EP Equipment CQD16RV Manuals

Manuals and User Guides for EP Equipment CQD16RV. We have 1 EP Equipment CQD16RV manual available for free PDF download: Service Manual

EP Equipment CQD16RV Service Manual

EP Equipment CQD16RV Service Manual (251 pages)

Electric Reach Truck

Brand: EP Equipment | Category: Trucks | Size: 9 MB

Table of Contents

Table of Contents
5
Section

15
Information & Specifications

15
- After-Sales Service Platform
  17
- Introduction
  18
- Common Tools
  19
- General Tightening Torques
  20
Maintenance

23
- Overview
  25
  - Maintenance
    26
    
    Cleaning
    26
    
    Inspection
    26
    
    Lubrication
    31
Structure & Functions

35
- Structure & Functions
  37
  - Travel Switch
    37
  - Emergency Stop Switch
    37
  - Key Switch
    37
  - Horn Button
    37
  - Control Switch (RVF/NRVF)
    38
  - Control Switch (RV/NRV)
    38
  - Instrument
    38
  - Horn
    38
  - Fan
    39
  - Accelerator Pedal
    39
  - Brake Pedal
    39
  - Foot Switch
    39
  - Warning Light
    40
  - Headlight
    40
  - Rocker Switch
    40
  - Stepper Motor
    40
  - AC2 Controller(Trancecontroller)
    41
  - AC2 Controller (Pump Controller)
    41
  - EPS-AC0 Controller
    41
  - DC-DC Converter
    41
  - Main Contactor
    42
  - Solenoid Valve Controller(RVF/NRVF)
    42
  - Multi-Way Solenoid Valve (RVF/NRVF)
    42
  - Multi-Way Manual Valve (RV/NRV)
    42
  - Pump Motor
    43
  - Gear Pump
    43
Section

45
Chassis System

45
- Load Wheel
  47
  - Removal and Installation
    47
  - Faults and Causes
    47
- Caster
  48
  - Removal and Installation
    48
- Brake Pedal
  49
  - Removal and Installation
    49
  - Faults and Causes
    50
- Seat
  50
  - Removal and Installation
    50
- Brakes
  51
  - Removal and Installation
    51
  - Faults and Causes
    52
Drive System

53
- Drive Wheel
  56
  - Removal and Installation
    56
  - Faults and Causes
    56
- Electromagnetic Brakes
  57
  - Removal and Installation
    57
  - Faults and Causes
    58
  - Checking and Testing
    58
  - Control Circuit Troubleshooting
    59
- Drive Motor
  60
  - Removal and Installation
    60
  - Faults and Causes
    60
  - Checking and Testing
    61
  - Control Circuit Troubleshooting
    62
- Gearbox
  63
  - Removal and Installation
    63
  - Faults and Causes
    63
- Proximity Switch
  64
  - Removal and Installation
    64
  - Faults and Causes
    64
  - Checking and Testing
    65
  - Control Circuit Troubleshooting
    65
- Steering Motor
  66
  - Removal and Installation
    66
  - Faults and Causes
    66
  - Checking and Testing
    67
Rev. 07/2016

67
Section

68
- Control Circuit Troubleshooting
  68
Operating System

69
- Control Lever
  71
- Control Panel
  71
- Horn Button
  72
  - Removal and Installation
    72
  - Faults and Causes
    72
  - Checking and Testing
    72
  - Control Circuit Troubleshooting
    72
- Control Switch (RVF/NRVF)
  73
  - Removal and Installation
    73
  - Faults and Causes
    73
  - Checking and Testing
    73
  - Control Circuit Troubleshooting
    74
- Control Switch (RV/NRV)
  76
  - Removal and Installation
    76
  - Faults and Causes
    76
  - Connection Mode
    76
  - Checking and Testing
    76
  - Control Circuit Troubleshooting
    77
- Stepper Motor
  79
  - Removal and Installation
    79
  - Faults and Causes
    79
  - Checking and Testing
    79
  - Control Circuit Troubleshooting
    79
- Key Switch
  80
  - Removal and Installation
    80
  - Faults and Causes
    80
  - Checking and Testing
    80
  - Control Circuit Troubleshooting
    80
- Emergency Switch
  81
  - Removal and Installation
    81
  - Faults and Causes
    81
  - Checking and Testing
    81
  - Control Circuit Troubleshooting
    81
- Rocker Switch
  82
  - Removal and Installation
    82
  - Faults and Causes
    82
  - Checking and Testing
    82
  - Control Circuit Troubleshooting
    82
Section

84
- Travel Switch
  84
  - Removal and Installation
    84
  - Faults and Causes
    84
  - Checking and Testing
    84
  - Control Circuit Troubleshooting
    84
Hydraulic System

85
- Overview
  87
  - Hydraulic Schematic Diagram RVF/NRVF
    88
  - Hydraulic Schematic Diagram RV/NRV
    89
- Hydraulic Power Unit
  90
  - Removal and Installation
    90
- Pump Motor
  90
  - Faults and Causes
    90
  - Checking and Testing
    91
  - Control Circuit Troubleshooting
    92
- Multi-Way Reversing Solenoid Valve (RVF/NRVF)
  93
  - Removal and Installation
    93
  - Interface Description
    93
  - Faults and Causes
    94
  - Checking and Testing
    94
  - Control Circuit Troubleshooting
    94
- Solenoid Valve (RVF/NRVF)
  95
  - Faults and Causes
    95
  - Checking and Testing
    95
  - Control Circuit Troubleshooting
    96
- Multi-Way Reversing Manual Valve (RV/NRV)
  97
  - Removal and Installation
    97
  - Interface Description
    98
  - Faults and Causes
    98
  - Checking and Testing
    98
- Gear Pump
  99
  - Removal and Installation
    99
  - Faults and Causes
    99
  - Checking and Testing
    99
- Reach Cylinder
  100
  - Cylinder Removal Precautions
    100
  - Cylinder Installation Precautions
    101
  - Removal and Installation
    102
  - Cylinder Maintenance
    103
Rev. 07/2016

103
Section

104
- Hydraulic Troubleshooting
  104
- Hydraulic Symbol
  105
Electrical System

107
- Controller
  109
  - Removal and Installation
    109
  - Controller Interface Function
    111
- Fuse
  121
  - Location of Fuses
    121
  - Checking and Testing
    122
- Main Contactor
  123
  - Removal and Installation
    123
  - Faults and Causes
    123
  - Checking and Testing
    124
  - Control Circuit Troubleshooting
    124
- Height Display (RVF/NRVF)
  125
  - Removal and Installation
    125
  - Faults and Causes
    125
  - Checking and Testing
    125
  - Control Circuit Troubleshooting
    126
- Limit Switch
  127
  - Removal and Installation
    127
  - Connection Mode
    127
  - Faults and Causes
    128
  - Checking and Testing
    128
  - Control Circuit Troubleshooting
    128
- Accelerator Pedal
  130
  - Removal and Installation
    130
  - Faults and Causes
    130
  - Checking and Testing
    130
  - Control Circuit Troubleshooting
    131
- Foot Switch
  132
  - Removal and Installation
    132
  - Faults and Causes
    132
  - Checking and Testing
    132
  - Control Circuit Troubleshooting
    133
- DC-DC Converter
  134
  - Removal and Installation
    134
  - Faults and Causes
    134
  - Checking and Testing
    134
  - Control Circuit Troubleshooting
    134
Section

135
- Warning Light / Headlight
  135
  - Removal and Installation
    135
  - Faults and Causes
    135
  - Checking and Testing
    135
  - Control Circuit Troubleshooting
    135
- Cooling Fan
  136
  - Removal and Installation
    136
  - Faults and Causes
    136
  - Checking and Testing
    136
  - Control Circuit Troubleshooting
    136
- Seat Switch
  138
  - Removal and Installation
    138
  - Faults and Causes
    138
  - Checking and Testing
    138
  - Control Circuit Troubleshooting
    138
- Instrument
  139
  - Instrument Operation Schematics
    139
- Handheld Unit (Optional)
  143
  - Handheld Unit Connection
    143
  - Handheld Unit Menu Options
    143
  - TESTER Menu
    145
- Controller Error Message
  147
  - Tractiong/Pump Controller
    147
  - Steering Controller (EPS-ACO)
    152
  - SICOS Controller
    161
  - Solenoid Valve Controller
    162
- Electrical Schematic Diagrams RVF/NRVF
  163
- Electrical Schematic Diagrams RV/NRV
  169
- Cable Wiring Diagrams (RVF/NRVF)
  174
- Cable Wiring Diagrams (RV/NRV)
  175
Section

176
- Wiring Harness and Connectors (RVF/NRVF)
  176
- Wiring Harness and Connectors (RV/NRV)
  177
Troubleshooting

179
- Preparation before Troubleshooting
  181
  - Check the Voltage of Battery
    181
- Troubleshooting Solutions of Common Faults
  182
Appendix

184
Appendix

187
A Service Manual - Mast

189
A1 Two-Stage Mast

191
- A1-1 Removal and Installation
  191
- A1-2 Lifting Chains
  192
  - A1-2.1 Chain Adjustment
    192
  - A1-2.2 Chain Replacement
    193
- A1-3 Mast Tubing
  194
- A1-4 Lift Cylinder
  195
- A1-5 Tilt Cylinde
  197
  - A1-5.1 Cylinder Removal
    197
  - A1-5.2 Cylinder Maintenance
    197
  - A1-5.3 Cylinder Installation
    198
- A1-6 Built-In Side Shifter
  198
  - A1-6.1 Side Shifter Removal
    198
  - A1-6.2 Side Shifter Installation
    198
  - A1-6.3 Side Shifter Maintenance
    199
A2 Three-Stage Mast(Lifting Height ≤ 7.5 M)

200
- A2-1 Removal and Installation
  200
- A2-2 Lifting Chains
  201
  - A2-2.1 Chain Adjustment
    201
  - A2-2.2 Chain Replacement
    202
    
    A2-2.2.1 Mast Chains
    202
    
    A2-2.2.2 Fork Carriage Chains
    202
- A2-3 Mast Tubing
  205
Section

207
- A2-4 Lift Cylinder
  207
  - A2-4.1 Cylinder Removal
    207
  - A2-4.2 Cylinder Maintenance
    208
  - A2-4.3 Cylinder Installation
    209
- A2-5 Tilt Cylinde
  210
  - A2-5.1 Cylinder Removal
    210
  - A2-5.2 Cylinder Maintenance
    210
  - A2-5.3 Cylinder Installation
    211
- A2-6 Built-In Side Shifter
  211
A3 Three-Stage Mast (8.0 M≤ Lifting Height ≤ 9.5 M) A3-1 Removal and Installation

213
- A3-2 Lifting Chains
  214
  - A3-2.1 Chain Adjustment
    214
  - A3-2.2 Chain Replacement
    215
    
    A3-2.2.1 Mast Chains
    215
    
    A3-2.2.2 Fork Carriage Chains
    215
- A3-3 Mast Tubing
  218
- A3-4 Lift Cylinder
  220
  - A3-4.1 Cylinder Removal
    220
  - A3-4.2 Cylinder Maintenance
    221
  - A3-4.3 Cylinder Installation
    222
- A3-5 Tilt Cylinde
  223
  - A3-5.1 Cylinder Removal
    223
  - A3-5.2 Cylinder Maintenance
    223
  - A3-5.3 Cylinder Installation
    224
- A3-6 Built-In Side Shifter
  224
  - A3-6.1 Side Shifter Removal
    224
  - A3-6.2 Side Shifter Installation
    224
  - A3-6.3 Side Shifter Maintenance
    225
A4 Three-Stage Mast(10 M≤ Lifting Height ≤ 11 M)

226
- A4-1 Removal and Installation
  226
- A4-2 Lifting Chains
  227
  - A4-2.1 Chain Adjustment
    227
  - A4-2.2 Chain Replacement
    228
    
    A4-2.2.1 Mast Chains
    228
    
    A4-2.2.2 Fork Carriage Chains
    228
- A4-3 Mast Tubing
  231
Section

233
- A4-4 Lift Cylinder
  233
  - A4-4.1 Cylinder Removal
    233
  - A4-4.2 Cylinder Maintenance
    234
  - A4-4.3 Cylinder Installation
    235
- A4-5 Tilt Cylinde
  236
  - A4-5.1 Cylinder Removal
    236
  - A4-5.2 Cylinder Maintenance
    236
  - A4-5.3 Cylinder Installation
    237
- A4-6 Built-In Side Shifter
  237
  - A4-6.1 Side Shifter Removal
    237
  - A4-6.2 Side Shifter Installation
    237
  - A4-6.3 Side Shifter Maintenance
    238
B Service Manual - Battery

239
B1 Lead-Acid Battery

241
- B1-1 Safety and Warnings
  241
- B1-2 Use of Battery
  241
  - B1-2.1 Pre-Use Checks
    241
  - B1-2.2 Discharging
    241
  - B1-2.3 Charging
    242
  - B1-2.4 Temperature
    242
- B1-3 Maintenance & Care
  242
  - B1-3.1 Daily Maintenance
    242
  - B1-3.2 Weekly Maintenance
    242
  - B1-3.3 Monthly Maintenance
    243
  - B1-3.4 Care
    243
- B1-4 Storage
  244
- B1-5 Troubleshooting
  244
B2 Maintenance-Free Battery

247
- B2-1 Safety and Warnings
  247
- B2-2 Use of Battery
  247
  - B2-2.1 Pre-Use Checks
    247
  - B2-2.2 Discharging
    247
  - B2-2.3 Charging
    248
- B2-3 Maintenance & Care
  248
C Schedule

249

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