 1370 1370
Lifting speed(loaded) mm/s 330 320
Travel speed km/h
10/11 10/11
(loaded/unload)
Reach distance mm 500 560
Climbing ability %
10/15 10/15
(loaded/unload)
Tilt angle(F/R) ° 2/4 2/4
Turning radius mm 1700 1780
Dimension Overall length mm 1800 1903
Overall width mm 1128 1266
Height of overhead
2210 2210
Height guard mm
Height of mast mm 2050 2050
Wheel base mm 1425 1500
Tread mm 988 1126
Fork spread mm 200-680 250-680
Fork length mm 1070 1200
Wheel Front wheel mm
285×108 343×108
(diameter×width)
driving wheel mm
343×114 343×114
(diameter×width)
Drive Drive motor kw 5.5 5.5
Lifting motor kw 11.5 11.5
Steering motor kw 0.6 0.6
Voltage v 48 48
Battery capacity Ah 500 500
Note: the rated capacity decrease 100kg if the truck installs with a side shift.

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IV. Construction and Principle of Reach Truck
4.1 Transmission system

Transmission type continuous speed control

Forward 1:17.96
Velocity ratio
Reverse 1:17.96
Drive wheel
343×114
( diameter×width)
Weight 35kg
Volume of oil 3.7L
Type of oil 85W/90

The transmission system of reach truck is gear assembly (see fig. 4-1). Drive

wheel is fixed on the flange of the drive shaft by way of hub nut and hub bolt. Power

is sent to drive shaft by way of gear assembly and makes the drive wheel rotate.

The gear assembly consists of a input shaft, a drive shaft and the parts on the

drive motor shaft. There is a kind of a gear or some kinds of gears on the shafts.

Power of motor is sent to input shaft by way of the gear on the drive motor shaft. And

then power on the input shaft is sent to out put shaft by way of a pair of bevel gear

and makes drive wheel rotate.

4.1.1 Drive motor shaft

Roller (with O–ring), oil seal and pinion are splined on the output of the drive

motor. They are limited by snap ring. The motor shaft is fixed on coupling chassis by

way of roller.

4.1.2 Input shaft

Input shaft is fixed on the transmission case by way of two roller bearings and

two spacers. Input shaft meshes with bevel gear of dive shaft. Driven gear is splined

on the input shaft, and it is fixed on input shaft by locking nut. Driven gear meshes

with pinion of motor shaft.

4.1.3 Drive shaft

Bevel gear fixes on the drive shaft by way of two roller bearings. Drive wheel

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fixes on the flange of the drive shaft by way of seven hub bolt. The clearance of a pair

of bevel gear is adjusted by two groups of shim. The clearance is 0.18-0.23mm.

4.1.4 Drive wheel installation

(1) Drive wheel Demounting

a) Put the rear part of the forklift on and stop the front with padding block.

b) Turn the hand wheel to make the side of the drive wheel towards the rear part.

c) Remove the nuts from the drive wheel.

d) Take out the drive wheel.

(2) Drive wheel installation

a) Fix the drive wheel and make the hole of the wheel fits the bolt of the drive

shaft.

b) Tighten the nuts with a torque of 650-900kg.cm

c) Turn the hand wheel back to make the drive wheel return to the going straight

position.

d) Remove the padding block.

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 Fig.4-1Clutch Type Transmission
1. Drive wheel 2. Hub bolt 3. Hub nut 4. Shim 5. Snap ring
6. Roller bearing 7. Bevel gear 8. Snap ring 9. Oil seal 10. Shim
11. Drive shaft 12. Spacer 13. Nut 14. Roller bearing 15. Oil seal
16. O-ring 17. Shaft 18. Roller bearing 19. Shim 20. Spacer
21. Shim 22. Roller bearing 23. Driven gear 24. Locking nut
25. Coupling chassis 26. Bearing support 27. O-ring 28. Roller
29. Oil seal 30. Shim 31. Pinion 32. Snap ring 33. Upper pad
34. Lower pad 35. Bracket

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4.2 Steering system
Model of steering system Electric power trailing rear wheel steering
Steering motor 48V 0.6KW 2275rpm
Steering gear decelerate ratio 1:25.83
Chain drive decelerate ratio 1:5.88
Control model AC
Diameter of hand wheel 200mm

The steering system consists of a steering column assembly, a steering control, a

steering motor, a steering gearbox, a sprocket wheel, a chain and a switch. The

principle of the system is below. Angle sensor will send the signal received from the

turning of the hand wheel to steering controller. And then the control voltage which is

get by the processing of the controller will be put on the two sides of the motor

through the duty ratio of the PWM signal. Through the steering gear deceleration and

chain drive deceleration, the steering wheel will turn a stated angle. The angle of 90

degrees will be controlled by the switch on the steering gearbox. The angle will be

feedback and it will be shown on the meter.

4.2.1 Steering column assembly

Steering column assembly (see fig. 4-2-1) consists of a hand wheel, steering axes,

a bracket, a bush bearing, a sensor and a cover. 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. Through the adjusting of the spring pressure, the driver can have a feel of force

in steering. The steering column assembly is assembled at the frame of the forklift,

and its site can be adjusted according to different demand as will.

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 Fig. 4-2-1 steering column assembly
1. Sensor 2. Securing plate 3. Bracket 4. Coupling 5. Connection shaft
6. Bearing 7. Snap ring 8. Friction ring 9. Spring 10. Bond
11. Washer 12. Nut 13. Front cover 14. Rear cover
15. Bond 16. Hand wheel 17. Washer 18. Nut 19. Space generator
20. Bracket 21. Washer 22. Washer 23. Bolt 24. Nut

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 Fig. 4-2-2 steering gearbox
1. Chain assembly 2. Steering motor 3. O-ring 4. Upper cover
5. Lower cover 6. Drive gear 7. Ball bearing 8. Ball bearing
9. Drive shaft 10. Output shaft 12. Ball bearing 13.Switch
14. Snap ring 15. Feedback shaft 16. Ball bearing 17. Feedback gear
18. Ball bearing 19. Oil seal 20. Ball bearing 21. Oil seal
22. Bond 23. Chain 24. Snap ring 25. Sensor plate assembly
4.2.2 Steering gearbox
Steering gearbox case is made up of two parts. Through three steps, the gearbox
realizes the shifting of the steering motor. First steering power will be reduced by
transforming gears, and then it will be transferred to drive wheel by chain. The third
transmission is rate-add feedback. It suits closed loop turning control. The drive gear
is fixed on the transmission shaft by way of interference fit, and the shaft is fixed
through two ball bearings on the box case; Output gear and chain which are fixed on
the output shaft through bong are used to output torque, and the output shaft is fixed
on the box case through two ball bearings. Oil seal prevents lubrication grease from
flowing away; feed back gear is fixed on the feedback shaft by way of interference fit,
and the feedback shaft is fixed on the case through two ball bearings, Oil seal prevents
lubrication grease from flowing away.
4.2.3 Spare steering system

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 The truck has a spare steering system in case of an electric failure or that the
truck doesn’t been dragged.
Move the rubber blanket away, you will find a hole in the bottom board. Then
put a allen key socket wrench with a adapter on the top of the steering motor and
rotate the wrench to turn the motor indirectly, and thus, the steering wheel will turn to
the required angle. Then drag the forklift to the repair shed.

Fig. 4-2-3
4.3 Braking system

4.3.1 Wheel Braking

Rear wheel with
Front two wheel braking
reducing pressure valve
Type type, internal expansion,
clip brake shoe, braking
hydraulic type
driving motor type
Pedal ratio 4.84
Master cylinder bore 19.05mm
Operating cylinder bore 22.22
Inner diameter of brake drum 180mm
Outer diameter of brake drum 140mm
The brake system (hydraulic) consists of the front two-wheel braking type and
the real wheel (with braking force restrictor) motor braking type. It is made up of
master cylinder, brake, braking force restrictor and brake pedal mechanism. When the
brake pedal is depressed and the piston master cylinder is driven by the push rod, the
brake fluid in the master cylinder passes through the oil return port to the tank until
the main leather bowl blocks the oil return port. After the main leather bowl passes the
oil return port, the brake fluid in the front chamber of the master cylinder is
compressed to open the brake force limiter, so that the brake fluid flows through the
brake pipeline to the brake sub-pump in the front wheel, and the front wheel brake
works. When the brake pedal is loosened, the piston in the master cylinder is pressed
by the return spring, and the sub-cylinder in the front wheel brake is compressed by
the return spring, so that the brake fluid returns to the master pump, the piston returns
to the original position, and the brake fluid in the master cylinder flows back to the
tank through the return port. The service braking principle is shown in Fig. 4-3-1.
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 brake pedal mater cyl. oil pipe sub-cyl. brake shoe brake drum

to electric system

brake light switch

Figure 4-3-1 service brake principle diagram

(1) Master cylinder
The master cylinder contains valve support, check valve, return spring, primary
cup, piston and secondary cup, which are all kept in place with a stop washer and a
stop wire. The exterior of the cylinder is protected from dust by means of a rubber
dust cover. The piston is actuated through the push rod by operation of the brake pedal.
As the brake pedal is pressed, the push rod pushes the piston forwards. The brake
fluid in the cylinder is pressurized and opens the check valve, flowing through the
brake pipeline to the operating cylinder. Thus, each operation cylinder piston is forced
outwards. This brings the friction pieces on the brake shoes into contact with the
brake drum and slows or stops the truck. Meanwhile, the cavity caused behind the
piston is filled with the brake fluid led through the return port and inlet port. When the
brake pedal is released, the piston is forced back by the return spring. At the same
time, the brake fluid in each operating cylinder is pressurized by the return spring,
returning to the master cylinder through the check valve. With the piston in its
original position, the fluid in the master cylinder flow into the reserved tank through
the return port. The brake fluid in the brake pipeline and operating cylinder has a
residual pressure proportional to the set pressure of the check valve, which makes the
each operating cylinder piston cup securely seated to prevent oil leakage and
eliminates a possibility of air locking when the truck is sharply braked. (see fig. 4-3-2)

Fig. 4-3-2 master cylinder

1. cylinder body 2. spring 3. seal ring assembly 4. primary cup
5. protecting cover 6. piston 7. secondary cup 8. washer
9.Snap ring 10. Dust cover 11. Push rod and supporting ear 12. Check valve
13. Primary cup 14. Joint

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 (2) Brake

Brake is distributed to wheel brake and driving motor brake.

Wheel brake is internal expansion hydraulic type and is made up of brake shoes,

springs, operating cylinder, adjuster and floor plates. They are installed in the front

wheels. One side of the brake shoe which is stressed to the floor plate by the spring is

connected to the anchor pin and the other side is connected to the clearance adjuster.

Primary brake shoe is assembled with hand brake rod while the secondary brake shoe

is assembled with clearance adjuster adjust rod.(see fig4-3-3)

The drive motor brake is also called parking brake. As the parking brake lever

actuate, the brake fluid in the brake pipeline is forced to operating cylinder and thus,

the cylinder works. It makes the two brake pieces attached closely to the driving

motor axle. Then it brakes.

Fig. 4-3-3 wheel brake

1. Brake shoe assembly 2. Floor plate 3.Operating cylinder 4. Spring
5. Clearance plate 6. Return spring 7. Push plate 8. Anchor pin
9. Stop ring 10. Spring support 11. Brake shoe 12. Clearance spring
13. Spring

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 (3) Brake force restrictor

Brake force restrictor consists of cylinder body, piston, spring, cup, bushing,

snap ring and seal. Its primary function is transferring the oil in the master cylinder

after reducing the oil pressure to the operating cylinder. And then it brakes.

Fig. 4-3-4 Brake force restrictor

1. Cylinder body 2. Piston 3. O-ring 4. Bushing 5. Cup
6. O-ring 7. Snap ring 8 . Spring support 9. Square seal 10. Spring
11. Protecting cover 12. Plug 13. Washer
(4) Brake pedal adjustment

a) Make the push rod shorter.

b) Adjust the pedal to the height of 120mm.

c) Press the pedal for 30-40mm and adjust the push rod until the front end of the

push rod get in contact with the master cylinder.

d) Tighten the push rod lock nut.

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 Fig. 4-3-5 Brake pedal adjustment
1. Pipeline assembly 2. Master brake pump 3. Brake pedal 4. Accelerator pedal
5. Bearing 6. Turning axle 7. Plate assembly 8. Spring 9. Bolt(M8×24)
10.Washer(M8) 11. Screw(M4×5) 12. Bolt(M6×24) 13. Bolt(M5×24)
14.Brake force restrictor 15. Shim(M6) 16. Bolt(M6×10) 17. Adjuster
(5) Electric pedal adjustment

The original angle of the electric pedal to the horizontal is 35°. Install the pedal

when the pedal is in its original position. While in max. acceleration, the angle is10°.

4.3.2 Parking brake

The parking brake is of cable mechanism, and is mounted on the driving motor.

It shares the two brake pieces with wheel brake. when pilling the hand brake, brake

cable make the brake pieces attached closely to the driving motor axle through brake

rod. So the driving motor axle can not run. And the forklift can not start up.

Push the hand brake before the truck starts to work. At the same time, the inching

switch under the instrument panel assembly loosens, the brake mood on the meter

shows loosening, and the truck can start.

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 Fig. 4-3-6
1. Parking brake 2. Brake cable assembly 3. Chassis 4. Brake piece
5. Brake wheel 6. Brake rod 7. Bolt 8. Bushing 9. Bearing
10. Operating cylinder 11. Spring

4.4 Hydraulic system

Model DSGO5C16
Type Gear pump
Drive Electromotor export
Lift pump Displacement 16ml/r
Output pressure 200bar
Highest pressure 250bar
Temperature range -20℃-80℃
Model
With relief valve and tilt
Control valve Type
lock valve
Pressure setting 145bar(1.6t)175bar(2t)
Type Plunger
Front lift cylinder Diameter of piston 65mm
Stroke 745-1270mm
Type Plunger
Rear lift cylinder
Diameter of piston 45mm
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 Stroke 1360-2410mm
Type Double-acting piston
Diameter of piston 30mm
Reach cylinder
Cylinder stroke 50mm
Stroke 485-549mm
Type Double-acting piston
Diameter of piston 35mm
Tilt cylinder
Cylinder stroke 80mm
Stroke 73mm
Type Plunger
Side shifting cylinder Diameter of piston 32mm
Stroke 50mm

The hydraulic system consists of lift pump, control valve, flow regulator, front

lift cylinder, rear lift cylinder, reach cylinder, tilt cylinder, side shifting cylinder and

hydraulic lines. Electromotor drives pump directly.

4.4.1 Lift pump

Lift pump is a gear pump. Lift electromotor drives it directly.

4.4.2 Control valve

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 Fig. 4-4-1 Control valve
The control valve(4 spools type0 consists of six valve housings, four spools, one

relief valve. The self lock valve is installed in tilt spool.

(1) Mater relief valve

The valve consists of main valve and pilot valve. It can limited the pressure of

the system.

(2) Tilt-lock valve

Tilt spool is assembled with self-lock valve. It is used to prevent the vibration

caused by the pressure inside of the tilt cylinder and also to avoid the danger of

disoperation of the lever. The mast will not tilt even the tilt lever being pushed sharply

if the engine is shut off.

4.4.3 Operation of control valve

The control valve is operated with the valve levers. All the levers are assembled
22
together with a shaft and the shaft is assembled on the front guard with the bracket.

The valve levers operate the control valve with the joints.

Operating the lift valve will change the voltage of the potentiometer , and the

operating will transfer the signal to lift controller.

Operating other levers and the valve switch will inspect the signal and transfer it

to lifting controller.

Fig. 4-4-2 Control valve

1. Lift lever 2. Reach lever 3. Tilt lever 4. Side shifting lever
5. Shim 6. Pin 7. Screw 8. Joint rod 9. Bracket
10. Joint shaft 11. Bushing
As you see in Fig. 4-4-3, the mast lift up when you push the lift lever forward,

the mast fall down when you pull the lever forward. The mast tilt forward when you

push the lever forward, and the mast tilt backward when the lever backward. When

you push the reach lever forward, the mast go forward and also reach lever backward

the mast backward. The mast go to the left when you push the side shifting lever

forward, and also the mast go to the right when you push the shifting lever backward.

23
 Fig. 4-4-3
4.4.4 Hydraulic pipeline system

Hydraulic pipeline system (fig. 4-4-4)

Hydraulic pipeline system is a single pump system. The system consists of four

pipelines, every one pipeline control relevant action.

(1) Pipelines for mast rising and falling down

a) Pipeline for mast rising (the direction of hydraulic oil)

pump--control valve--cut off valve—SB valve—front cylinder—rear cylinder

b) Pipeline for mast falling down (the direction of hydraulic oil)

rear cylinder—front cylinder—SB valve—cut off valve—flow regulator—oil

tank

(2) Pipeline for mast tilting (the direction of hydraulic oil)

Pump—control valve—reach cylinder

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(3) Pipeline for mast reaching (the direction of hydraulic oil)

Pump—control valve—reach cylinder

(4) Pipeline for lifting bracket shifting (the direction of hydraulic oil)

Pump—control valve—side shifting cylinder

Fig. 4-4-4 hydraulic pipeline system

25
4.4.5 Rear lifting cylinder

] The two rear lifting cylinder is fixed inside of the outer mast. The bottom of the

cylinder is fixed on the under cross beam of the outer mast by bolt while the top of the

cylinder is connected with the upper cross bean by stretch clip. The strokes of the two

cylinder should be synchronous during the lifting and falling down. If not, adjust the

shim.

The rear lifting cylinder is made up of cylinder cap, cylinder body, snap ring,

piston, valve and seals. There is an inlet for oil in the inner part of the bottom of the

cylinder. A support ring is fixed at the bottom of the piston rod. Rod and the support

ring move along the inner surface of the cylinder of the cylinder by the high pressure

oil from the cylinder bottom. The dust seal, Yx type seal are assembled in the slots of

the inner surface of the cylinder. The seal keep the dust out and oil from leakage. The

stroke of the cylinder is controlled by the stretch ring.

When pull the lever backward, the control valve begins to change direction. The

high pressure oil which comes from the lift cylinder push the piston rod and the fork,

inner mast and middle mast lift up with the lift chain. When pushing the lever forward,

the lift cylinder fall down by the gravity of rod, side shifter, fork, inner mast, middle

mast and the load. So the oil under the rod will flow out from the cylinder bottom.

The oil will be controlled by the flow regulator valve and go back to oil tank from

control valve.

26
 Fig. 4-4-5 rear lift cylinder
1. Dust seal 2. Yx ring 3. Bolt 4.Shim 5. O-ring
6. Cylinder cap 7. Cylinder body 8. Stretch ring 9. Piston rod
10.Support ring 11.Valve core 12. Spring 13. Bushing
14. Spring seat 15. O-ring 16.Seat 17. Cylinder body
There is a buffering valve at the bottom of the cylinder to avoid the impact

caused by the mast falling. If the speed is too slow, inspect the inlet of the valve

whether there is dirty.

A cut-off valve is assembled in the pipeline. It is used to cut off the loop pipeline

to prevent the load drop sharply in case of hose rapture. The oil from the cylinder

from the lift cylinder flows through the valve and produce a pressure difference

between two chambers. The cut-off valve will not act when the difference between the

pressures is less than the force of the spring. On the other hand, if the hose bursts, the

pressure difference will be big enough to overcome the force of the spring and the

cut-off valve will be pressed to the valve seat to block the circumference oil holes.

Thus the valve is on the off state and only little oil can flow through the hoses. The

loads will descend slowly.

4.4.6 Front lift cylinder (fig. 4-4-6)

27
 The bottom of the oil cylinder is fitted to the cylinder fixing hole in the lower

cross bean and it is held by the pin. The top of the cylinder is connected to the chain

in order to connect with the lifting chain and the pipes and is fixed by stretch clip.

One side of the front lifting chain is fixed on the cylinder bushing, while the other side

is fixed on the side shifter bracket.

The front lifting cylinder consists of cylinder cap, bushing, cylinder body, piston,

joint bushing, flow regulator, cut-off valve and seals. There is an inlet for oil in the

inner part of the bottom of the cylinder. The piston is fixed on piston rod by bolt and

spring. The spring is used in buffering. A support ring is fixed at the bottom of the

piston rod. Rod and the support ring move along the inner surface of the cylinder of

the cylinder by the high pressure oil from the cylinder bottom. The bushing, dust seal,

Yx type seal are assembled in the slots of the inner surface of the cylinder. The seal

keep the dust out and oil from leakage. The stroke of the cylinder is controlled by the

cylinder cap.

When pulling the lever backward, the control valve changes direction. The high

pressure comes from the bottom of the cylinder to push the piston rod. The side shifter

and the fork will lift with the lifting chain. When pushing the lever forward, the lift

cylinder fall down by the gravity of rod, side shifter, fork and the load. So the oil

under the rod will flow out from the cylinder bottom. The oil will be controlled by the

flow regulator valve and go back to oil tank from control valve.

The flow regulator with two gateways is at the bottom of the cylinder. It is used

to take advantages of self load to avoid little vibration. It can restrict the decline speed

according to the weight of the lode. When the oil from the lift cylinder flowing

through the valve, the flow is changed as the load, and thus, the decline speed is

changed.

28
 Fig. 4-4-6 front lift cylinder
1. Piston rod 2. Dust seal 3. Yx seal 4. Screw 5. Shim
6. O-ring 7. Cylinder cap 8. bushing 9. screw 10. Snap ring
11. Joint bushing 12. Cylinder body 13. bolt 14. Piston 15. Support ring
16. Spring 17. Flow regulator 18. Cut-off valve 19. O-ring
4.4.7 Tilt cylinder (fig. 4-4-7)

The tilt cylinder is of double-acting type and is installed on the top of the mast

support. The piston rod of the tilt cylinder is connected with the bottom of the outer

mast support and the bottom of the cylinder is connected with tilt cylinder support

with pin.

The tilt cylinder assembly is made up of piston, piston rod, cylinder body,

cylinder base, guide sleeve and seals. The piston, welded to the piston rod, is fitted

with two Yx-rings and a one support ring. A bearing with Yx-ring, snap ring and dust

seal is pressed into the hole in the guide sleeve. The bearing is used to support the

piston rod and the seals and snap ring are used to prevent oil leakage and keep dust off.

The guide sleeve is screwed into the cylinder body.

29
 Fig. 4-4-7
1. Bearing 2. Snap ring 3. Bearing 4. Washer 5. Nut
6. Piston rod assembly 7. Dust seal 8. Snap flake 9. Yx seal
10. Guide sleeve 11. O-ring 12. Bearing 13. Cylinder assembly
14. Support ring 15. Snap flake 16. Yx seal 17. Bearing 18. Cup
When the tilt cylinder is pushed forward, the control valve will change direction

and the high pressure oil flows from the cylinder bottom to push the piston rod

forward. Thus the mast tilts forward. When the tilt cylinder is pulled backward, the

control valve will change direction and the high pressure oil flows from the upper of

the cylinder body to push the piston rod backward. And thus the mast tilts backward.

4.4.8 Reach cylinder

The reach cylinder is of double-acting type and is installed between the mast

support and the frame. The piston rod is connected with the reach support in the mast

support and the cylinder bottom is connected with the support in the frame with pin.

The reach cylinder is made up of piston, piston rod, cylinder body, cylinder base,

guide sleeve and seals. The piston, welded to the piston rod, is fitted with one support

ring and two Yx seals. A bearing with Yx-ring, snap ring and dust seal is pressed into
30
the hole in the guide sleeve. The bearing is used to support the piston rod and the seals

and snap ring are used to prevent oil leakage and keep dust off. The guide sleeve is

screwed into the cylinder body.

Fig. 4-4-8 reach cylinder

1. Ring 2. Snap ring 3. Bearing 4. Washer 5. Nut
6. Piston rod assembly 7. Dust ring 8. O-ring 9. Yx seal
10. Guide sleeve 11. Cylinder assembly 12. Yx seal 13. Support ring

When the reach cylinder is pushed forward, the control valve will change

direction and the high pressure oil flows from the cylinder bottom to push the piston

rod forward. Thus the mast goes forward. When the reach cylinder is pulled backward,

the control valve will change direction and the high pressure oil flows from the upper

of the cylinder body to push the piston rod backward. And thus the mast goes

backward.

4.5 Loading system

4.5.1 Inner, middle, outer mast

Loading system is a telescopic triple full free lift mast. It consists of inner mast,

middle mast, outer mast and side shifter. The inner and middle masts have I-shape

cross section and the outer mast has C-shape cross section. (see fig. 4-5-1).

The bottom of the outer mast is connected with mast support with bearing. The

load that is borne mostly by mast support is sent to frame by roller. The mast can

forward and backward on the channel guide. The triple free lift mast which is of

telescopic type bears the horizontal and vertical load depending on the rollers and side

rollers to make the inner and middle masts move up and down stably.

31
 Fig.4-5-1 The shape of mast cross section
Roller: Main roller φ88.8
Side roller φ40
Lifting: Rear cylinder chain Lh1244
Front cylinder chain Lh1288
Fork, mast lifting system hydraulic
Lift bracket, side shifter hydraulic
Fork spacing adjustment manual
Reach truck with the function of the triple full lift have more superiority

comparing with common reach trucks. The truck can lift the loads to the height of the

forklift truck with the whole height of the forklift truck unchanged. Thus the truck can

handle, stack loads with the whole height unchanged. What is more, the mast can

32
move forward for a certain distance. So the truck has a great passing ability and

improves the utilization of the stacking space. The mast is equipped with side shifter

which can precisely master the center and stack the loads in good order. The

efficiency and quality of working are largely improved.

When the oil flows into rear lift cylinder and front lift cylinder from control

valve, the front lift cylinder begins to work because the force of the front lift cylinder

is two times larger than the rear lift cylinder. In that case, the inner mast will not lift

and the whole height will not change.

After the working stroke of the front cylinder is completed, the rear cylinder

begins to work. It pushes the inner mast and then the front lift cylinder, side shifter,

load and the middle mast will lift up together. The speed of the rear lift cylinder is the

same as the lifting speed of the loads. The mast is on a state of maximize lifting height

when the working stroke of the rear lift cylinder is completed.

When dropping, the piston rod of the front lift cylinder will drops down first and

then the rear lift cylinder piston rod, at last, the loads and fork drop down.

Main Specification
Number Parameter name Unit CQD16S CQD20S
1 Rated capacity kg 1600 2000
2 Lode center mm 600
3 Full free lifting height mm 1370-2790
4 Lifting height mm 4250-8500
5 Maximize height mm 4920-9170
6 Reach distance mm 500 600
7 Fork thickness mm 40 50
Tilt
8 ° 2/4(≦6200mm)
angle(forward/backward)
9 Side shift distance mm 50

4.5.2 Side shifter (fig. 4-5-2)

33
 Fig. 4-5-2
The side shifter is made up of side shifter bracket, fork bracket, side shift

cylinder and so on. The side shifter bracket is of welded structure. Side shifter can

move up and down smoothly along the inner mast and bear the vertical and horizon

load through three pairs of main roller and two pairs of side roller which can adjust

clearance. When the fork lifts to the maximize height, the distance between the center

of the two main rollers in the upper point and the upper point of the inner mast is

15-20mm. The fork bracket is of welded structure. The bushing that is fixed between

the fork bracket and the side shifter bracket acts as a guider of the side shifting. The

side shifter cylinder is welded to the side shifter bracket and the cylinder is pushed to

one side of the fork bracket. When the cylinder works, fork bracket finish the action

of side shifting (both the fork and goods shift). The maximize shifting is 50mm to

either right or left. Equipping a side shifter makes the truck stack goods precisely and

safely and improve working efficiency. It is not suitable to make side shifting when

the truck is working. It is not allowed to make shifting when the fork is at its

maximize lifting height or the mast tilts forward.

34
 Fig.4-5-3 side shift cylinder
1. Dust seal 2. Yx seals 3. Cylinder cover 4. Screw 5. Washer
6. Washer 7. O-ring 8. Side shift cylinder staff 9. Side shift cylinder body
10. Snap ring 11. Snap ring 12. Snap ring
4.5.3 The adjustment of loading system

(1) Make the mast be vertical and drop the fork to the ground. Adjust the nut on

the top of the lifting chain of the front cylinder. Make sure the distance between the

bottom roller center of the side shift bracket and the bottom of the inner mast is

15-20mm.

(2) Make the mast tilt backward and then adjust the nut on the top of lift chain of

the rear cylinder to make the tightness of the two chain equal.

(3) The synchronization adjustment of the rear cylinder: lift the mast to the

maximize stroke slowly. Take away the shim that installed beforehand from

undersurface of the cylinder which stops first. The shims are 0.2mm and 0.5mm thick.

4.6 Electric System

4.6.1 General description

The electric system of the AC type electric reach truck is equipped with a whole

AC control system. With the system, the control of the whole truck can be low noise,

high efficiency, smoothness and safeness.

The electric system is made up of intelligent instrument, traction control system,

lift control system, steering control system, battery, illumination system (optional),

back buzzer (optional), harness and so on.(fig. 4-6-1)

35
 Traction control system consists of direction switch, accelerator, safe pedal,

speed reduction switch, traction control module, AC traction motor;

Lift control system consists of valve control switch, lift speed adjust sensor, lift

control module, AC pump motor;

Steering control system consists of motor (sending out instruction signal), turn

angle switch (feeding back turn angle position signal), automatic centering switch,

steering control module, AC steering motor.

The principle diagram of the eclectic system is followed.(fig. 4-6-1)

Note: The products are subject to improvements and changes. If the products are

not corresponding with the manual, please contact with the manufacturer.

36
Fig. 4-6-1 Electric system principle diagram

37
4.6.2 Detail description of electric system

4.6.2.1 CAN bus technology

CQD16/20S AC type electric reach truck applies the CAN bus technology. It links

with each CAN module (traction control module, lift control module, steering control

module, instruments display module) and acts as a connection point between the

outside equipments and the CAN bus. The hand manual of ZAPI brand can link with

every module and any other module in the network through CAN bus.

STE MODEL in the sub-menu is used to choose the module user wants to link

with. The data relating to the each module in the CAN bus is followed:

Data relating to the each module in the CAN bus module

02 Traction type
05 Lifting type

06 EPS-AC
16 Intelligent displayer

4.6.2.2

(1) Description

a) SMART DISPLAY is a kind of intelligent instrument display connected to the

truck system through CAN bus. The instrument displays the whole truck’s setup and

diagnosis.

b) Link the intelligent displayer with the ZAPI hand manual and then you can

read or alter the setup of every module in the CAN system. The display becomes an

interface between truck and human through menu and sub-menu.

(2) Display layout

38
 Fig4-6-2

a) The six buttons fixed in the bottom of the display are used to enter the display

menu structure. (Only in the case of permission)

Button 5---the function of the “OUT” button in the hand manual;

Button 4--- the function of the “SET DOWN” button in the hand manual;

Button 3--- the function of the “SET UP” button in the hand manual;

Button 2--- the function of the “ROLL DOWN” button in the hand manual;

Button 1--- the function of the “ROLL UP” button in the hand manual;

Button * --- the function of the “ENTER” button in the hand manual;

b) The intelligent display has six red luminescent diodes which are used to give

operators some information of the truck.

(3) Instrument instruction

a) Turn on the key switch, and the crystal display will displays “AC SYSTEM”

and then begins self-check. And when it is doing self-check, the home page of the

display will show the battery electric, speed and total traction hours

39
 Fig. 4-6-3
b) After the self-check, it will display the changeable steering angle. (Replace the

total traction hours)

Fig. 4-6-4
c) Display of safe and brake: the truck is on a state of brake when loosen the safe
pedal. The truck can not drive but it can steer, lift, tilt mast and move mast. The

picture is on all the time. When pressing the safe pedal, the truck can drive

and the picture is off all the time.

d) The electric of the battery display: The battery electric (BDI) is shown by 20

LED lights in the instrument. When the battery is full, 20 lights are on. The lights will

decrease as the decreasing of the battery electric. When 20 lights are all off, the signs

of fault and electric decreasing will flicker. The driving speed will slow down and the

operation of lifting will not act. In that case, charge the battery at once.

40
 Fig. 4-6-5
e) Timer: Timer will work when the key switch turns on. Operator can maintain

the truck in required time referring to the total time displayed in the instrument .

f) Fault code display: if there is a fault, the sigh of fault will be on all the
time. Fault code is shown in the first row; the number of the corresponding control
module is in the second row.

Fig. 4-6-6
(4) Instrument working environment

a) The height above the sea lever should be less than 1200m.

b) The temperature should be in the range of -25℃-40℃.

c) The maximize relative humility should be less then 95%.

4.6.2.3 Controller system instruction

CQD16/20S AC type electric reach truck is assembled with two Italy ZAPI

motor controller. It controls the traction system, loading system and steering system

separately.

41
 Fig. 4-6-7 controller assembly of the CQD16/20S electric reach truck

Fig. 4-6-8 Steering controller of the CQD16/20S electric reach truck

(1) Traction and pump motor controller

Traction motor controller type: ZAPI COMBIAC2 48V/450A

● COMBIAC2 controller is a three phase AC type asynchronous motor inverter,

which controls traction motor and pump motor. It has a CAN BUS interface, digital

control of micro processor (feed back of the motor speed), and regeneration function.

● The temperature should be in the range of -30℃-40℃. The highest

temperature that is permitted is 75℃.

● COMBIAC2 traction motor has a protection function.

a) Battery polarity protection;

b) Error connection protection

c) Over heat, over loaded and short circuit protection;

42
 d) Protection degree of the controller: IP54

e) Out of control protection; start order protection;

f) Over use of battery protection;

g) Missed start protection.

● Function achieved by hand manual:

a) Check and adjust the traction and lifting control system;

b) Adjust the accelerator and lifting speed adjust signal;

c) Minute fault check and query about the traction and lifting control system. It is

convenient to maintain the system.

(2) Steering motor controller

a) CQD16/20S AC type electric reach truck applies advanced electric power

steering control system. It is assembled with Italy EPS-ACO controller.

Steering motor control type: ZAPI EPS-ACO 48/45A

● EPS-ACO controller applies high-frequency MOS technology. The control is

not only reliable but also efficient, low cost, smooth and mute.

● EPS-ACO controller applies single-chip control system. It has perfect

diagnostic and protection function. It can monitor electric inner ad outside component

that affect the steering system all the time.

● EPS-ACO controller applies a turn angle proximity switch protection to the

right and left maximize turning.

● EPS-ACO controller can achieves steering wheel automatic centering through

SET function switch inching. And also the function can realized through turning on

the electric lock.

● The temperature should be in the range of -30℃-40℃. The highest

temperature that is permitted is 85℃.

● Protection function of the steering motor controller:

a) Battery polarity protection;

43
 b) Over loaded and short circuit protection;

c) Protection degree of the controller: IP54

● Function achieved by hand manual:

a) Check and adjust the steering control system;

b) Minute fault check and query about the steering control system. It is

convenient to maintain the system.

Note:

◆ Test the truck with four wheels raised after the chopper being fixed, in that

case there will be no danger even the connection is in error.

◆ A certain amount of voltage will remain in filter capacitance after the turn off

of the electric switch. Cut off the battery and make the remained voltage short circuit

by connecting the 10-100ohm resistance to the inverter before checking the inverter.

◆ Do not connect the controller to a battery that has a different voltage. The

high voltage will cause power unit error, while the low voltage will not make the logic

card work.

◆ The quality is assured by the producer. W hen there is a fault, inform the

producer of the after-sale service. Do not repair as will unless getting the permission

from the producer. Or the user should bear the personal and property damage caused

by the unauthorized repair by oneself.

4.6.2.4 Motor

Motor type: three phase AC type induction motor (free from maintenance)

Driving motor Pump motor Steering motor

Power 5.5 11.5kw 0.6kw

Voltage 48V 48V 48V

Rated current 145 295A

Rotation speed 2395rpm 2500rpm 2275rpm

Note: Cut off the electricity before checking and maintaining the motors to avoid
accident.
44
 4.6.2.5
(1) Battery construction and specifications
The battery is made up of + pole plate, - pole plate, separator, battery cover and
electrolytic.
Type DA600
Capacity 600Ah/5
Voltage 48V
Electrolytic density 1.280-1.290g/cm³(25℃)
Monadelphous number 24

Fig. 4-6-9 battery construction

Note: Battery can be customized.
(2) The usage of battery
The usage and routine maintenance of the battery will influent battery life and
performance. So the operator should maintain the battery according to the manual and
actual conditions.
(3) Battery maintenance
Maintain and observe the battery regularly and carefully. So your truck can be
more economical and reliable. Refer to the operation and service manual to avoid
incorrect and unless operation.
a) Keep the surface of the battery clean and dry. Take care of the bolts, poles and
connectors, it there is a loose or poor contact, adjust it.
b) Do not put any conductor on the battery set to avoid a short circuit.
c) 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 degree is 70%-100%,
charge the battery 8-12 hours.
d) When charging, open the cap of the fluid adder. Close it after charging.
e) Keep the ventilation well and keep the fire away from the battery because of
the giving out of the oxyhydrogen.

45
 f) The electrolytic lever will decrease and the density will increase as the
evaporation and electrosis of the water in the electrolytic when charging. Add the
distilled water regularly to keep the electrolytic lever and density.
g) Avoid over charging and over use of the battery which will affects the battery
life.
h) Charge the battery in time (in 24 hours after use). The performance of the
battery will drop caused by the vulcanizing of the pole plate if the battery is not
charged in time, over charged, over used and not recharged after a long time of no
using.
i) Make a balanced charging every month during the usage to keep the single of
the battery works well.
j) For battery compartment without liquid leakage hole, check if there is hydrops
inside of compartment every month. If there is electrolyte spillage caused by improper
adding of distilled water, please clean the hydrops in the compartment with sucker in
time.
(4) Battery storage and keep
a) Store the battery in a clean, dry and well ventilated warehouse. Keep the
temperature in a range of 5℃-40℃.
b) Avoid exposing under the sunshine and drenching in the rain. Keep the battery
more than 2M away from the heat source.
c) Do not keep the battery upside down, or side or tossed or rolled, nor pressed
heavily.
d) Keep the poisonous and corrosive goods away from the battery. No metal and
substance should be dropped into the battery.
e) Do not store the battery with electrolytic. When it is necessary to do so, they
should be fully charged, charge the battery and adjust the electrolytic lever and density.
In storage time, charge the battery once a month in the normal charging way.
Note:
a) Stop charging when the temperature of the electrolytic is above 40℃.
b) The life of the battery will be affected when the temperature of the
electrolytic is above 50℃.
c) Do not charge the battery in low temperature (such as cold outside) which
will affects the battery life.
Note:

46
 ● The rated voltage of the battery is not the safe voltage. Look out for a
electric shock.
● The battery is lead acid battery which electrolytic is dilute sulfate. Wear
protection tools when testing, adding and adjusting to avoid accidents.
● The case of the battery is conductor. Make sure the grounding wires in
well connected to avoid a electric shock.
● Avoid pulling out the connector before the turning off of the charger. In
that case, the spark will be created because of the inadequate charging.
(5) Battery error and resolution
The cause that made the battery error is various, except the effect of the quality
manufacture and transport storage, mostly due to the improper maintenance. Find out
the faults and analyze the causation as soon as possible to exclude.
The characteristics of faults, causation and repair measure are bellowed;
fault Characteristics Causation Repair measure
1) Inefficient first
charging 1) Adopt the
2) Inefficient measure of
charging for a long balanced charging
1) decrease of the time when the actuality
3) Discharging for is not severity
battery capacity many times 2) Adopt the
2) low density of the 4) No timely hydrotherapeutics
electrolytic ( below the charging after when the actuality
normal lever)
3) High battery voltage 5) High density of is
discharging severity
3) Do not over
Pole plate when beginning or the electrolytic discharging
sulfide finishing the charging.
4) high rising of the 6) Low lever of 4) The density of
electrolytic temperature 7) electrolytic the electrolytic
No timely should below the
when charging balanced charging regular lever.
5) air bubble in the early
time of charging or 8) Too low or high 5) the lever of the
discharging current electrolytic and
beginning 9)Impure of the content of the
electrolytic impurity should be
10) Inside short in the prescribed
circuit or electric range.
leakage
1) low battery voltage or
close to zero indeed when 1) curve pole plate;
charging
2) few or no air bubble at expanded reactive 1) Replace the
matter; plate.
the end of the charging desquamated 2) Clean the
Inside short 3) high rising of reactive matter precipitate and
circuit electrolytic temperature 2) Much precipitate conductor.
or slow or no rising of 3) Falling of 3) Replace the
electrolytic density conductor to the plate.
4) Low battery voltage battery
under the condition of
open circuit or a quick
47
 drop to the limit value
when discharging
5)Serious
self-discharging

1) Being unsuitable
to the electrolytic
quality standard
2) Frequent
discharging and 1) Clean the
Shedding off 1) Decrease of the battery charging or over precipitate when
of the capacity charging or the actuality is not
reactive 2) Turbid electrolytic discharging severity.
matter 3) Much precipitate 3)High .electrolytic 2) Discard when
temperature when severity.
charging
4) Outside short
circuit when
discharging

(6) Auto liquid replenishing device of battery

1) diagram of auto liquid replenishing device
At the end of battery charging, liquid replenishing will be carried out
automatically. The special water in the storage tank is pumped out by automatic liquid
filling plug, and liquid is injected into each battery unit through liquid injection pipe
and flow indicator with filter.

▎ ▎ ▎ ▎

¨ † ¨ † ¨ † ¨ †

▎ ▎ ▎ ▎

¨ † ¨ † ¨ † ¨ †

▎ ▎ ▎ ▎

¨ † ¨ † ¨ † ¨ †

Figure 4-6-10 diagram of auto liquid replenishing device

48
 2) Use notice:
● Auto liquid replenishment shall be carried out at the end of charging, and it is
strictly prohibited to be done before charging.
●The auto liquid replenishment device shall ensure the correct liquid pressure.
● Liquid storage devices and pipelines shall be kept clean and there shall be no dirt.
●Only special liquid for batteries shall be used.
●It is strictly forbidden to flush the injection plug with tap water.
● Pay attention to the temperature to prevent the auto liquid replenishment system
from freezing.
4.6.2.6 Panel switch
Switches on the panel can be on or off according to the customer’s choose.
：If the button is pressed, the speed of the whole truck will slow down.
If the two buttons are pressed at the same time, the steering wheel
will center automatically.
4.6.3 Diagnosis
4.6.3.1 General instruction
The traction control system, loading control system, steering control system and
intelligent instrument system assembled in the truck are continually monitoring
micro-processor controller. They all have a diagnosis program to a main function. The
program includes the following 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 of the watch dog, phase voltage, current
censor, driving of the connector, can-bus connector
(3) Check when working: the circuit of the watch dog, the driving of the
connector, the current sensor, can-bus connector
(4) Continuously check: inverter temperature, motor temperature
Ways of diagnosis: the digital hand manual which can supply detailed diagnosis
information; the can-bus which will send fault code and the code and module node
will display in the meter.

49
 4.6.3.2 Fault code of the COMBIA AC2 inverter
The states of the
controller
The condition
Cod Fault Tracti Liftin The The
The description of excluding the
e name on g initial worki
alert faults
izing ng
state
state state
Exclude the fault
and the alarm will
disappear if in the
WATC initializing state;
The failure of
8 HDOG X X X X X if in other states,
the watch dog
exclude the faults
and make the
traction require in
force
LOGIC Exclude the faults
Overload
FAILU and make the
17 X X X protection of the
RE#3 traction require in
hardware circuit
force
The fault of the Exclude the faults
LOGIC
feedback circuit and make the
18 FAILT X X X
of U,V,W phase traction require in
URE#2
voltage force
LOGIC
Over voltage or Reclose the
19 FAILT X X X X
short of voltage electric lock
URE#1
Exclude the fault
The fault of the and the alarm will
output of motor disappear if in the
power; the fault initializing state;
VMN
30 X X X X X of power if in other states,
LOW
assessment, or exclude the faults
MOS driving and make the
circuit or motor traction require in
force
The fault of the Exclude the fault
output of motor and the alarm will
power; the fault disappear if in the
VMN
31 X X X X of power initializing state;
HIGH
assessment, or if in other states,
MOS driving exclude the faults
circuit or motor and make the

50
 traction require in
force
Exclude the fault
and the alarm will
disappear if in the
The fault of
initializing state;
STBY I feedback circuit
53 X X X X if in other states,
HIGH voltage of the
exclude the faults
current sensor
and make the
traction require in
force
No increase of
the voltage of
the power
capacity when
the electric
CAP being off; the Exclude the fault
60 CHAR X X X faults of the and the alarm will
GE power disappear
assessment or
PCB plate of the
logic card or the
driving PCB
card or motor
Exclude the fault
and the alarm will
disappear if in the
DRIVE
The short circuit initializing state;
R
74 X X X X of the main if in other states,
SHOTR
connector coil exclude the faults
TER
and make the
traction require in
force
CONT The broken of
Exclude the faults
ACTO the driving
and make the
75 R X X X circuit in the
traction require in
DRIVE main
force
R connector’s coil
Initializing Exclude the fault
state: the broken and the alarm will
COIL
of the driving disappear if in the
76 SHORT X X X X
protection initializing state;
ED
circuit in the if in other states,
coils of the exclude the faults

51
 main connector and make the
and traction require in
electromagnetic force
brake; alert state
or working
state: short
circuit of coils
in main
connector and
electromagnetic
brake
Exclude the faults
CONT The
when working;
ACTO un-returning of
reclose the
37 R X X touch point of
electric lock
CLOSE the main
when
D contactor
off-working.
Exclude the faults
CONT when working;
Poor connect of
ACTO reclose the
38 X X the main
R electric lock
contactor
OPEN when
off-working.
ENCO
Abnormal of the
DER Reclose the
82 X X X motor speed
ERRO electric lock
sensor (encoder)
R
Exclude the faults
PEDAL
The fault of the and make the
86 WIRE X X X X
NPOT circuit traction require in
KO
force
WRON A disparity Exclude the faults
G SET between the and make the
245 X X
BATTE battery voltage traction require in
RY and battery set force
A fault of lifting
micro-processor
PUMP Reclose the
246 X X X X checked by
KO electric lock
traction
micro-processor
A fault of
MAST traction Reclose the
246 X X X X
ER KO micro-processor electric lock
checked by

52
 lifting
micro-processor
or a disparity
between the
input order and
the main order
A disparity
between the
input state
checked by
INPUT lifting
Reclose the
250 MISM X X X X micro-processor
electric lock
ATCH input state from
traction
micro-processor
through
CANBUS
Exclude the fault
and the alarm will
The short circuit disappear if in the
AUX or broken way initializing state;
253 OUTP X X X X of if in other states,
UT KO electromagnetic exclude the faults
brake coil and make the
traction require in
force
The fault of the
EEPRR EEprom as the Exclude the fault
13 OM X X X X controller using and the alarm will
KO the initiating disappear
parameter
Temperature of
HIGH either lifting or
Exclude the fault
TEMP traction motor
61 X X X X X and the alarm will
ERATU or both motors
disappear
RE higher than
75℃
MOTO High
R temperature of Exclude the fault
65 TEMP X X X X either traction or and the alarm will
ERATU lifting motor or disappear
RE both
BATTE Battery capacity Exclude the fault
66 X X X X
RY lower than 20% and the alarm will

53
 LOW disappear
CPOT voltage
higher than the
VCC set min. number Exclude the fault
78 NOT X X X 1 volt when and the alarm will
OK switches of the disappear
traction
allowance point
INCOR Exclude the fault
Error traction
79 RECT X X X X and the alarm will
require order
START disappear
FORW Both existence
Exclude the fault
ARD+ of the backward
80 X X X X and the alarm will
BACK and forward
disappear
WARD input signal
The traction or
THER
lifting controller Exclude the fault
MIC
249 X X X X X temperature and the alarm will
SENSO
sensor exceeds disappear
R KO
its range.
The lifting
WAITI
processor is on
NG Exclude the fault
alert state
251 FOR X X X X and the alarm will
displayed in
NODE disappear
traction
#5
controller.
The traction
WAITI
processor is on
NG Exclude the fault
alert state
251 FOR X X X X and the alarm will
displayed in
NODE disappear
lifting micro
#3
processor
Traction
NO controller loses
Exclude the fault
CAN the connection
247 X X X X and the alarm will
MESS with the
disappear
AGE#5 lifting
controller.
Traction
NO
controller loses Exclude the fault
CAN
247 X X X X the connection and the alarm will
MESS
with the lifting disappear
AGE#3
controller.
242 PUMP X X X X The traction Exclude the fault
54
 WARN controller will and the alarm will
ING send alert signal disappear
if the lifting
micro controller
checks the fault
of lifting
chopper.
PUMP Error starting Exclude the fault
243 INC X X X order of the and the alarm will
START lifting controller disappear
The voltage of
PUMP the lifting
Exclude the fault
VACC acceleration is
244 X X X and the alarm will
NOT higher than the
disappear
OK set min. voltage
1V.

4.6.3.3 The fault code of EPS-ACO inverter

Glimmer Fault Description in The condition
description
ing times code the hand manual of excluding the faults
A disparity between the
MICRO SLAVE
1 246 controller and the walking and Change the chopper
KO
steering motors
A disparity of rotation direction
MICRO between the steering motor and
2 221 Change the chopper
SLAVE#4 the walking motor checked by
controller
The frozen of OxFF field data
3 250 MICRO SLAVE of the principle and Change the chopper
subordinate micro processor
A disparity of the decoding
MICRO
4 212 between the principle and Change the chopper
SLAVE#8
subordinate processor
Before the turning off of
the safe switch, the
voltage of the CAN#4
close to 0V whether the
The voltage of the CAN#4
switch is connected to
INPUT higher than 12V before the safe
5 99 the positive or negative
ERROR#1 switch inside the controller
point. If the switch is
being off
connected to the
positive point, the
CAN#4 will connect the
negative point through a
55
 load.
No communication between
6 6 SERIAL ERR#1 the principle and subordinate Change the chopper
processor
No communication between
SLAVE COM.
7 227 the principle and subordinate Change the chopper
ERROR
processor
The principle can not carry out
8 226 NO SYNC the electric code cycle and the Change the chopper
NO SYNC can not update.
The safe switch inside the
Find the causes or
9 253 KM CLOSED controller is on before the
Change the chopper
turning off of the key switch.
The safe switch inside the
principle processor is off
10 251 KM OPEN Change the chopper
checked by subordinate
controller. But it is on.
The safe switch inside the
subordinate processor turns off
Find the causes or
11 254 KS CLOSED before receiving the order
Change the chopper
which is checked by principle
processor.
The safe switch inside the
subordinate processor is on
12 252 KS OPEN Change the chopper
when it should be off which is
checked by principle processor.
The analogue signal sent by
CLOCK PAL principle processor is error,
13 218 Change the chopper
NOT OK which is checked by
subordinate processor.
Check whether the
The current exceeds the
motor and the controller
HIGH restricted current to the
1 70 are matched with each
CURRENT controller’s parts when the
other or change the
motor starts or works.
chopper.
Check the fuse; check
the input of the
controller’s positive
POWER The current of the phase W is
2 73 battery;
FAILURE#1 0V when the motor works.
Check the cable of the
phase W;
Change the chopper.
POWER The current of the phase U is Check the fuse; check
3 72
FAILURE#2 0V when the motor works. the input of the
56
 controller’s positive
battery;
Check the cable of the
phase V;
Change the chopper.
POWER The current of the phase V is
4 71 Change the chopper.
FAILURE#3 0V when the motor works.
The voltage of the phases W
LOGIC
5 19 and U of the steering motor is Change the chopper.
FAILTURE#1
different is abnormal.
The voltage of the phases W
LOGIC
6 18 and V of the steering motor is Change the chopper.
FAILTURE#2
different is abnormal.
Find out the reason of
The principle contactor can not
MAIN CONT. making the main
7 48 connect, which is checked by
OPEN contactor open circuit in
controller.
the traction control.
Check the CAN BUS
8 247 CAN BUS KO No communication
line
The steering motor’s current
MOTOR Check whether the
9 220 closes to the motor’s maximize
LOCKED motor seizures or not.
current morn than 1 second.
Check the connection of
the walking motor
D LINE The voltage of A,B phases of especially the resistance
1 243
SENSOR KO the walking motor is null. between the CAN#9 and
the B-( it should be
30ohms more or less)
Check the connection of
the walking motor
Q LINE The voltage of A,B phases of especially the resistance
2 242
SENSOR KO the walking motor is null. between the CAN#9 and
the B-( it should be
30ohms more or less)
S.P OUT OF Check the order digital
3 248 The range of the digital resistor
RANGE resistor
F.B OUT OF Check the feedback
4 249 The range of the digital resistor
RANGE digital resistor
Check whether the
The feedback digital resistor digital resistor input or
POEITION
5 228 and the feedback encoder’s not; check the
ERROR
angle are different. installation of the
encoder.
6 84 STEER A disparity between the order digital resistor and the
57
 SENSOR KO feedback potential( the truck did not apply to it)
JERKING FB The output voltage of the Change feedback digital
7 223
POT digital resistor is incorrect. resistor
Check whether the
feedback digital resistor
lose or not; check
whether the steering
FB POT wheel seizures or not.;
LOCKED OR The output voltage of the check whether the
8 222
FB SENS digital resistor is invariable. feedback digital resistor
LOCKED exceeds the limit of the
electricity when the
steering wheel moving;
check the rotation of the
steering motor.
A disparity between the
STEPPER
9 219 frequency and the amplitude of Change the chopper
MOTOR MISM
the walking motor.
A disparity between the
ENCODER Change the second
241 encoder frequency and the
ERROR channel of the encoder.
order frequency
1 13 EEPROM KO A failure of EPROM writing Change the chopper.
GAIN It is necessary to adjust current
2 244 Connect with ZAPI.
EEPROM KO of the controller.
CURRENT It is necessary to adjust current
3 255 Connect with ZAPI.
GAIN of the controller.
HIGH The temperature of the Change the way of heat
1 61 TEMPERATUR controller board is higher than transferring or change
E 75°。 the controller.
Check the temperature
MOTOR The temperature sensor of the
2 65 sensor or change the
TEMPERATE. motor is higher than 150°。
way of heat transferring.
The current of the current
1 53 STBY I HIGH Change the chopper
amplifier is high.
The voltage of the voltage
2 32 VMN NOT OK Change the chopper
amplifier is high,
The voltage amplifier of
LOGIC Vu-Vw exceeds the range of
3 17 Change the chopper
FAILURE#3 -0.25V-+0.25V under the
alternate condition.
The voltage amplifier of
LOGIC Vw-Vv exceeds the range of
4 16 Change the chopper
FAILTURE#4 -0.25V-+0.25V under the
alternate condition.
58
 The error occurs when
DATA adjusting the parameter of the Turn the key switch
5 245
ACQUISITION current amplifier or obtaining again
the .motor impedance.
STEER A warning of the exceeding of
1 85
HAZARD steering angle
A warning that the set of the
CAN BUS is PRESENT; The
WAITING
2 237 data of the steering controller
DATA
is transferred through traction
controller by CAN BUS.
Steering controller works on
the condition that traction warning
WAITING FOR
3 239 controller sends out the order
TRAC
of shutting off the safety
switch.
There is a disparity between
the data from the processor’s
EPS NOT
4 238 diagnosis and the set one. Cut
ALIGNED
the steering and traction after 6
seconds.

4.6.3.4 Fault code on the intelligent instrument

Code Fault name code Fault name
00 NODE 51 RIGHT I=0 EVER
01 CHOPPER RUNNING 52 PUMP I=0 EVER
02 NO COMMUNICATION 53 STBY I HIGH
03 UNKONWN CHOPPER 54 LEFT STBY I HIGH
04 CONSOLE EEPROM 55 RCG STBY I HIGH
05 SEARIAL ERROR#2 56 PUMP STBY I HIGH
06 SEARIAL ERROR#1 57 HIGH FIELD CUR.
07 CHOPPER NOT CONF 58 NO FIELD CUR.
08 WATCHDOG 59 HIGH BRAKING I
09 FIELD FF FAILURE 60 CAPACITOR CHARGE
10 EEPROM DATA KO 61 HIGH TEMPERATURE
11 EEPROM PAR. KO 62 HIGH TEMPERATURE
12 EEPROM CONF. KO 63 THERMIC LEVER#2
13 EEPROM KO 64 PUMP TEMPEATURE
14 EEPROM OFFLINE 65 MOTOR TEMPERAT.
15 LOGIC FAILURE#5 66 BATTERY LOW
16 LOGIC FAILURE#4 67 BATTERY LEVER#2
17 LOGIC FAILURE#3 68 BATTERY LEVER#1
18 LOGIC FAILURE#2 69 CURRENT SES. KO

59
 19 LOGIC FAILURE#1 70 HIGH CURRENT
20 FORW VMN LOW 71 POWER FAILURE#3
21 FORW VMN HIGH 72 POWER FAILTURE#2
22 BACK VMN LOW 73 POWER FAILURE#1
23 BACK VMN HIGH 74 CURRENT SENS. KO
24 LEFT VMN LOW 75 CONNECTER DRIVER
25 LEFT VMN HIGH 76 COIL SHORTED
26 RIGHT VMN LOW 77 COIL INTERRUPTED
27 RIGHT VMN HIGH 78 VACC NOT OK
28 PUMP VMN LOW 79 INCORRECT START
29 PUMP VMN HIGH 80 FORW+BACK
30 VMN LOW 81 BAD STEER 0-SET
31 VMN HIGH 82 ENCODER ERROR
32 VMN NOT OK 83 BAD ENCODDER SIGN
33 NO FULL COND 84 STEER SENSOR KO
34 RGT NO FULL COND 85 STEER HAZARO
35 LFT NO FULL COND 86 PEDAL WIRE KO
36 PU NO FULL COND 87 PEDAL FAILURE
37 CONNECTOR CLOSED 88 TRACYION BRUSHES
38 CONNECTOR OPEN 89 PUMP BRUSHES
39 BRAKE CON. CLOSED 90 DRIVER 1 KO
40 BRAKE CONT. OPEN 91 DRIVER 2 KO
41 DIR CONT. OPEN 92 DRIVER 1 SIC. KO
42 DIR CONT. CLOSED 93 DRIVER 2 SIC. KO
43 DIR CONT. OPEN 94 INPUT ERROR#6
44 RIGHT CONT CLOSED 95 INPUT ERROR#5
45 LEFT CONT. CLOSED 96 INVERTION
46 LEFT CONT. OPEN 97 POSITION HANDLE
47 MAIN CONT. CLOSED 98 INPUT ERROR#2
48 MAIN CONT. OPEN 99 INPUT ERROR#1
49 I=0 LEVER
50 LEFT I=0 EVER

Fault analysis

“EEPROM KO”

It means a fault of parameter storing and adjustment in memory. “EEPROM KO”

means the truck can work on under the set value before selling. If the fault still exists

after restarting the electric lock, replace the instruments. If it disappears, the value set

before will be replaced by the one set before selling.

“CAUSE KO”
60
 If the intelligent instrument can not receive information from the CAN chain, the

following can be done:

--- If the fault occurs with other faults, it is probably the problem of the CAN

interface of the display. That means the display can not receive any information from

CAN. It is suggested to check CAN lines or other circuits to the display.

---if it do not occur with other faults, the problem may exists in the CAN

interface of other modules.

“SEVICE REQUIRED”

The routine maintenance falls due, it needs a thoroughly check and maintain.

“COIL SHORTED”

A short circuit occurs in a load which connects to the power output (A19 and

A20). So the relative drivers generate big current the following can be done:

---.check whether the load is broken or shot circuit or not.

--- check the relative circuit

---if the fault still exists when the load connective circuit is open, it is probably

the broken of the big current protective circuit of the display. Change the instrument.

“HYDRAULIC OIL”

The input of the hydraulic oil lever is effective when starting. The following can

be done to resolve the problem:

Check whether the relative digital input (A9) of the display is effective. (To

TESER menu). And check the effective type of the electric lever of the input point.

(=VB or GND) (To SET OPTIONS menu)

---if the input point is effective, check the condition of the relative switch,

circuit and oil lever.

--if the input point is ineffective check the input circuit of the intelligent

instrument..

“PUMP MOTOR TEMPERATURE”

61
 The lifting motor temperature sensor sends out a signal of high temperature of

motor windings. The following can be done to resolve the problem.

Check whether the relative digital input point (A6) is effective. (To teser menu).

Check the effective lever type of the input point (+VB or GND). (To SET OPTIONS

menu):

---if the fault exists when the input point is effective, check the temperature of

the lifting motor, circuit and the motor temperature sensor.

--- If the input point is ineffective check the input circuit of the intelligent

instrument..

“BRUSHES”

The electric brush wear sensor of the lifting motor sends out a signal of wear.

The following can be done to solve the fault:

Check whether the relative digital input point (A5) is effective. (To teser menu).

Check the effective lever type of the input point (+VB or GND). (To SET OPTIONS

menu):

--- If the fault exists when the input point is effective, check the wear of the

electric brush, circuit and the electric brush wear sensor;

--- If the input point is ineffective check the input circuit of the intelligent

instrument.

4.6.4 Routine maintenance

Check the wear and connect condition of the contactor point. Check it every

three months.

Check the pedal and inching switch. Make sure there is no resistance between

two contactors with a proper universal electric meter when turning off .or on switches,

make sure there is clear sound. Check the inching switch every three months.

Check the cables of the battery, chopper and motor. Make sure they are insulate

and well connected. Check the main cables every three months.

62
 Check the pedal and the mechanical working of the knobs. Check the returning

springs. Check whether the digital resistor can go to its max. value or its set value or

not. Check them every three months.

Check the mechanical working of the contactor. Check whether there is a

seizure or wear of the contactor point. Check them every three months.

Check should be done by 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 technician who

periodically checks the equipment, which can create damage or defects to the device,

should be transferred to our company.

4.6.5 Battery moving

(1) Take out the battery

Draw the valve’s reach lever back, and take the mast back as it will. Pull the

system’s knob to upraise the lock pillar. (To fig. 4-6-11). Separate the hook under the

battery rack and the lock pillar in the middle plate on the truck. The hook will hang up

the lock assembly on the mast support under the force of the spring. (To fig. 4-6-12.

Then pull the reach lever, the battery and the rack will be drawn out with the mast.

The truck can not do other operations such as driving, loading and unloading at this

time.

(2) Draw back the battery

Loosen the knob and pull the reach lever back. The battery and its rack will be

pulled back as the back moving of the mast. Draw the lever until the battery reaches

its setting position. At this time, the hook under the battery rack will lock the lock

pillar on the middle plate on the truck with a clatter sound. The hook will overcome

63
the spring force and separate from the lock assembly. The mast is thoroughly drawn

back. Loosen the knob after 1 second, and then the battery will be locked. The

operation is finished.

Fig. 4-6-11 The system for separating the battery rack

1. Knob 2. Washer 3. Bolt M8×40 4. Lever 5. Bracket

6. The lock system 7. Bolt M6×12 8. Bolt M6×20

9. Cupreous gasket 10. Washer 11. Washer

64
 Fig. 4-6-12 The hook and lock assembly

1. Hook and lock assembly 2.Washer 3 Nut M16 4.The extending spring

When the locking system does not work, separate the hook and pillar by hand,

then draw the reach lever. And the battery can be taken out.

4.7 Supporting wheel assembly

CQD16/20-GA2S 1.6/2t sit-on type reach truck is of three wheeled type. Front

support is of two symmetric distributed supporting wheel assemblies. (Refer to figure

4-7-1)

65
 1. drive wheel 2. Floor board assembly 3. Supporting wheel assembly

Figure 4-7-1 reach truck three supporting point diagram

Supporting wheel assembly（refer to figure 4-7-2）is mainly made up of wheel

(item 1),brake drum (part 2) , retainer ring (item 3), screw M8x30(item 5), lock bolt

(item 6), tapper roller bearing (item 7), supporting wheel shaft( item 8) and so on.

before install supporting wheel, apply enough lubricating grease to the two tapper

roller bearings. Change the tapper roller bearing every two months.

66
 Figure 4-7-2 Supporting wheel assembly

1. wheel 2. Brake drum 3. Retainer ring 68 4. Washer 8

5. screw M8x30 6. Lock bolt 7. Tapper roller bearing 8. Supporting wheel shaft

67
 Figure 4-7-3 supporting wheel assembly installation drawing

1. supporting wheel 2. Brake drum 3. Retainer ring 68 4.washer 8

5. screw M8x30 6. Lock bolt 7. Tapper roller bearing

8. Supporting wheel shaft 9. Shoe brake 13. Outrigger steel channel

Supporting wheel installation (refer to figure 4-7-2 and 4-7-3)

1. Before install the supporting wheel, suspend the right and left legs to make the

supporting wheel rotate freely.

2. Make sure matching surface of the brake drum and shoe brake inside of the

supporting wheel is smooth and dry and there is no paint, scratch, burr and oil stain.

3. Install brake drum into the supporting wheel rim and fix with screw M8x30 (item

3). Install two tapper roller bearings (item 7) into rim inner hole. Separate and fix the

68
bearings with retainer ring 68 (item 3) in the middle.

4. Match the wheel assembly and brake assembly to make sure the clearance between

the brake and brake drum inside of the rim is between 0.2mm and 1.5mm. Make sure

the brake assembly can be rotate with hand easily and it can rotate freely.

5. Then install the wheel assembly into wheel assembling bracket in front of the left

and right leg from upside. Install supporting wheel shaft (item 8) from the coaming

hole into the inner ring of the two tapper roller bearing. Install the thin end of

supporting wheel shaft into steel channel hole in the inner side of the leg.

6. Fix the left and right brake assemblies onto steel channel of the left and right legs

inner side through 8 screws(M12X25)( item 7). The tighten torque is 90~110Nm and

apply GY-340 anaerobic adhesive. Be care to make the coaxiality of the supporting

wheel shaft andф35 hole of the inner side steel channel.

7. Install lock bolt (item 6) into the thin end of the supporting wheel fromф35 hole in

the inner side of the steel channel and tighten it with 90~110Nm torque. Make sure

the supporting wheel can be rotate with hand. Then apply GY-340 anaerobic adhesive

on it.

8. when the supporting wheel is assembled, make sure it can be rotate with hand when

the wheel is suspended. If it is tight and it can not be rotated, large travelling damp is

exist and hydraulic parts may he damaged early. Then adjust it. Rotate the lock nut 1/8

circle back and apply with GY-340 anaerobic adhesive. Make sure the tapper roller

bearing clearance is proper.

Make sure each part is installed reliably and can rotate freely.

69
V. Troubleshooting
5.1 Transmission system

problem Possible cause Remedies

1)too much clearance
Adjust
between the gears
Loud noise of gears when
2) much wear of the gears Replace
driving
3) lower oil lever in oil
Add oil
tank
1) too much clearance
Loud striking noise when Adjust
between the gears
steering
2) much wear of the gears Replace
Adjust or replace the
1) leakage in the plug
gasket
2) seeping next to the
Leakage of the gear box Replace o-ring
monitor’s axis
3) Seeping between the Check the combine surface
linker and gear box and smear sealant again

5.2 steering system

problem Possible cause Remedies
1) no working of the Check and replace the
steering motor power supply
2) no working of the turn Check and replace the
No steering
angle sensor power supply
3) damage of the chain
Replace
keeper
1) too much clearance
Adjust
between the gears
Loud noise of gears when
2) much wear of the gears Replace
steering
3) Short of lubricating
Add lubricating grease
grease
Adjust the restrict bolt in
1) Tighten or loosen chain
the gearbox
Inflexible steering
Adjust the hand wheel to
operation 2) Inequality hand wheel
make it homocentric-ally
swerve
with the swerve’s axis

5.3 Braking system

Problem Possible cause Remedies
1) oil leakage in braking
Poor braking Check and repair
system

70
 2) gas existing in the
Exhaust gas
pipeline
3) poor clearance
adjustment of the brake Adjust
shoe
4) over heat of the brake Check and repair
5) poor adjustment of the
adjust
brake pedal
1) dirty existing in the
Check and repair
friction surface
2) torn out or incorrect fix
Check and repair
Braking noise of the brake shoe
3) Wear of the friction Replace
4) loose of the wheel
Check and repair
bearing
1) bad working of the
Adjust
break tight wire
Poor hand braking
2) bad adjustment of the
Adjust
hand wheel

5.4 Hydraulic system

Problem Possible cause Remedies
1) oil leakage in the
Check and repair
pipeline or the connector
2) low oil lever in the oil
Add oil
tank
3) too much impurity in
Low oil in the system
the oil and the filter being Change oil
blocked
4) much wear of the gears Change
Check the o-ring or
5) oil leakage of the gears
replace
1) too much wear of the
Change
gears
2) low pressure of the Adjust the pressure of the
system safety valve
3) too much wear between
Poor lifting the control valve and the Change levers
lever
4) oil leakage in lifting
Change o-ring
cylinder
5) no return of the safety
Check and repair
valve

71
 6) poor adjustment of the
Adjust
knob

5.5 Electric system

Problem Possible cause Remedies
1) poor contact of the key
Check and repair
switch
2) broken wire Connect again
No signal after the turning
3) poor contact of the
on of the key switch Check and repair
connector
4) poor connection of the
Tighten the bolt
battery connector
1) broken wire Connect again
2) poor contact of the
Check and repair
connector
3) poor contact of the
No working of the Check and change
direction switch
accelerator
4) a fault of the driving
Check and change
controller
5) a fault of the steering
Check and change
controller
1) a short circuit in the
Change the connector
contactor coil
2) abnormal working of
Check and change
the lifting switch
No working of the lifting
3) broken wire Connect again
motor
4) poor contact of the
Check and repair
connector
5) a fault of the lifting
Check and repair
controller
Long-working of the 1) abnormal working of
Check and repair
lifting motor the lifting switch
1) poor contact of the
Check and change
connector
No working of the horn 2) poor contact with the
Check and repair
horn switch
3）broken horn Change
1) long-contact of the horn
Long-working of the horn Check and repair
switch
1) broken fuse Change
Abnormal working of the 2) poor contact of the
Cheek and repair
illuminative lights connector
3) broken bulb Change

72
VI. Maintenance
6.1 Routine maintenance

In the use of the work, especially during the first operation period of the new

truck, carefully operation and timely adjustment, maintenance and service are all

necessary for keeping the truck in good condition. Do as the following.

(1) When a new truck has been used for 100 hours, replace the gear oil in

differential and main reducer, and tighten all fixing parts.

(2) When a new truck has been used for 200 hours, readjust the clearance

between the gears.

(3) All motors, controllers and 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
Change gear 1200h
1 Drive gear box
oil
Change 1200h
Steering gear
2 lubrication
box
grease
When
3 Brake liquid Add liquid
necessary
Add 100h
Pin, reach
4 lubricating
cylinder
grease
Add 100h
Pin, tilt
5 lubricating
cylinder
grease
Add 100h
Bearing, mast
6 lubricating
support
grease
7 Pin, foot brake Add 100h

73
 lubricating
grease
Hydraulic oil 1000h
8 Clean
tank and filter
9 Hydraulic oil Replace 1000h
3000h Replace it at
10 Lift chain Replace once when
damaged
3000h Replace it at
High pressure
11 Replace once when
pipe
damaged

6.2 Oil for forklift truck

Trademark/code Trademark/code
Name
name(home) name(abroad)
Hydraulic oil N32# or N46# ISOVG30
Gear oil 85W/90 SAE90/SAE80W
4640 compound brake
Brake liquid JISK-2233
liquid
Lubricating grease 3# JISK-2220, 1#，2#

74
6.3 Lubricating chart

75
VII. Others
7.1 The size and weight of the main takedown parts of the truck
Type
Parameter Unit CQD16S CQD20S

Max. figure size mm 700×1100×995 700×1170×995

Overhead guard
Weight kg 75 76
Max. figure size mm 1070×100×40 1200×125×50
Fork
Weight kg 47 78
Mast Max. figure size mm 2010×304×735
(lift height
Weight kg 670
4250mm)
Mast Max. figure size mm 2360×304×735
(lift height
Weight kg 770
5300mm)
Mast Max. figure size mm 2460×304×735
(lift height
Weight kg 790
5600mm)
Mast Max. figure size mm 2530×304×735
(lift height
Weight kg 810
5800mm)
Mast Max. figure size mm 2660×304×735
(lift height
Weight kg 840
6200mm)
Mast Max. figure size mm 2860×304×735
(lift height
Weight kg 890
6800mm)
Mast Max. figure size mm 3060×304×735
(lift height
Weight kg 940
7400mm)
Mast Max. figure size mm 3260×304×735
(lift height
Weight kg 990
8000mm)
Mast Max. figure size mm 3430×304×735
(lift height
Weight kg 1030
8500mm)
Battery Max. figure size mm 970×335×760
（400A.H） Weight kg 730
Battery Max. figure size mm 970×400×760
(500A.H) Weight kg 920
Battery Max. figure size mm 970×464×760
(600A.H) Weight kg 1070

76
 7.2 Mast breakout

Reaching forward and tilt backward the mast, hook in the swing position of the

mast with a cord; dismantle three high pressure hose in the bottom of the mast and the

pin installed in the tilt cylinder. Loose the bolt（M16×8）in the outer mast’s cap, and

take off the cap, and then the mast can be dismantled from the truck body.

Dismantle the truck’s left and right cover and cabinet (remember to unplug the

wire),and loose the bolt (M16×8). Hook the overhead guard with a cord and you can

take off the overhead guard.

7.3 The vibration parameter of the truck

Name Type Value
Driving direction 900m/s²
Vibration acceleration
Lifting direction 300 m/s²

77
HELi
妥徽合力殷份有限公司
�NHUI HELJ CO., LTD.

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S117-4:2019