HELI gleen CQD15 Operation & Service Manual
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HELI gleen CQD15 Operation & Service Manual

Reach truck (stand-on type)
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  • Page 2 The G2 series 1.5-1.8t stand on type battery powered reach trucks are new offering of HELI to meet market needs. The new series is designed on the base of the advantages of some reach trucks made by domestic and foreign manufacturers. It has modern designed appearance, simple structure, comfortable operation, superior maneuvering performance and high lifting.
  • Page 3 bring the highest efficiency. The graphic illustrations such as pictures, drawings and parts characters and so on in the manual are not in real proportion because of the limit of space, so you can not get the size and weight accurately from the graphic illustrations which are to describe the correct operation methods of the devices and parts.

  • Page 4: Table Of Contents

    CONTENTS I. Safety Instructions of Operation and Driving……………………………………..1 II. External View of Reach Truck……………………………………………………6 III. Main Specifications………………………………………………………………7 IV. Construction and Principle of Reach Truck………………………………………8 4.1 Transmission system………………………………………………………..8 4.2 Steering system……………………………………………………………10 4.3 Supporting wheel assembly and brake system…………………...…………11 4.4 Hydraulic system………………………………………………………...….13 4.5 Lifting system………………………………………………………….……14 4.6 Electric system………………………………………...……………………18 4.7 lifting system…………………………………………………………30...

  • Page 5: Safety Instructions Of Operation And Driving

    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;...
  • Page 6 Figure 1-1 instrument and operation mechanism of high end truck model...
  • Page 7 Figure 1-2 Instrument and operation mechanism of standard truck model 1. brake pedal 2. Steering wheel 3. Key switch 4. Instrument 5,6 Automatic centering switch 7. Parking brake switch 8. Head lamp switch 9. Side shifting knob 10. Tilting knob 11.Front reaching knob 12.
  • Page 8 4.8 Check main fixing parts for tightness; 4.9 Make the trial of the mast for lifting, lowering, forward and backward tilting , side shifting and the truck for steering and braking. 5 Precaution in driving 5.1 Grasp the left leg when getting on the forklift truck. Do not grasp the steering wheel.
  • Page 9 5.12 When driving, be careful of the passersby, obstacles and rough road, and make sure there is enough clearance between the mast and the entrance. 5.13 Do not brake suddenly when it is travelling with load. 5.14 Before leaving the forklift truck, lower the fork fully, place levers in neutral, turn off the battery and pull the hand brake.

  • Page 10: External View Of Reach Truck

    II. External View of Reach Truck Figure 2-1 External view of stand-on type reach truck...

  • Page 11: Main Specifications

    III. Main Specifications CQD15 CQD18 Model GB2R GB3R GC2R GC3R GB2R GB3R GC2R GC3R Operation type Stand-on type Stand-on type Voltage /capacity V/Ah 48/345 48/360 Battery weight Parking brake Electromagnetic brake Electromagnetic brake Tyre type Polyurethane Polyurethane Ф254x114 Ф254x114 Support wheel size Ф330x114 Ф330x114 Driving wheel size...

  • Page 12: Construction And Principle Of Reach Truck

    IV. Construction and Principle of Reach Truck 4.1 Transmission system 4.1.1 Working principle The drive unit of the truck is compact and reasonable arranged. Please see table 1 for its main performance parameters and figure 4-1-1 for structure. The working principle is that the output shaft of the motor is connected with drive gear through spline housing, positioned through spline and fixed through lock nut.
  • Page 13 Figure 4-1-1 Drive unit 1. transmission box case 24. retainer ring 28 47. plug 1/2‟ 2. case cover 25. spline housing 48. screw M12X40 3.drive axle 26. lock nut 49. plate 4. tighten but 27. Screw M6X14 50. Bolt M12X30 5.
  • Page 14 4.1.2 Disassembling of steering motor Remove the 3 M6 screws on steering motor; pull the steering motor from steering gear box. 4.1.3 Disassembling of driving motor Remove the 6 M12 bolts on the driving motor and then pull the driving motor from the gear box.

  • Page 15: Steering System

    4.3 Steering system Steers by steering wheel Steering system type Steering motor 48V 0.6kw 2275rpm Deceleration ratio of steering 1:25.83 gear box Deceleration ration of gear 1:5.85 transmission Control type φ200mm Steering wheel diameter The steering system consists of a steering wheel assembly, a electric steering controller, a steering motor, a steering reduction mechanism and so on.
  • Page 16 Figure 4-3-1 Steering wheel 1. Steering wheel 2. Steering spindle 3. Spring 4. Steering racket assembly 5. bearing 6002-RS 6. Elastic coupling 7. Steering angle sensor 4.3.2 Steering deceleration mechanism The steering deceleration mechanism (figure 4-3-2) realizes the deceleration of steering motor.

  • Page 17: Hydraulic System

    4.4 Supporting wheel assembly The truck is a kind of truck with four supporting points. The front supporters are two symmetric distributed support wheels. See figure 4-4-1. 1. Drive wheel 2. Small castors 3. Chassis assembly 4. Front support wheel assembly Figure 4-4-1 Diagram of reach truck four supporting points The supporting wheel (see figure 4-4-2) is mainly made up of supporting wheel, 2 rollers, retainer ring 40, nut M40X1.5, bolt M8X16, washer 8, cover plate and front...
  • Page 18 1. support wheel 2. roller 110×50×27 3. Roller 90×40×23 4. retainer ring 40 5. Nut M40×1.5 6. Bolt M8×16 7. Washer 8 9. front wheel shaft Figure 4-4-2 Support wheel assembly 4.5 Brake system 4.5.1 Service brake The truck adopts AC type traction motor‟s current regenerated brake. There are two ways to apply service brake: one is to release driving operation knob and this way has weak brake strength.
  • Page 19 1. driving operation knob 2. Brake pedal Figure 4-5-1 service brake 4.5.2 Parking brake Electromagnetic parking brake which is on the top of the shaft end cover of the AC type traction motor is applied on the truck (see figure 4-5-2). The friction disc is together with motor shaft.
  • Page 20 Electromagnetic brake Figure 4-5-2 Drive unit diagram 1. electromagnetic parking brake 2. Socket head cap screw M8x16 3. washer 8 4. Shim 8 5. Key A8×7×15 6. Retainer ring 25 See figure 4-5-2 and figure 4-5-3 for electromagnetic parking brake assembling. (1) Fix the electromagnetic parking brake (item 1) onto the top of the shaft end cover...
  • Page 21 of the traction motor with 3 socket head cap screws M8x16 (item 2). The tighten torque of the screw is 25Nm and apply anaerobic adhesive GY-340. (2) Fix the friction disc built-in spine sleeve of the electromagnetic parking brake with travelling and traction motor shaft through key 8x25 (item 1).
  • Page 22 4.6 Hydraulic system TMG1H15 Model Type Gear pump 15ml/r Nominal displacement Rated pressure 20.6MPa Hydraulic pump Highest pressure 22MPa Oil temperature -20℃～100℃ Hydraulic oil（mineral oil），viscosity ：9～430mm Applicable oil Suction pressure -0.02～0.1MPa Model Q61K7-30401 proportion control on lowering Control valve Front and rear reach with balance valve （electromag Function Tilting self lock valve...
  • Page 23 cylinder, side shifting cylinder pipelines and so on. According to different control valve type, hydraulic system for high end truck (with electromagnetic control valve) and hydraulic system for standard truck model ( with manual control valve) are included. See figure 4-6-1 and 4-6-2. Figure 4-6-1 hydraulic system principle diagram for high end truck...
  • Page 24 Figure 4-6-2 hydraulic system principle diagram for standard truck model 4.6.1 Hydraulic oil tank The hydraulic oil tank is used to store oil and besides it can dissipate heat in the oil (when the environment temperature is low, it can be used to keep the heat in the oil), dispel the gas in the oil and sediments dirt in the oil.
  • Page 25 Figure 4-6-3 hydraulic oil tank 1. Hydraulic oil tank 2. Oil tank cover assembly 3. Ventilation cap 4. Oil adding cover assembly 5. Bolt M8x20 6. Combined washer 8 9. Magnet φ68/φ37x4 7. Gasket for oil tank cover 8. Oil return filter 10.
  • Page 26 pipe to fill the gears. With the rotation of chamber, gears bring the oil into the left chamber from right chamber to make the pressure of the left chamber increase and the oil goes out from the oil discharging port. Because the gears keep going, the oil suction port and oil discharging port keep sucking oil and discharging oil.
  • Page 27 1. electromagnetic valve for lifting 2. electromagnetic valve for reaching forward 3. electromagnetic valve for tilting backward 4. electromagnetic valve for left shifting 5. electromagnetic proportional valve for lowering control 6. Emergency manual lowering valve 7. electromagnetic valve for drawing back 8.
  • Page 28 (4) Drawing back: the electromagnetic valve for drawing back gets electricity; (5) Tilting forward: the electromagnetic valve for tilting forward gets electricity; (6) Tilting backward: the electromagnetic valve for tilting backward gets electricity; (7) Left shifting: the electromagnetic valve for left shifting gets electricity; (8) right shifting: the electromagnetic valve for right shifting gets electricity;...
  • Page 29 6. Connection port for oil tank 7.safety valve 8. Lifting speed regulating sensor Figure 4-6-6 Structure for manual control valve B) The functions of the valve are followed: (1) Lifting and lowering valve: it controls mast lifting and lowering; (2) Reaching forward valve: it controls mast reaching forward and drawing back. (3) Tilting valve: it controls mast tilting forward and backward.
  • Page 30 the fork will shift to the right and it will shift to the left when pushing forward. 2) Operation of manual control valve The manual control valve is operated through operation knobs. See figure 4-6-8. All operation knobs are installed on a connecting shaft and the shaft is fixed on truck‟s floor board through bracket.
  • Page 31 According to the arrow directions shown in figure 4-6-9, push forward or pull back the knob for lowering and lifting and the mast will lower down or lift up; push forward or pull back the knob for tilting, the mast will tilt forward or backward respectively;...
  • Page 32 Figure 4-6-10 Structure of front lifting cylinder 1. Plunger rod 2. Dust proof ring 3. Cylinder cover 4. Separate blade 5. Seal ring for axle 6. O ring 7. Separate blade 8. O ring 9. Shim 10. Screw 11. Support ring 12.
  • Page 33 Figure 4-6-12 Pipeline anti-bursting valve structure 1. valve body 2. Guide shaft 3. Spring 4. Separate blade 4.6.6 Front reach cylinder The front reach cylinder is of piston type double acting hydraulic cylinder to realize mast moving backward and forward. The front reach cylinder is made up of piston, piston rod, cylinder body, cylinder bottom, guide sleeve and sealing parts.

  • Page 34: Lifting System

    Figure 4-6-14 Tilting cylinder structure 1. Piston rod 2. Retainer ring 3. Bearing 4. Dust proof ring 5. Guide sleeve 6. O ring 7. Bearing 8. Separate blade 9. Separate blade 10. O ring 11. Seal ring for axle 12. Retainer ring 13.
  • Page 35 masts have I-shape cross section and the outer mast has C-shape cross section. (see fig. 4-7-1). The support seat axles of outer mast two sides are supported by mast half. The lower end of outer mast is connected with mast support through tilting cylinder and the weight is supported by mast seats through seat axles.
  • Page 36 Figure 4-7-1 Cross section of mast The inner mast, outer mast and middle mast are welded structure. The middle of the outer mast is installed onto the mast support through support axle and the bottom of the outer mast is connected to the mast support through connecting plate with bolt. The outer mast channel steel is of C type and combined roller is installed on its upper end.
  • Page 37 Side shifting device: hydraulic type Fork space adjusting device: manual type 2) Side shifter The side shifter is made up of side shifting rear bracket, side shifting front bracket and side shifting cylinder and so on. There are two pairs of combined roller, one pair of main roller and on pair independent side roller to ensure the stable moving of side shifter in the inner mast channel steel and bear vertical and lateral load.
  • Page 38 Side shifting rear bracket Side shifting front bracket Side shifting cylinder Figure 4-57-2 Side shifter structure 3) Roller position and adjusting There are two kinds of roller. One is combined rollerⅠwith inclined 1.3° and combined rollerⅡwith straight flange. Only the lower end of the middle mast uses combined rollerⅡwith straight flange and the other positions use combined rollerⅠwith inclined 1.3°...
  • Page 39 combined rollerⅡ combined roller I Figure 4-7-3 combined roller installation instruction Figure 4-7-4 Combined roller structure 1. Main roller train 2. Side roller 3. Axle head 4. Adjusting shim 5. Retainer ring for axle Note: (a) Adjust the side roller clearance with adjusting shim. The clearance is about...
  • Page 40 0~0.5mm. (b) Apply grease to the surface of the roller and connecting surface with the mast. 4) Adjusting of lifting cylinder Readjusting the lifting cylinder travel distance according to the following method after changing the lifting cylinder, inner mast, middle mast and outer mast. Middle mast beam Adjusting shim Rear lifting cylinder...
  • Page 41 lower edge of the inner mast is 15-20mm. B). Lower the fork to the ground and tilt backward. Adjust the connector on the top of the chain. Adjust the nut to make the two chains have same tension. (The adjusting of the lifting cylinder is important and take care of its safety.) Chain End connector Adjusting nut...
  • Page 42 Cross section of inner mast channel steel: Figure 4-7-7 Cross section of mast channel steel The inner mast and outer mast are welded structure. The middle of the outer mast is installed onto the mast support through support axle and the bottom of the outer mast is connected to the mast support through tilting cylinder.
  • Page 43 Lifting: Chain: LH1234 Lifting system: hydraulic type Tilting device: hydraulic type Side shifting device: hydraulic type Fork space adjusting device: manual type 2) Side shifter The structure and functions of side shifter is the same with the one for three stage full free lift telescopic mast.

  • Page 44: Electric System

    cylinder , inner mast and outer mast. Refer to the methods for three stage full free lift telescopic mast. 5) Adjustment of chain tensioning 4.8 Electric System 4.8.1 General description The electric system is equipped with a whole AC control system. With the system, the control of the whole truck can be low noisy, high efficient, smooth and safe.
  • Page 45 2) ZAPI GRAPHIC instrument A) General description GRAPHIC DISPLAY is an intelligent instrument connected to the truck through CAN bus. The intelligent instrument offers truck working mode shifting and set of lifting height pre-selector (optional). The instrument is for GB2R truck model. B) ZAPI GRAPHIC instrument Figure 4-8-1 ZAPI GRAPHIC instrument (1) Fork height indicator (optional)
  • Page 46 arrows is highlighted. (5) Working mode indicator It shows current working mode. The working mode has “1-3” and turtle speed mode. (6) Speed display It shows current truck speed and the unit is km/h (7) Lifting/lowering lock indicator It shows lifting or lowering is locked. (8) Fault code indicator It shows the fault node and fault code.
  • Page 47 For example, the fault “79TR” in the figure below means: traction controller detects starting sequence order. Refer to fault code table for fault diagnosis or consult with HELI engineer. The definition of the control modules are followed:...
  • Page 48 Figure 4-8-5 ZAPI SMART instrument C) Instrument instruction: (1) Turn on the key switch and “HELI AC SYSTEM” is shown on the instrument and self checking is carried out. After self checking, normally, battery dump power, truck speed and hour meter are shown on the instrument.
  • Page 49 (2) Then, figure of steering wheel‟s steering angle is shown on the instrument in the place of hourmeter. (3) Display of safety and brake. When releasing pedal safety switch, the truck is under brake condition. At this time, the truck can not travel, but it can steer, lift, reach forward and backward and tilt.
  • Page 50 “ ALARM 79 ON NODE 2” means: the traction controller detects incorrect starting sequence. Refer to fault code table for fault diagnosis or consult with HELI engineer. The definition of the control modules are followed: Number of control module in CAN bus...
  • Page 51 Number of control module in Module CAN bus Traction controller Pump controller Steering controller Instrument A. Navigation key B. Battery dump power C. Speed D. Hourmeter E. Display of steer wheel angel F. Operation mode display G. Numeric keyboard H. Back I.
  • Page 52 ⑧-Neutral indicator ⑨-Warning light Figure 4-8-9 Jiacheng Intelligent instrument (1) Operation mode It shows current operation mode and there are four gears:1, 2, 3 and S. (2) Travelling speed It shows current truck travelling speed and the unit is KM/h or MPH. (3) Battery dump power It shows current battery dump power.
  • Page 53 When battery dump power is no more than 20%, low battery dump power indicator will turn on; when battery dump power is lower than 10%, the lifting lock indicator will be on. When the driver leaves the seat, the seat indicator will be on; when the parking brake switch is applied, the parking brake indicator will be on.
  • Page 54 d) controller protection degree:IP65; e) out of control protection f) battery over discharging protection g) Mis-starting protection (4) The following functions can be realized through controller‟s hand console: a) On line inspection and adjusting on traction and lifting control system b) On line correction on travelling accelerator and lifting speed adjusting signal c) Fault detection and inquiry on traction and lifting control system B) Steering motor controller for CQD 15/18-GB2R and CQD 15/18-GC2R...
  • Page 55 (4) EPS-ACO controller can achieves steering wheel automatic centering through function switch inching. And also the function can realized through turning on the electric lock. (5) The working environment temperature should be in the range of -30℃-40℃. The highest work temperature that is permitted is 85℃. (6) Protection function of the steering motor controller: a) Battery polarity protection;...
  • Page 56 (5) Functions: a) 16 bit microprocessor is mainly for main functions and safety functions. It has 384KB flash memory. b) It has 11 high level effective digital input terminals and 10 analog input terminals. c) It has 2 progressive increase encoder‟s terminals. d) It has 2 CAN communication terminals.
  • Page 57 Model of pump controller: Inmotion ACS48S -35P 48V/350A (1) ACE2 controller which is three phase AC asynchronism motor inverter controls traction motor and pump motor. It has regenerative brake function, CAN bus port and digital control function (based on motor speed feedback). (2) Allowable working environment temperature: -40 ℃...
  • Page 58 Sweden imported steering controller is installed on the truck which applies advanced electric powered steering control system. Steering motor controller type: Inmotion APS48M-70C-35P (1) APS48M-70C-35P controller applies high-frequency MOS technology. The control is not only reliable but also efficient, low cost, smooth and mute. (2) APS48M-70C-35P controller applies single-chip control system.
  • Page 59 Figure 4-8-15 VMC valve controller VMC30 is a new generation general type main controller of kollmorgen and it is for electric truck using CAN bus. All modules on electric truck can be integrated into a completed system for uniform control through I/O terminals and control functions of VMC 30.
  • Page 60 (10) USB connector and it is easier for system connection. (11) It has real time large capacity record back up. Note: ◆ Test the truck with four wheels raised after the controller being fixed, in that case there will be no danger even the connection is in error. ◆...
  • Page 61 A) Battery construction and specifications The battery is made up of + pole plate, - pole plate, separator, battery cover and electrolytic. CQD15 battery specifications (for GB2R、GC2R、GB3R、GC3R） Model 3PzS345 Capacity （C5） 345Ah Voltage Density of electrolyte 1.280-1.290g/cm3(25℃) Monadelphous number CQD15 battery specifications (for GB2R、GC2R、GB3R、GC3R） Model 4PzS360 Capacity(cs)
  • Page 62 more economical and reliable. Refer to the operation and service manual to avoid incorrect and unless operation. ○ 1 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. ○...
  • Page 63 temperature in a range of 5℃-40℃. ○ 2 Avoid exposing under the sunshine and drenching in the rain. Keep the battery more than 2m away from the heat source. ○ 3 Do not keep the battery upside down, or side or tossed or rolled, nor pressed heavily.
  • Page 64 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 Adopt Inefficient...
  • Page 65 1) Being unsuitable to the electrolytic quality standard Frequent discharging Clean charging or over Shedding 1) Decrease of the battery precipitate when charging off of the capacity the actuality is not discharging reactive 2) Turbid electrolytic severity. 3)High .electrolytic matter 3) Much precipitate 2) Discard when temperature when...
  • Page 66 (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.
  • Page 67 2. Over low or over high of battery voltage 3. Check if the cables on binding post such as B+, B and main contactor are firmly connected. 4. Check if the calibration parameter of the controller voltage agrees with the actual voltage. 5.

  • Page 68: Battery Low

    CHARGE capacitor charge the capacitor through a power resistance, and charging check if the capacitor is charged within a timeout. If this is not true and capacitor voltage is less than 20% of the battery voltgae: an alarm is signaled; the main contactor is not closed.
  • Page 69 function is locked. Charge the battery then. If the battery has electricity, check if the value of “ ADJUST BATTERY” agrees with the battery voltage. DRIVER Driver short When the key is turned off, the microprocessor SHORTED circuit will check if the driver of the main contactor has short circuit.
  • Page 70 Man-made operation can also cause the fault, so restart the truck. for example for the following operations: 1. Truck runs into barriers suddenly and the truck can not travel; 2. Brake suddenly when travelling with high speed; If the “2.5 POT” is programmed to be “ON”, the PROG VACC NOT Accelerator programming...
  • Page 71 INPUT fault contactor opens and electromagnetic or auxiliary output coil is driven. Check if the connection of A11 is correct. If all outskirt is all right, change the controller. COIL SHORTED Main Reason: when short circuit coil of the main contactor is contactor coil connected to can#16 output terminal, the fault occurs.

  • Page 72: Analog Input

    The max. current gain parameter is factory setting fault value. It means the max, current adjusting parameter program is not yet operated. Remedy: HELI technician set the correct program on current gain parameter. ANALOG INPUT Analog signal When A/D input by all analog signal is converted into a input fault fixed value, the fault occurs.
  • Page 73 SENS MOT TEMP Temperature Phenomenon: motor temperature sensor output signal sensor exceeds range. fault Remedy: check sensor value and wiring condition. If all is right, the interior of the controller has fault. SOFTWARE Software fault Causes of this fault are many, such as CAN bus fault, EEPROM FAULT and so on.
  • Page 74 B) Pump control system common fault Fault Meaning explanation Remedy code EEPROM KO Damage Fault in the area of memory in which the adjustment programmable parameters are stored; this alarm inhibits machine memorizer operation. If the defect persists when the key is switched OFF and ON again, replace the logic.
  • Page 75 voltage. Possible causes: 1. incorrect wiring or fault of motor circuit; check if the three phase connecting of the motor is correct; check if the motor to earth leaks; check if the motor coil has broken circuit. 2. Change controller STBY I HIGH HIGH The output signal of the current sensor tested by...
  • Page 76 the motor temperature reaches to 120℃，the truck still can travel but truck performance degrades because the max. current is reduced. when the temperature reaches to 125℃， the motor stops working. At this time, cool the motor. If the fault still occurs when the motor is cold, check the wirings.
  • Page 77 WAITING Wait for node One controller receives a signal that the other signal can NODE signal no t work normally and the controller is under waiting condition until all CAN bus are ok. Check the unable communicating module wiring; check its software edition and programming.
  • Page 78 converter fault or analog signal conversion. Fault analysis: if fault exists all the time, change the controller. WRONG Zero voltage VAM high terminal voltage feedback voltage is very ZERO VOLTAGE fault higher or lower than 2.5V, that means the controller circuit is broken.
  • Page 79 operation of truck. Remedy: turn off the key switch and turn it on again. if fault still occurs, change the controller. DATA Data When adjusting current gain, fault alarms. Nothing ACQUISITION acquisition need to be done. The fault will disappear after adjusting.
  • Page 80 three redundant locations in which it is recorded. It occurs also when the busy bit of the EEPROM does not rise within 12s. LOGIC FAILURE This alarm occurs in the rest Change the controller state if the output of the voltage amplifilter of the phase Vw-Vv have a drift larger than ±0.25V.
  • Page 81 of the current amplifilter at rest have a drift larger than ± 0.15v. HIGH This alarm occurs Improve cooling change TEMPERATURE temperature of the controller controller. base plate overtakes 75℃. MOTOR When DIAG MOTOR TEMP is 1. Check if the temperature sensor is TEMPERATURE temperature is higher than 2.
  • Page 82 CLOCK PAL NOT main encoder Change the controller disagrees with slave encoder. MICRO SLAVE #8 The main Uc encoder disagrees Change the controller with slave uC encoder. STEPPER MOTOR If the leading wire of D and Q Change the controller MISM are connected incorrectly, it will alarm.

  • Page 83: Position Error

    CURRENT GAIN The parameter is used to The alarm disappears after the fault is compensate current ampilifilter solved. parameter （ ADJUSTMENT#3 and ADJUSTMENT#4） NO SYNC Every 16ms, inside the code Change the controller cycle, the main uC rises and then lowers an input for the slave uC.

  • Page 84: Line Sensor

    the traction. It occurs at the work normally. initial alignment if the straight 1. Check the steering proximity switch ahead condition is not matched power. within 6s. throughout this 6s 2. Check the position of proximity delay, the steer is not activated switch sensing iron...
  • Page 85 uC is detecting a direction of the stepper motor not matched with the one the slave uC is detecting. Furthermore, this alarm occurs also if the main uC is detecting no limitation meanwhile the slave uC is detecting a steering limitation.
  • Page 86 expected being closed. KS CLOSED This alarm occurs if the main Change the controller uC detects the safety contact, of the slave uC, open when expected being closed. KM CLOSED This alarm occurs if the slave Change the controller uC detects the safety contact, of the main uC, closed when expected being open.
  • Page 87 PUMP VMN LOW INCORRECT START PUMP VMN HIGH FORW + BACK VMN LOW BAD STEER 0-SET VMN HIGH ENCODER ERROR VMN NOT OK BAD ENCODER SIGN NO FULL COND. STEER SENSOR KO RGT NO FULL COND STEER HAZARD LFT NO FULL COND PEDAL WIRE KO PU NO FULL COND PEDAL FAILURE...

  • Page 88: Troubleshooting

    wiring and connection. Otherwise, the fault is in the can interface of other module present on canbus network. “SERVICE REQUIRED” It is due to maintain the truck. “COIL SHORTD” This alarm occurs when there is a short circuit of the coil connected to output, so over current is produced on relative driver.
  • Page 89 LOGIC LOGIC FAILURE #1 FAILURE #1 Check if lifting and lowering Short circuit of OUT1/2 COIL SH. solenoid valve and outskirts wirings coil 1 and 2 short circuit. Check if lifting and lowering Short circuit of OUT3/4 COIL SH. solenoid valve and outskirts wirings coil 3 and 4 short circuit.
  • Page 90 encode signal No CAN communication Check the connection between NO CAN MSG.C to traction 3A11\3A12 and 1A20\1A21 controller Overtime of Turn on the key switch again and if NO CAN MSG.4 the fault still occurs, change the communication controller Incorrect control CONTROLLER ID code in Change controller...
  • Page 91 3) Fault diagnosis (for GB3R and GC3R truck model) Fault code Display on instrument Fault analysis （0-25 5） Before steering calibration is finished, ERROR: acceleration pedal acceleration pedal switch is connected. activated when starting. Please loose the acceleration pedal. Before steering calibration is finished, ERROR: direction switch...
  • Page 92 1. fault of lifting speed adjusting sensor or ERROR : the analog quantity the analog quantity of lifting needs to be exceeds the range. recalibrated. 2. fault of harness 1. Thumb switch fault of forward and ERROR: the analog quantity of backward reaching or the analog quantity forward and backward reaching needs to be recalibrated.
  • Page 93 ERROR: short circuit of traction check the power harness motor’s driver ERROR: high temperature The temperature is high and it needs to be traction driver cooled down. 1. The temperature is over high and it needs ERROR: high temperature to be cooled down. traction motor 2.
  • Page 94 1. check if the harness of output port has ERROR: output port fault of pump short circuit or open circuit ; driver 2. the driving coil has open circuit or short circuit. WARNING: over current or short circuit of pump driver 1.
  • Page 95 ERROR fault of steering motor‟s 1、fault of steering motor’s thermistor temperature sensor 2. harness fault ERROR: fault of steering driver‟s The temperature of steering driver is over temperature sensor high and over low 1. fault of steering contactor ERROR: fault of steering contactor 2.
  • Page 96 4.8.4 Routine maintenance Check the wear and connect condition of the contactor point. Check it every three months. Check the pedal and thumb 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.
  • Page 97 battery up. After the mast seat goes back completely, step on the lock pedal (refer to figure 4-8-18), pull the forward/backward operation switch forward, the battery is moving out with the reaching forward of the mast. At this time, the truck can not travel or carry out load operation.
  • Page 98 (2) Draw back the battery Push the forward/backward operation switch forward and make the mast reach forward. Make the left sliding block and right sliding block to be straight. Put the battery on the mast seat and make left and right sides of the battery have the same clearance with the truck frame.
  • Page 99 Figure 4-8-19：electric system principle diagram (for GB2R truck model)
  • Page 100 Figure 4-8-20：electric system principle diagram (for GC2R truck model)
  • Page 101 Figure 4-8-21：electric system principle diagram (for GB3R truck model)
  • Page 102 Figure 4-8-22：electric system principle diagram (for GC3R truck model)

  • Page 103: Troubleshooting

    V. Troubleshooting 5.1 Transmission system problem Possible cause Remedies too much clearance between Adjust the gears Loud noise of gears when driving much wear of the gears Replace lower oil level in oil tank Add oil too much clearance between Loud striking noise when Adjust the gears...

  • Page 104: Parking Brake System

    5.3 Parking brake system problem Possible cause Remedies Low electricity supply Adjust the electricity supply Break off of electricity supply Reconnect power supply over large of brake gas gap Readjust brake gas gap The parking brake can replace the brake and readjust not be released.

  • Page 105: Electric System

    electromagnetic wiring Disconnect of control knob Check and repair wiring Damage of forward/backward Replace tilting solenoid valve Damage tilting Replace backpressure lock Internal leakage of tilting Fork can not tilt forward and Replace sealing ring cylinder backward. Disconnect forward/backward Check and repair electromagnetic wiring Disconnect of control knob Check and repair...
  • Page 106 Long-working of the lifting abnormal working Check and repair motor lifting switch poor contact of the connector Check and change poor contact with the horn No working of the horn Check and repair switch broken horn Change Long-working of the horn long-contact of the horn switch Check and repair broken fuse...

  • Page 107: Maintenance

    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 transmission box, and tighten all fixing parts.
  • Page 108 3000h Replace it at High pressure Replace once when pipe damaged 6.2 Oil for forklift truck Trademark/code Trademark/code Name name(home) name(abroad) Hydraulic oil N40# ISOVG30 Gear oil 85W/90 SAE90/SAE80W 3# lithium base grease Lubricating grease JISK-2220, 1#，2# dropping point 170...
  • Page 109 6.3 Lubricating chart...

  • Page 110: Others

    VII. Others 7.1 The size and weight of the main takedown parts of the truck Parts name Parameters Unit Value Max. dimensions 1090*1260*665 Overhead guard Weight Max. dimensions 982*100*538 Fork Weight Max. dimensions 1620*400*756 Basic type mast (lifting height 2000mm) Weight Max.

  • Page 111: Mast Disassembly

    6000mm) Weight Three stage full free lifting mast (lifting height Max. dimensions 2847*410*790 6500mm) Weight Max. dimensions 1020*649*531 Battery 360Ah (for CQD18) Weight Max. dimensions 1020*629*531 Battery 360Ah (for CQD18/side pull battery ) Weight Max. dimensions 1020*649*451 Battery 345Ah (for CQD15) Weight Max.

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