EP Equipment CQD16, Service Manual

Page 1: ...Service Manual Electric Reach Truck CQD16NRVF NRV CQD16 20RVF RV...

Page 2: ...Service Manual Electric Reach Truck CQD16NRVF NRV CQD16 20RVF RV...

Page 3: ...CQD20RV 2 000 kg Capacity Full Height Series Medium Configuration CQD20RVF 2 000 kg Capacity Full Height Series Premium Configuration Some sections of the manual only involve certain model please ref...

Page 4: ...w the complete operation and maintenance information in this Manual for vehicle maintenance Before using please check if the pages of the Manual are clear and complete so as not to affect your normal...

Page 5: ...utton 23 3 1 5 Control Switch RVF NRVF 24 3 1 6 Control Switch RV NRV 24 3 1 7 Instrument 24 3 1 8 Horn 24 3 1 9 Fan 25 3 1 10 Accelerator Pedal 25 3 1 11 Brake Pedal 25 3 1 12 Foot Switch 25 3 1 13 W...

Page 6: ...tromagnetic Brakes 43 5 2 1 Removal and Installation 43 5 2 2 Faults and Causes 44 5 2 3 Checking and Testing 44 5 2 4 Control Circuit Troubleshooting 45 5 3 Drive Motor 46 5 3 1 Removal and Installat...

Page 7: ...5 3 Connection Mode 62 6 5 4 Checking and Testing 62 6 5 5 Control Circuit Troubleshooting 63 6 6 Stepper Motor 65 6 6 1 Removal and Installation 65 6 6 2 Faults and Causes 65 6 6 3 Checking and Testi...

Page 8: ...79 7 4 1 Removal and Installation 79 7 4 2 Interface Description 79 7 4 3 Faults and Causes 80 7 4 4 Checking and Testing 80 7 4 5 Control Circuit Troubleshooting 80 7 5 Solenoid Valve RVF NRVF 81 7...

Page 9: ...esting 111 8 4 4 Control Circuit Troubleshooting 112 8 5 Limit Switch 113 8 5 1 Removal and Installation 113 8 5 2 Connection Mode 113 8 5 3 Faults and Causes 114 8 5 4 Checking and Testing 114 8 5 5...

Page 10: ...age 133 8 14 1 Tractiong Pump Controller 133 8 14 2 Steering Controller EPS ACO 138 8 14 3 SICOS Controller 147 8 14 4 Solenoid Valve Controller 148 8 15 Electrical Schematic Diagrams RVF NRVF 149 8 1...

Page 11: ...Cylinder 181 A1 4 1 Cylinder Removal with mast on the vehicle 181 A1 4 2 Cylinder Maintenance 182 A1 4 3 Cylinder Installation 182 A1 5 Tilt Cylinde 183 A1 5 1 Cylinder Removal 183 A1 5 2 Cylinder Ma...

Page 12: ...nt 201 A3 2 2 1 Mast Chains 201 A3 2 2 2 Fork Carriage Chains 201 A3 3 Mast Tubing 204 A3 4 Lift Cylinder 206 A3 4 1 Cylinder Removal 206 A3 4 2 Cylinder Maintenance 207 A3 4 3 Cylinder Installation 2...

Page 13: ...ERVICE MANUAL BATTERY 225 B1 Lead acid Battery 227 B1 1 Safety and Warnings 227 B1 2 Use of Battery 227 B1 2 1 Pre use Checks 227 B1 2 2 Discharging 227 B1 2 3 Charging 228 B1 2 4 Temperature 228 B1 3...

Page 14: ...ntenance underneath the vehicle make sure that the lifting device or jack leg is secure Park your vehicle in a safe and secure area Never use an open flame to check level of electrolyte other oils or...

Page 15: ...1 1 1 INFORMATION SPECIFICATIONS...

Page 16: ...2 NOTE...

Page 17: ...Tel 400 0550 205 Customer Components Warehouse Customer service to input into After sales System After sale Engineer to call back to confirm the accuracy of the information about the components Shippe...

Page 18: ...verhead Guard 3 Free Lift Cylinder 4 Controller 5 Load Wheel 6 Reach Outrigger 7 Battery 8 Tank No Name 9 Drive Wheel 10 Seat 11 Foot Switch 12 Brake Pedal 13 Accelerator Pedal 14 Battery Slider Unloc...

Page 19: ...the truck The truck is equipped with foot switch only by pressing the switch can the truck be operated which has greatly reduced the possibility of misuse by the operator Truck can only be operated by...

Page 20: ...10 9 8 8 5 8 1 4 General Tightening Torques Screws or bolts used on the truck are of 8 8 grade or higher performance level When you are conducting truck maintenance you can refer to Table 1 4 1 and Ta...

Page 21: ...186 219 294 353 406 481 481 570 M18 1 5 210 247 331 397 457 541 541 641 M20 264 312 417 500 576 683 683 808 M20 1 5 294 345 463 555 640 758 758 897 M22 360 431 568 680 786 941 918 1099 M22 1 5 395 473...

Page 22: ...REV 07 2016 INFORMATION SPECIFICATIONS 1 8...

Page 23: ...9 2 2 MAINTENANCE...

Page 24: ...10 NOTE...

Page 25: ...ith wooden wedges disconnect the key switch and disconnect the battery connections When lifting the truck the lifting tools can only be installed on the fixed positions as specified When jacking up th...

Page 26: ...e vapor steam to clean the equipm ent 2 2 2 Inspection Regular inspection and maintenance under normal conditions of use Operating Hours h Requirements 50 At least once per 7 days 150 At least once pe...

Page 27: ...mation records and operating hours A Power Supply Drive System Check the battery cables for damage and replace if necessary A Check the battery charge connector A Check if the cable connections betwee...

Page 28: ...of drive mounting base A Check the travel speed A Hydraulic System Check the functions of hydraulic system A Check if the hoses pipes and interfaces are fastened or sealed securely and check if there...

Page 29: ...l A Check the installation and connection of brake A Check the braking distance of brake A Mast System Check the mast for damages A Clean and lubricate the rolling surface of lift mast column with gre...

Page 30: ...L Lubricate the forward tilting guides and rollers A L Check the fixation of battery and battery tray A Check the forward tilting safety blocks A Check the seat fixation and adjustment functions A Che...

Page 31: ...x different types and specifications of lubricants with each other except for those can be mixed under clear statement The use and disposal of lubricants must be carried out in strict accordance with...

Page 32: ...x D Brake fluid ZSM207DOT3 After the gas within the system is completely discharged add to 2 3 of the oil cup Brakes Table 2 3 Application Amount of Hydraulic Oil 1 Mast Series Lifting height mm Amoun...

Page 33: ...NANCE 2 Table 2 4 Sliding Surface Lubrication Table Code Position L1 Steering gear L2 Engine hood hinges L3 Caster L4 Load Wheel L5 Forward tilting guides and rollers L6 Chains L7 Steel channel and ro...

Page 34: ...20 REV 07 2016 MAINTENANCE 2...

Page 35: ...21 3 3 STRUCTURE FUNCTIONS...

Page 36: ...22 NOTE...

Page 37: ...ergency braking Description under normal circumstances switch cover is at high position and the circuit is connected when pressing this switch the circuit is disconnected Note Unserviceable 3 1 3 Key...

Page 38: ...de the controller with lift lower forward retract tilt forward tilt backward shift left shift right and other signal inputs Description the control switch is normally open Note Unserviceable 3 1 7 Ins...

Page 39: ...witch cover Function to provide acceleration signal for the travel of truck Description 48V operating voltage Note Unserviceable 3 1 11 Brake Pedal Location on foot switch cover Function to brake the...

Page 40: ...overhead guard Function to provide lighting for operator Description 12V operating voltage Note Unserviceable 3 1 15 Rocker Switch Location on front cover of control panel Function to control the on a...

Page 41: ...gnal input by the control switch Description 48V operating voltage to control the pump motor circuit Note Unserviceable 3 1 19 EPS AC0 Controller Location electrical mounting plate Function to control...

Page 42: ...der the front cover of control panel Function connection and disconnection of oil passage Description manual valve control Note Unserviceable Location electrical mounting plate Function to control the...

Page 43: ...g of carriage Description upon receiving the signal input by control switch AC2 pump controller to control the power transmission of pump motor Note Unserviceable 3 1 26 Gear Pump Location left side o...

Page 44: ...30 REV 07 2016 STRUCTURE FUNCTIONS 3...

Page 45: ...31 4 4 CHASSIS SYSTEM...

Page 46: ...32 NOTE...

Page 47: ...placing wheels be sure that the truck won t tilt WARNING see Figure 90102 Unscrew the three screws 1 in dust cover 2 and remove the dust cover Unscrew the round nut 3 on the axle then remove lock wash...

Page 48: ...can both be in contact with the ground When the truck is running check if the three wheels are functioning properly After long time of use the drive wheel will wear and tear to certain level at this...

Page 49: ...tion Install according to the reverse order of rem oval After replacing the brake master cylinder or tubings the air within the entire brake pipeline must be discharged CAUTION Air Discharge Adding Br...

Page 50: ...r failure Cause a Insufficient brake fluid b Brake master cylinder blocked c Brake pipeline leaks 4 4 Seat 4 4 1 Removal and Installation Removal Unscrew the star shaped handle on engine hood and open...

Page 51: ...remove the brake 2 Installation Install according to the reverse order of rem oval Adjustment Toggle the toothed flange on the lash adjuster with slotted screwdriver through the opening on brake bott...

Page 52: ...fluid running out of the vent it indicates that the air discharge is completed release the brake pedal and close the vent During the entire process of operation there must always be brake fluid in the...

Page 53: ...39 5 5 DRIVE SYSTEM...

Page 54: ...40 NOTE...

Page 55: ...E SYSTEM 5 No Name 1 Drive Wheel 2 Electromagnetic Brakes 3 Drive Motor 4 Large Steering Bearing 5 Large Ring Gear No Name 6 Gearbox 7 Steering Motor 8 Proximity Switch 9 Pinion Gear 10 Drive Mounting...

Page 56: ...move the drive wheel 2 from the gearbox 3 Installation Install according to the reverse order of rem oval Screw the seven nuts as shown in Figure 90203 Tighten the nuts by order and mark with the torq...

Page 57: ...ve motor from rotating thus to brake the vehicle No Name 1 Mounting screws 2 Brake pads 3 Brake gear 4 Dust cover 5 Friction plate 6 Electromagnetic coil 7 Spring 8 Pressure plate The brake is install...

Page 58: ...bnormal noise after absorption Cause a Fully absorbed but plate not flat b Mechanical resistance 4 Fault Brake temperature is too high Cause Pressure plate does not fully absorb overcurrent of the coi...

Page 59: ...n body in the air gap that may affect the absorption or bouncing off of the pressure plates Spring Checks Deformation or foreign bodies stuck in the spring may affect the normal absorption of pressure...

Page 60: ...the motor make sure that the woodruff key on the motor shaft is fully seated on the motor gear Motor gear should fully engage with the gear within the gearbox rotate the gearbox without blocking and...

Page 61: ...low resistance range CAUTION Resistance Measurement Judgment With readings but very low Normal 0 Winding internal short circuit replace the motor Winding internal open circuit replace the motor The di...

Page 62: ...lways 0 speed encoder failure motor encoder disc failure Speed Encoder Speed encoder is used to detect the speed of the motor and covert the speed into fixed signals Check if the motor encoder and the...

Page 63: ...ION Gear oil injection nozzle Gear oil discharge nozzle Loosen the oiling port plug and observe the oil level If oil level is aligning with lower level of oiling port it indicates that the oil level i...

Page 64: ...on driver s seat Make sure that Lock Washer 2 Figure 90213 has been mounted Adjust the height of Proximity Switch 3 Figure 90214 to make the spacing between proxi mity switch end face and upper surfac...

Page 65: ...with multimeter If there is no voltage check if the circuit is connected if there is voltage move on to the next step Measure the voltage between Pin 78 and Pin 92 If there is 24V voltage or the swit...

Page 66: ...val During installation fasten the bottom surface of steering motor into the groove of motor mounting base and then tighten the four mounting screws CAUTION Speed Encoder Switch off the truck power co...

Page 67: ...n measu ring with a multimeter put it on a low resistance range CAUTION Resistance Measurement Judgment With readings but very low Normal 0 Winding internal short circuit replace the motor Winding int...

Page 68: ...encoder if it is steering motor encoder disc failure replace the motor Speed Encoder Speed encoder is used to detect the speed of the motor and covert the speed into fixed signals Check if the motor...

Page 69: ...55 6 6 OPERATING SYSTEM...

Page 70: ...56 NOTE...

Page 71: ...er of rem oval When removing or installing please pay attent ion to protect the cables from being damaged CAUTION 6 2 Control Panel Removal Unscrew the 10 screws 1 Figure 90302 raise the front cover 2...

Page 72: ...Carry out ON OFF test to the push button switch with a multimeter push button switch at original position broken circuit press the button key switch to ON emerg ency stop switch to Pulled out status t...

Page 73: ...ch and its wiring harness See Figure 90304 Check if the port of each control switch wiring harness is conducted with a multimeter if not conducted replace the harness of travel switch if conducted mov...

Page 74: ...a multi meter Set the multimeter to ON OFF Check if 5 6 8 9 circuit circuit between control switch and instruments is conducted Forward Shifting Retract Switch Control Circuit Figure 90306 Check if t...

Page 75: ...et the multimeter to ON OFF Check if 10 11 12 13 circuit circuit bet ween control switch and instruments is con ducted Left Shifting Right Shifting Switch Control Circuit Figure 90308 Check if the cir...

Page 76: ...erminal 3 for connection of wiring harness connector to switch base Checking Check if the appearance of control switch is in good condition also check for deformation of handwheel Check if the handwhe...

Page 77: ...g a multi meter Set the multimeter to ON OFF Check if 7 8 circuit circuit between control switch and instruments is conducted Forward Shifting Retract Switch Control Circuit Figure 90319 Check if the...

Page 78: ...meter Set the multimeter to ON OFF Check if 10 11 circuit circuit between control switch and instruments is conducted Left Shifting Right Shifting Switch Control Circuit Figure 90321 Check if the cir...

Page 79: ...ecure and if there is loosening 6 6 3 Checking and Testing STEPPER MOTOR turn the steering wheel if the voltage display is always 0 it indicates that the stepper motor has no signal output see Section...

Page 80: ...the appearance of key switch its wiring harness are in good condition and if the connectors are connected securely 6 7 3 Checking and Testing Testing Check if the key switch circuit is conducted Carr...

Page 81: ...b Emergency switch shorted short circuit Checking Check if the appearance of emergency switch its wiring harness are in good condition and if the connectors are connected securely 6 8 3 Checking and T...

Page 82: ...h shorted short circuit Checking Check if the appearance of rocker switch is in good condition and if the plug connection is secure 6 9 3 Checking and Testing Testing Check if the rocker switch circui...

Page 83: ...uit is broken by using a multi meter Set the multimeter to ON OFF Check if 93 circuit circuit between switch and converter is conducted Check if 95 circuit circuit between switch and warning light is...

Page 84: ...lug connection is secure 6 10 3 Checking and Testing Testing Enter TESTER Menu to check the status of the switches toggle the switch backward if the display does not change then it indicates the trave...

Page 85: ...71 7 7 HYDRAULIC SYSTEM...

Page 86: ...72 NOTE...

Page 87: ...g and lowering of the mast If hydraulic oil is becoming less please tho roughly check the hydraulic system for leaks Disassembly of cylinder needs to be perfor med in a clean environment Before removi...

Page 88: ...74 REV 07 2016 HYDRAULIC SYSTEM 7 7 1 1 Hydraulic Schematic Diagram RVF NRVF...

Page 89: ...75 REV 07 2016 HYDRAULIC SYSTEM 7 7 1 2 Hydraulic Schematic Diagram RV NRV...

Page 90: ...oving the tubing and gear pump the system will lose some hydraulic oil please refer to Section 2 2 3 for supplementary adding of hydraulic oil CAUTION 7 3 2 Faults and Causes 1 Fault Motor does not ro...

Page 91: ...a low resistance range CAUTION Resistance Measurement Judgment With readings but very low Normal 0 Winding internal short circuit replace the motor Winding internal open circuit replace the motor The...

Page 92: ...always 0 speed encoder failure motor encoder disc failure Speed Encoder Speed encoder is used to detect the speed of the motor and covert the speed into fixed signals Check if the motor encoder and t...

Page 93: ...olenoid Valve Tilting Solenoid Valve Installation Install according to the reverse order of rem oval As some hydraulic oil will be lost when removing the multi way solenoid valve please add appropriat...

Page 94: ...fe has expired already Checking Check the valve seat for leakage and dama ge Check the solenoid valve connector for loosening or poor connection of leads 7 4 4 Checking and Testing Testing Switch off...

Page 95: ...he solenoid valve blocked by impurities c Spring deformation d Balancing hole blocked by impurities e High frequency of use service life has expired already 3 Fault Internal leakage Cause Damaged seal...

Page 96: ...isassembly pay attention to the sequence of assembly and position of external wiring for correct re assembly and wiring also check the oil mist spray orifice for blockage and if the lubricant is suffi...

Page 97: ...e cotter pin on pin shaft 3 remove the connecting rod 4 between multi way valve and control lever Unscrew the two bolts 5 and remove the multi way valve from the mounting plate 6 Unscrew the bolt 7 an...

Page 98: ...Tank 25 7 6 3 Faults and Causes 1 Fault The vehicle cannot perform the hydraulic control instructions Cause a Valve failure b Valve seat blocked by large impurities c External leakage sealing damaged...

Page 99: ...ration and noise Cause a Pump body defects b Gear pump inlet tubing diameter is too small c Oil filter clogging or motor speed is too high d Motor and oil pump shaft misalignment 7 7 1 Removal and Ins...

Page 100: ...be used for the parts having such requirements do not hammer forcefully or pry Fine pitch threaded cylinder cap after being shaken loose loosen it with cylinder wrench with even force copper rod can b...

Page 101: ...d pay attention if it is moving without blocking and if there is uneven resistance during the moving Upon the pressure testing raise the pressure slowly and observe carefully for leaks 7 8 2 Cylinder...

Page 102: ...n container under it for discharge of hydraulic oil CAUTION Unscrew the anchor bolt 1 underneath the chassis with socket wrench and pull out the pin shaft 2 Unscrew the anchor bolt 4 underneath the fo...

Page 103: ...ut the piston rod 1 from cylinder block 7 Remove the seal 9 and support ring 10 on the piston Unscrew the lock screw 11 from the piston and unscrew the piston 8 from the piston rod 1 Remove the sleeve...

Page 104: ...ature is too high a Oil is too thin b Pump cavitation c Valve body internal relief 1 Discharge and clean and add new hydraulic oil 2 Check the oil inlet piping for air leaks 3 Replace the valve body 4...

Page 105: ...Check valve Filter Cylinder Single acting direction Service line Supply line or return line Cylinder D o u b l e a c t i n g direction Control line Drain line Relief valve Connecting pipe Solenoid Val...

Page 106: ...92 REV 07 2016 HYDRAULIC SYSTEM 7...

Page 107: ...93 8 8 ELECTRICAL SYSTEM...

Page 108: ...94 NOTE...

Page 109: ...or Pump controller mainly used for the control of pump motor Steering controller mainly used for the control of steering motor SICOS controller mainly used for the control of instrument communication...

Page 110: ...remove the solenoid valve controller 6 Unscrew the four screws 7 with a wrench and remove the steering controller 8 Installation Apply appropriate amount of thermal grease on the back of controller Pl...

Page 111: ...n A 5 GND Negative console power supply A 6 12V Positive console power supply A 7 FLASH It must be connected to A8 for the Flash memory programming A 8 FLASH It must be connected to A7 for the Flash m...

Page 112: ...Electrode Terminal stud Pin No Signal Name Description B Negative of the battery B Positive of the battery FU FV FW Connection bars of the three motor phases follow this sequence and the indication on...

Page 113: ...smission A 5 GND Negative console power supply A 6 12V Positive console power supply A 7 FLASH It must be connected to A8 for the Flash memory programming A 8 FLASH It must be connected to A7 for the...

Page 114: ...n No Signal Name Description D 1 5V 12V positive of encoder power supply D 2 GND negative of encoder power supply D 3 A phase A of encoder D 5 B phase B of encoder E Interface Pin No Signal Name Descr...

Page 115: ...Bus Low Connected to solenoid valve controller RVF NRVF Connected to pump controller RV NRV A 7 KEY Key Switch Signal Input Port A 8 CPOC2 QL Stepper Motor Q line A 9 CPOC1 DL Stepper Motor D line A...

Page 116: ...e power supply C 7 FLASH It must be connected to A8 for the Flash memory programming C 8 FLASH It must be connected to A7 for the Flash memory programming B Interface Pin No Signal Name Description B...

Page 117: ...t Port A 16 Seat Switch Positive Electrode 48V B Interface RVF NRVF Pin No Signal Name Description B 1 Lifting Lowering Signal Input Port B 2 Lifting Lowering Potentiometer Sliding Access Port B 3 Lif...

Page 118: ...ing Translation Negative Electrode C Interface RV NRV Pin No Signal Name Description C 1 Tilting Signal Input Port C 2 Forward Reverse Signal Input Port C 3 Forward Reverse Positive Electrode 5V C 6 T...

Page 119: ...TT Power Supply Negative Electrode B 6 PAUX Power Supply Positive Electrode A Interface Pin No Signal Name Description A 2 I3 Reset Switch Signal Input Port A 4 I5 Forward Shifting Limit Switch Signal...

Page 120: ...Forward Shifting Solenoid Valve Coil Negative Electrode A 7 NEV2 Lifting Solenoid Valve Coil Negative Electrode A 8 NEV1 Lowering Solenoid Valve Coil Negative Electrode A 9 PEV Left Shifting Solenoid...

Page 121: ...g Fan 5 Instrument 6 Horn 7 Warning Light 8 Headlight Failure Normal 8 2 Fuse The entire vehicle is installed with three fuses altogether When there is fuse failure the truck may not be able to run pr...

Page 122: ...to OFF remove key pull out the battery plug and disconnect the power supply Set the multimeter to resistance measure ment with black probe connected to one end of the fuse red probe connected to anot...

Page 123: ...e the cables and wiring harness on the main contactor and remove the main contactor from the electrical mounting plate Unscrew the two fastening screws 4 with a Phillips screwdriver and remove the top...

Page 124: ...esistance on the multimeter As shown in the following table Resistance Measurement Judgment Approx 145 Normal 0 Coil shorting replace the contactor Coil breaking replace the contactor Contact Checks C...

Page 125: ...r bolts 8 and remove the switch mounting plate 10 Unscrew the four screws 11 and remove the reset switch 9 Make sure the lifting equipment is solid and secure and the load capacity should be greater t...

Page 126: ...should be 12V Testing 8 4 4 Control Circuit Troubleshooting Height Display Control Circuit Figure 90513 Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 88 8...

Page 127: ...e sure it is fully seated in the mounting slot of the switch seat CAUTION Adjustment The direction of roller lever seat 5 can be adjusted through adjusting the adjustment screw 8 The sensing distance...

Page 128: ...FF normally open NO terminal with a multimeter with handwheel at natural position Terminal 3 and 4 not conducted toggle the handwheel Terminal 3 and 4 conducted Check the ON OFF normally closed NC ter...

Page 129: ...g Speed Reduction Switch Control Circuit Figure 90515 Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 103 104 circuit circuit between lifting speed reductio...

Page 130: ...Unscrew the two bolts with wrench and remove the accelerator pedal from the chassis Installation Install according to the reverse order of rem oval See Section 3 1 for mounting position of acce lerat...

Page 131: ...timeter as shown in the following table Testing Check if the accelerator pedal and its wiring harness are in good condition and if the connectors are connected securely Accelerator pedal at original p...

Page 132: ...s off Cause a Foot switch failure b Foot switch shorted short circuit 2 Fault Foot switch pressed the vehicle cannot travel foot switch indicator on the instrument is on Cause a Foot switch failure b...

Page 133: ...Control Circuit Troubleshooting Foot Switch Control Circuit Figure 90517 Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if 27 30 circuit circuit between foot...

Page 134: ...e a voltage of 48V between converter interfaces 3 and 18 if there is voltage output of 12V between interfaces 93 and 94 the converter is working properly if the output voltage is not 12V the converter...

Page 135: ...rding to the reverse order of rem oval Checking Check if the appearance of warning light headlight and its wiring harness are in good condition and if the connectors are connected securely 8 9 3 Check...

Page 136: ...ntroller won t start when the vehicle is started only when the temperature of the controller reaches 46 degrees the fan will then be running Checking Check the cooling fan for blockage of foreign bodi...

Page 137: ...Fan at Controller Control Circuit Figure 90527 Check if the circuit is broken by using a multi meter Set the multimeter to ON OFF Check if the 3 105 circuit circuit between fan and pump controller is...

Page 138: ...switch and its wiring harness are in good condition and if the connectors are connected securely Repeatedly press the seat switch to check if it can reset properly 8 11 3 Checking and Testing Enter TE...

Page 139: ...G 8 12 Instrument Hydraulic action display area Speed model display area Foot Switch Display Area Power capacity display area OK ENTER button PageUp button EXIT button Steering display area Height dis...

Page 140: ...orward shift retracting switch I10 Check left shifting right shifting switch I11 Check forward tilting backward tilting switch tester 2 TRACTION ACCEL 0 37 VOLT LIFT LOW POT 2 49 VOLT FEACH FW REV POT...

Page 141: ...Description CURRENT TRACTION Check the current of drive motor VOLTAGE TRACTION Check the voltage of drive motor FREQUENCY TRAC Check the speed of drive motor TEMPERATURE TR Check the temperature of dr...

Page 142: ...0 03 27 6 4 00000 02 27 1 5 00000 07 27 5 ALARMS Menu Code Description ALARMS 1 Fault information HOURS Runtime of the most recent failure NUM Number of the same fault occurs NTC Controller temperatur...

Page 143: ...ptional Handheld unit must be used together with con troller if necessary it can be purchased from our company or dealer Navigation button EXIT Display Power button Parameter adjustment button Enter O...

Page 144: ...hing OK select ENTER the menu PARAMETER CHANGE parameter change TESTER vehicle running test ALARMS error alrms PROGRAM VACC accelerator match SAVE PARAMETERS read parameter RESTORE PARAMETERS write pa...

Page 145: ...ltage of travel switch Display the current voltage V MOTOR TEMPERAT Check motor temperature Display the current temperature TEMPERAT URE Check the temperature of controller Display the current tempera...

Page 146: ...NDSTROKE ACW ENDSTROKE CW ENC SPEED Check the speed of steering motor Display the current frequency Hz MOTOR CURRENT Check the current of steering motor Display the current value A MOTOR VOLTAGE Check...

Page 147: ...e the logic If the alarm disappears remember that the parameters stored previously have been cancelled and replaced by the default values LOGIC FAILURE 1 This alarm signals that an undervoltage overvo...

Page 148: ...dby Possible causes A problem with the motor connections or the motor power circuit check if the 3 phases are correctly connected check if there s a dispersion of the motor towards ground B inverter f...

Page 149: ...CONTACTOR DRIVER When the initial diagnosis is finished the traction logic closes the MC and checks the voltage on the Drain of the driver If this is not low an alarm is signalled Replace the logic CO...

Page 150: ...led check the connection of the sensors PEDAL FAILURE This alarm can be activated on request and it is signalled if the accelerator signal is out of the range Possible cause an hardware problem on the...

Page 151: ...o p e n T h e SAFETY circuit gets active and opens the drivers of LC and EB and stops the machine Verify the SAFETY input connection SAFETY KO This alarm is present in combi systems traction pump If a...

Page 152: ...s necessary to replace the controller 17 LOGIC FAILURE 3 This alarm occurs in the rest state if the output of the voltage amplifier of the phase Vu Vw have a drift larger than 0 25 V It is necessary t...

Page 153: ...motor higher than 150 degree still with DIAG MOTOR TEMP to ON Check the thermal sensor in the motor is right working If it is improve the cooling of the motor 70 HIGH CURRENT This alarm occurs if the...

Page 154: ...pot 85 STEER HAZARD This is just a warning to inform that the steering controller is limiting the angle in the steering direction No speed reduction occurs on the traction 218 CLOCK PAL NOT OK The ma...

Page 155: ...the stator voltage phasor rotates in the opposite direction respect to the sign of the stepper motor speed this alarm occurs Closed loop application only If the slave uC detects the stator voltage ph...

Page 156: ...lowers an input for the slave uC SYNC When the slave uC detects no edge for more than 100 msec on this input this alarm occurs This is just a watch dog function when the main uC does not execute the c...

Page 157: ...It occurs at the initial alignment if the straight ahead condition is not matched within 6sec Throughout this 6 secs delay the steer is not activated yet the safety relays are open and the traction is...

Page 158: ...he acquiring the motor resistance or when adjusting the parameters to compensate for the gain of the current amplifiers maximum current factory adjusted Recycle the key 244 GAIN EEPROM KO The paramete...

Page 159: ...5 Vdc to 5 5 Vdc Check the connections of the potentiometer This alarm occurs when one connection of the command potentiometer is broken 249 F B OUT OF RANGE This alarm occurs for a fault on the feedb...

Page 160: ...t when the safety contacts are open K1 is expected being connected to a battery voltage not 12 V Search for a harness problem or replace the controller 254 KS CLOSED This alarm occurs if the main uC d...

Page 161: ...CAN BUS don t communicate correctly CHECK UP NEEDED Programmed maintenance request EEPROM KO EEprom parameters managing error CLEARING EEPROM Appears when pressing the buttons EP DOWN ENTER at key swi...

Page 162: ...e fault continues when the Key Switch is re cycled replace the logic If the fault disappears the previously stored Parameters will have been replaced by the default parameters CAN BUS KO There is a pr...

Page 163: ...EV 07 2016 ELECTRICAL SYSYTEM 8 149 8 15 Electrical Schematic Diagrams RVF NRVF 8 15 1 Electrical Schematic Diagram RVF NRVF 1 6 Emergency Switch Key Switch FAN Horn Switch Horn Warning Light Headligh...

Page 164: ...8 15 2 Electrical Schematic Diagram RVF NRVF 2 6 LIFT LOWER REACH IN TILT LOWER SIDE SHIFT L SIDE SHIFT R TILT LIFT REACH OUT LIFT LOWER EN REACH EN LIFT LOWER POT REACH POT TILT EN TILT POT SIDE SHIF...

Page 165: ...REV 07 2016 ELECTRICAL SYSYTEM 8 151 8 15 3 Electrical Schematic Diagram RVF NRVF 3 6 ACCELERATOR SW ACCELERATOR TEMP SENSOR MC EM BRAKE...

Page 166: ...REV 07 2016 ELECTRICAL SYSYTEM 8 152 8 15 4 Electrical Schematic Diagram RVF NRVF 4 6 SPEED RED TEMP SENSOR...

Page 167: ...REV 07 2016 ELECTRICAL SYSYTEM 8 153 8 15 5 Electrical Schematic Diagram RVF NRVF 5 6 ENCODER SPEED RED LOWER REACH OUT REACH IN TILT LOWER LIFT TILT LIFT SIDE SHIFT R SIDE SHIFT L...

Page 168: ...REV 07 2016 ELECTRICAL SYSYTEM 8 154 8 15 6 Electrical Schematic Diagram RVF NRVF 6 6 VCC CHA CHB GND...

Page 169: ...REV 07 2016 ELECTRICAL SYSYTEM 8 155 8 16 Electrical Schematic Diagrams RV NRV 8 16 1 Electrical Schematic Diagram RVF NRVF 1 5 Emergency Switch Key Switch FAN Horn Switch Horn Warning Light Headlight...

Page 170: ...REV 07 2016 ELECTRICAL SYSYTEM 8 156 8 16 2 Electrical Schematic Diagram RVF NRVF 2 5 LIFT TILT SIDE SHIFT REACH SEAT SW BACK FORW...

Page 171: ...REV 07 2016 ELECTRICAL SYSYTEM 8 157 8 16 3 Electrical Schematic Diagram RVF NRVF 3 5 ACCELERATOR SW ACCELERATOR TEMP SENSOR MC EM BRAKE...

Page 172: ...REV 07 2016 ELECTRICAL SYSYTEM 8 158 8 16 4 Electrical Schematic Diagram RVF NRVF 4 5 SPEED RED TEMP SENSOR...

Page 173: ...REV 07 2016 ELECTRICAL SYSYTEM 8 159 8 16 5 Electrical Schematic Diagram RVF NRVF 5 5 VCC CHA CHB GND...

Page 174: ...Name 1 Power Supply Cable 2 Cable Positive Electrode 3 Cable Negative Electrode 4 Pump Motor Cable U 5 Pump Motor Cable V 6 Pump Motor Cable W No Name 7 Drive Motor Cable U 8 Drive Motor Cable V 9 Dri...

Page 175: ...ame 1 Power Supply Cable 2 Cable Positive Electrode 3 Cable Negative Electrode 4 Pump Motor Cable U 5 Pump Motor Cable V 6 Pump Motor Cable W No Name 7 Drive Motor Cable U 8 Drive Motor Cable V 9 Driv...

Page 176: ...REV 07 2016 ELECTRICAL SYSYTEM 8 162 8 19 Wiring Harness and Connectors RVF NRVF...

Page 177: ...REV 07 2016 ELECTRICAL SYSYTEM 8 163 8 20 Wiring Harness and Connectors RV NRV...

Page 178: ...REV 07 2016 ELECTRICAL SYSYTEM 8 164...

Page 179: ...165 9 9 TROUBLESHOOTING...

Page 180: ...166 NOTE...

Page 181: ...battery voltage is normal according to the measured voltage As shown in the following table Battery Voltage Judgment 48V Greater than 48V Normal Less than 48V Needs to be charged i Enter TESTER Menu...

Page 182: ...t code information on the instrument see Section 8 14 1 Check if the foot switch and seat switch or the connection of its circuit is normal See Section 8 7 and Section 8 11 2 Electromagnetic brake and...

Page 183: ...Pump motor works 1 Refer to the rated capacity marked on the nameplate 2 Lower the mast to the bottom check if the amount of oil in the oil tank can meet the requireme nts see Section 2 2 3 3 Check t...

Page 184: ...rs 3 Adjust the side roller spacing through roller screw or replace the roller 4 Replace the accumulator Under the circumstances of normal lifting and lowering if failure occurs to any of other hydrau...

Page 185: ...conducted Check the light and its circuit connection see Section 8 9 2 Horn does not sound a Horn switch or its circuit connection failure b Horn failure 1 Check the horn button and its connection cir...

Page 186: ...REV 07 2016 TROUBLESHOOTING 9 172...

Page 187: ...173 APPENDIX...

Page 188: ...174 NOTE...

Page 189: ...175 A A SERVICE MANUAL MAST...

Page 190: ...176 NOTE...

Page 191: ...shifting tubing and mast tubing Remove the connections between forward shift cylinder and the mast mounting base see Section 7 8 Unscrew the screw 1 and remove the forward shift safety block 2 from th...

Page 192: ...adjusting nut 9 in the middle the chain will slowly tension When the chain is adjusted to be tensioned with no obvious loosening fasten the upper and lower lock nuts When the adjustment is completed...

Page 193: ...d chain joint 6 Remove the cotter pin 3 and flat washer 8 pull out the pin shaft 4 separate the chains 5 from the chain joint 1 on outer mast Remove the chain assembly from the chain sprocket Replace...

Page 194: ...07 2016 SERVICE MANUAL MAST A A1 3 Mast Tubing Code Description A Lifting Lowering Mast Tubing B Forward Tilting Mast Tubing C Backward Tilting Mast Tubing D Left Shift Mast Tubing E Right Shift Mast...

Page 195: ...to avoid the falling of cylinder during removal resulting in personal injury CAUTION Unscrew the mounting bolt 8 from the bottom of the cylinder Unscrew the bolt 6 lift the cylinder 5 up and remove it...

Page 196: ...same specifica tions Replace the problem parts and assembly in reverse steps Use suitable hose clamps to avoid cylinder deformation caused by severely tight hose clamp Carry out the maintenance work i...

Page 197: ...ic oil may damage truck parts and cont aminate the environment When removing joints or tubings place a clean container under it for discharge of hydraulic oil CAUTION Unscrew the four 4 bolts 5 Figure...

Page 198: ...6 Built in Side Shifter A1 6 1 Side Shifter Removal Shift the mast forward to the bottom press the emergency stop switch and disconnect the key switch Block the truck wheel with wooden wedge Unscrew t...

Page 199: ...t the piston 2 from the side shift bracket Hammer out the end cap 4 and remove the dust ring 3 from the end cap Remove the retaining ring 5 and seal 6 on the cylinder tube Clean with hydraulic oil of...

Page 200: ...bing and right shifting tubing and mast tubing Remove the connections between forward shift cylinder and the mast mounting base see Section 7 8 Unscrew the screw 1 and remove the forward shift safety...

Page 201: ...t 9 in the middle the chain will slowly tension When the chain is adjusted to be tensioned with no obvious loosening fasten the upper and lower lock nuts When the adjustment is completed there sh ould...

Page 202: ...mast chain hanging plate screw the adjusting nut 9 and lock nut 2 Adjust the chains according to Section A2 2 1 A2 2 2 1 Mast Chains Block the truck wheels with wooden wedges raise the fork carriage f...

Page 203: ...189 REV 07 2016 SERVICE MANUAL MAST A...

Page 204: ...190 REV 07 2016 SERVICE MANUAL MAST A...

Page 205: ...191 REV 07 2016 SERVICE MANUAL MAST A A2 3 Mast Tubing Code Description A Lifting Lowering Mast Tubing...

Page 206: ...192 REV 07 2016 SERVICE MANUAL MAST A Code Description B Forward Tilting Mast Tubing C Backward Tilting Mast Tubing D Left Shift Mast Tubing E Right Shift Mast Tubing...

Page 207: ...ers at both ends for supporting Remove the tubing 5 Figure 90614 to make it separate from the direct coupling 6 Hydraulic oil may damage truck parts and contaminate the environment When removing joint...

Page 208: ...seals are aged or damaged please replace the complete set of seals CAUTION Secure the cylinder to hose clamp and gently clamp the cylinder bottom Unscrew the cylinder cap 4 Figure 90607 with cylinder...

Page 209: ...he piston rod 1 from the cylinder tube 6 If the piston rode or cylinder tube is damaged please replace the entire cylinder If the seals are aged or damaged please replace the complete set of seals CAU...

Page 210: ...rts and contaminate the environment When removing joints or tubings place a clean container under it for discharge of hydraulic oil CAUTION Slightly raise the side shifter 2 unscrew the two bolts 5 Fi...

Page 211: ...2 6 Built in Side Shifter A2 6 1 Side Shifter Removal Shift the mast forward to the bottom press the emergency stop switch and disconnect the key switch Block the truck wheel with wooden wedge Unscrew...

Page 212: ...the seals are aged or damaged please replace the complete set of seals CAUTION Unscrew the four bolts 16 and remove the two adjustable lower hooks 13 Remove the lower side shift bracket 19 upper slid...

Page 213: ...ng tubing and mast tubing Remove the connections between forward shift cylinder and the mast mounting base see Section 7 8 Unscrew the screw 1 and loosen the wheel shaft 5 Unscrew the nut 4 and remove...

Page 214: ...t 9 in the middle the chain will slowly tension When the chain is adjusted to be tensioned with no obvious loosening fasten the upper and lower lock nuts When the adjustment is completed there sh ould...

Page 215: ...mast chain hanging plate screw the adjusting nut 9 and lock nut 2 Adjust the chains according to Section A3 2 1 A3 2 2 1 Mast Chains Block the truck wheels with wooden wedges raise the fork carriage f...

Page 216: ...202 REV 07 2016 SERVICE MANUAL MAST A...

Page 217: ...203 REV 07 2016 SERVICE MANUAL MAST A...

Page 218: ...204 REV 07 2016 SERVICE MANUAL MAST A A3 3 Mast Tubing Code Description A Lifting Lowering Mast Tubing...

Page 219: ...205 REV 07 2016 SERVICE MANUAL MAST A Code Description B Forward Tilting Mast Tubing C Backward Tilting Mast Tubing D Left Shift Mast Tubing E Right Shift Mast Tubing...

Page 220: ...ers at both ends for supporting Remove the tubing 5 Figure 90621 to make it separate from the direct coupling 6 Hydraulic oil may damage truck parts and contaminate the environment When removing joint...

Page 221: ...seals are aged or damaged please replace the complete set of seals CAUTION Secure the cylinder to hose clamp and gently clamp the cylinder bottom Unscrew the cylinder cap 4 Figure 90607 with cylinder...

Page 222: ...he piston rod 1 from the cylinder tube 6 If the piston rode or cylinder tube is damaged please replace the entire cylinder If the seals are aged or damaged please replace the complete set of seals CAU...

Page 223: ...rts and contaminate the environment When removing joints or tubings place a clean container under it for discharge of hydraulic oil CAUTION Slightly raise the side shifter 2 unscrew the two bolts 5 Fi...

Page 224: ...3 6 Built in Side Shifter A3 6 1 Side Shifter Removal Shift the mast forward to the bottom press the emergency stop switch and disconnect the key switch Block the truck wheel with wooden wedge Unscrew...

Page 225: ...the seals are aged or damaged please replace the complete set of seals CAUTION Unscrew the four bolts 16 and remove the two adjustable lower hooks 13 Remove the lower side shift bracket 19 upper slid...

Page 226: ...ng tubing and mast tubing Remove the connections between forward shift cylinder and the mast mounting base see Section 7 8 Unscrew the screw 1 and loosen the wheel shaft 5 Unscrew the nut 4 and remove...

Page 227: ...t 9 in the middle the chain will slowly tension When the chain is adjusted to be tensioned with no obvious loosening fasten the upper and lower lock nuts When the adjustment is completed there sh ould...

Page 228: ...mast chain hanging plate screw the adjusting nut 9 and lock nut 2 Adjust the chains according to Section A4 2 1 A4 2 2 1 Mast Chains Block the truck wheels with wooden wedges raise the fork carriage f...

Page 229: ...215 REV 07 2016 SERVICE MANUAL MAST A...

Page 230: ...216 REV 07 2016 SERVICE MANUAL MAST A...

Page 231: ...217 REV 07 2016 SERVICE MANUAL MAST A A4 3 Mast Tubing Code Description A Lifting Lowering Mast Tubing...

Page 232: ...218 REV 07 2016 SERVICE MANUAL MAST A Code Description B Forward Tilting Mast Tubing C Backward Tilting Mast Tubing D Left Shift Mast Tubing E Right Shift Mast Tubing...

Page 233: ...ers at both ends for supporting Remove the tubing 5 Figure 90621 to make it separate from the direct coupling 6 Hydraulic oil may damage truck parts and contaminate the environment When removing joint...

Page 234: ...seals are aged or damaged please replace the complete set of seals CAUTION Secure the cylinder to hose clamp and gently clamp the cylinder bottom Unscrew the cylinder cap 4 Figure 90607 with cylinder...

Page 235: ...he piston rod 1 from the cylinder tube 6 If the piston rode or cylinder tube is damaged please replace the entire cylinder If the seals are aged or damaged please replace the complete set of seals CAU...

Page 236: ...rts and contaminate the environment When removing joints or tubings place a clean container under it for discharge of hydraulic oil CAUTION Slightly raise the side shifter 2 unscrew the two bolts 5 Fi...

Page 237: ...4 6 Built in Side Shifter A4 6 1 Side Shifter Removal Shift the mast forward to the bottom press the emergency stop switch and disconnect the key switch Block the truck wheel with wooden wedge Unscrew...

Page 238: ...the seals are aged or damaged please replace the complete set of seals CAUTION Unscrew the four bolts 16 and remove the two adjustable lower hooks 13 Remove the lower side shift bracket 19 upper slid...

Page 239: ...225 B B SERVICE MANUAL BATTERY...

Page 240: ...226 NOTE...

Page 241: ...rolyte overflow Only distilled water can be added the adding of tap water or mineral water is prohibited As for the decrease of battery capacity or even damage to the battery due to failure to comply...

Page 242: ...mpleted B1 2 4 Temperature Rated temperature of electrolyte is 30 C If the temperature is too high it will reduce the service life of the battery too low may reduce the battery capacity When the tempe...

Page 243: ...s less than 1 05 then that battery cell has been damaged and needs to be replaced CAUTION And you can identify if the battery is fully discharged according to the specific gravity of battery electroly...

Page 244: ...fficient Battery Charge 1 Low static voltage 2 Low density cannot meet the requirements after being charged 3 Short working time 4 When running the instrume nt displays quick drop of capacity 1 Charge...

Page 245: ...er discharge 3 Battery electrolyte is impure 1 Clean up the precipitation 2 Adjust the density 3 Battery needs to be replaced if necessary Battery overcharged 1 Color of battery filling cap becomes ye...

Page 246: ...uit 3 Large current discharge 4 Poor wiring connection or disconnected 5 Electrode plate corrosion 1 Battery needs to be repaired 2 Battery needs to be replaced if necessary Battery Reverse Electrodes...

Page 247: ...ns for use maintenance without using origi nal parts user corruption or violation of provisions when adding electrolyte and other circumstances the quality assurance will automatically void B2 2 1 Pre...

Page 248: ...ng measures the charging must be stopped when the temperature reaches 45 degrees When the battery voltage remains constant for more than 2 hours and the load voltage of the battery is within the speci...

Page 249: ...235 C C SCHEDULE...

Page 250: ...236 NOTE...

Page 251: ...or No Daily Check Items O K Remark Drive Wheel Load Wheel Casters Horn Warning Light Lifting Lowering Control Functions Optional Features Forward Reverse Control Functions Steering control functions B...