EP Equipment CQD16 User manual

Service Manual

Electric Reach Truck

CQD16NRVF/NRV

CQD16/20RVF/RV

Service Manual

Electric Reach Truck

CQD16NRVF/NRV

CQD16/20RVF/RV

Release Date Version No. Changes (Serial number)

2016-07-07 SM-3316 07.16 New Version

This manual applies to:

Model Speciﬁcations

CQD16RV 1,600 kg Capacity, Full Height Series, Medium Conﬁguration

CQD16NRV 1,600 kg Capacity, Full Height Series, Medium Conﬁguration,

Narrow Body

CQD16RVF 1,600 kg Capacity, Full Height Series, Premium Conﬁguration

CQD16NRVF 1,600 kg Capacity, Full Height Series, Premium Conﬁguration,

Narrow Body

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 refer to the manual

according to the actual conﬁguration of the vehicle.

*If there are any changes, revised version will be published once every 12 months;

if there is no change, please follow the most recent version.

*Please refer to the corresponding version of the service manual against the purchase time

of your vehicle.

*If you need the latest versions of the manual, please contact our service department or

dealer to obtain.

EP Equipment Co., Ltd.

EP Industrial Park, Xiaquan Village,

Dipu Town, Anji County, Zhejiang Province

Tel: 400-0550-205

www.ep-zl.com

Safety signs and instructions:

Please strictly adhere to these safety instructions to avoid personal injury.

Please pay attention to the important safety instructions.

Instructions.

FOREWORD

This Service Manual can help readers learn more about the truck system components,

maintenance and troubleshooting, and other related information. The operation and

maintenance personnel must read this Manual carefully before using the product. And when

vehicle is in use, be sure to follow 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 use because of incomplete information. If the contents of the Manual

have been illegible or damaged, which may affect reading, please contact our company or

dealer for replacement.

With the constant update and improvement of our products, the equipment you are using

may be slightly different from what has been described in this Manual, therefore, we must

reserve the right to modify the appearance, conﬁguration and technical speciﬁcations. If you

have any questions, please contact our sales department or dealer.

EP Equipment Co., Ltd.

REV. SM-3316 07.16

REV. 07/2016

TABLE OF CONTENTS

1. INFORMATION & SPECIFICATIONS..............................1

1.1 After-sales Service Platform .........................................3

1.2 Introduction...................................................................4

1.3 Common Tools..............................................................5

1.4 General Tightening Torques .........................................6

2. MAINTENANCE...............................................................9

2.1 Overview..................................................................... 11

2.2 Maintenance............................................................. 12

2.2.1 Cleaning ......................................................................12

2.2.2 Inspection ....................................................................12

2.2.3 Lubrication...................................................................17

3. STRUCTURE & FUNCTIONS........................................ 21

3.1 Structure & Functions................................................. 23

3.1.1 Travel Switch ...............................................................23

3.1.2 Emergency Stop Switch ..............................................23

3.1.3 Key Switch...................................................................23

3.1.4 Horn Button .................................................................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 Warning Light ..............................................................26

3.1.14 Headlight .....................................................................26

3.1.15 Rocker Switch..............................................................26

3.1.16 Stepper Motor..............................................................26

3.1.17 AC2 Controller(TranceController) ................................27

3.1.18 AC2 Controller (Pump Controller)................................27

3.1.19 EPS-AC0 Controller ....................................................27

3.1.20 DC-DC Converter ........................................................27

3.1.21 Main Contactor ............................................................28

3.1.22 Solenoid Valve Controller(RVF/NRVF)........................28

3.1.23 Multi-way Solenoid Valve (RVF/NRVF) .......................28

3.1.24 Multi-way Manual Valve (RV/NRV)..............................28

3.1.25 Pump Motor.................................................................29

3.1.26 Gear Pump ..................................................................29

SECTION PAGE

1-9

REV. 07/2016

TABLE OF CONTENTS

4. CHASSIS SYSTEM........................................................ 31

4.1 Load Wheel ................................................................ 33

4.1.1 Removal and Installation ...............................................33

4.1.2 Faults and Causes.........................................................33

4.2 Caster......................................................................... 34

4.2.1 Removal and Installation ...............................................34

4.3 Brake Pedal................................................................ 35

4.3.1 Removal and Installation ...............................................35

4.3.2 Faults and Causes.........................................................36

4.4 Seat ............................................................................ 36

4.4.1 Removal and Installation ...............................................36

4.5 Brakes ........................................................................ 37

4.5.1 Removal and Installation ...............................................37

4.5.2 Faults and Causes.........................................................38

5. DRIVE SYSTEM............................................................. 39

5.1 Drive Wheel................................................................ 42

5.1.1 Removal and Installation ...............................................42

5.1.2 Faults and Causes.........................................................42

5.2 Electromagnetic 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 Installation ...............................................46

5.3.2 Faults and Causes.........................................................46

5.3.3 Checking and Testing ....................................................47

5.3.4 Control Circuit Troubleshooting .....................................48

5.4 Gearbox...................................................................... 49

5.4.1 Removal and Installation ...............................................49

5.4.2 Faults and Causes.........................................................49

5.5 Proximity Switch ......................................................... 50

5.5.1 Removal and Installation ...............................................50

5.5.2 Faults and Causes.........................................................50

5.5.3 Checking and Testing ....................................................51

5.5.4 Control Circuit Troubleshooting .....................................51

5.6 Steering Motor............................................................ 52

5.6.1 Removal and Installation ...............................................52

5.6.2 Faults and Causes.........................................................52

5.6.3 Checking and Testing ....................................................53

2-9

TABLE OF CONTENTS

SECTION PAGE

REV. 07/2016

TABLE OF CONTENTS

5.6.4 Control Circuit Troubleshooting .....................................54

6. OPERATING SYSTEM................................................... 55

6.1 Control Lever.............................................................. 57

6.2 Control Panel.............................................................. 57

6.3 Horn Button ................................................................ 58

6.3.1 Removal and Installation ...............................................58

6.3.2 Faults and Causes.........................................................58

6.3.3 Checking and Testing ....................................................58

6.3.4 Control Circuit Troubleshooting .....................................58

6.4 Control Switch (RVF/NRVF) ....................................... 59

6.4.1 Removal and Installation ...............................................59

6.4.2 Faults and Causes.........................................................59

6.4.3 Checking and Testing ....................................................59

6.4.4 Control Circuit Troubleshooting .....................................60

6.5 Control Switch (RV/NRV) ........................................... 62

6.5.1 Removal and Installation ...............................................62

6.5.2 Faults and Causes.........................................................62

6.5.3 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 Testing ....................................................65

6.6.4 Control Circuit Troubleshooting .....................................65

6.7 Key Switch.................................................................. 66

6.7.1 Removal and Installation ...............................................66

6.7.2 Faults and Causes.........................................................66

6.7.3 Checking and Testing ....................................................66

6.7.4 Control Circuit Troubleshooting .....................................66

6.8 Emergency Switch...................................................... 67

6.8.1 Removal and Installation ...............................................67

6.8.2 Faults and Causes.........................................................67

6.8.3 Checking and Testing ....................................................67

6.8.4 Control Circuit Troubleshooting .....................................67

6.9 Rocker Switch............................................................. 68

6.9.1 Removal and Installation ..............................................68

6.9.2 Faults and Causes........................................................68

6.9.3 Checking and Testing ...................................................68

6.9.4 Control Circuit Troubleshooting ....................................68

3-9

TABLE OF CONTENTS

SECTION PAGE

REV. 07/2016

TABLE OF CONTENTS

6.10 Travel Switch ............................................................ 70

6.10.1 Removal and Installation .............................................70

6.10.2 Faults and Causes.......................................................70

6.10.3 Checking and Testing ..................................................70

6.10.4 Control Circuit Troubleshooting ...................................70

7. HYDRAULIC SYSTEM................................................... 71

7.1 Overview..................................................................... 73

7.1.1 Hydraulic Schematic Diagram RVF/NRVF ....................74

7.1.2 Hydraulic Schematic Diagram RV/NRV.........................75

7.2 Hydraulic Power Unit.................................................. 76

7.2.1 Removal and Installation ...............................................76

7.3 Pump Motor................................................................ 76

7.3.1 Removal and Installation ...............................................76

7.3.2 Faults and Causes.........................................................76

7.3.3 Checking and Testing ....................................................77

7.3.4 Control Circuit Troubleshooting .....................................78

7.4 Multi-way Reversing Solenoid Valve (RVF/NRVF) ..... 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

7.5.1 Faults and Causes.........................................................81

7.5.2 Checking and Testing ....................................................81

7.5.3 Control Circuit Troubleshooting .....................................82

7.6 Multi-way Reversing Manual Valve (RV/NRV)............ 83

7.6.1 Removal and Installation ...............................................83

7.6.2 Interface Description......................................................84

7.6.3 Faults and Causes.........................................................84

7.6.4 Checking and Testing ....................................................84

7.7 Gear Pump ................................................................. 85

7.7.1 Removal and Installation ...............................................85

7.7.2 Faults and Causes.........................................................85

7.7.3 Checking and Testing ....................................................85

7.8 Reach Cylinder........................................................... 86

7.8.1 Cylinder Removal Precautions ......................................86

7.8.2 Cylinder Installation Precautions ...................................87

7.8.3 Removal and Installation ...............................................88

7.8.4 Cylinder Maintenance....................................................89

4-9

TABLE OF CONTENTS

SECTION PAGE

REV. 07/2016

TABLE OF CONTENTS

7.9 Hydraulic Troubleshooting .......................................... 90

7.10 Hydraulic Symbol...................................................... 91

8. ELECTRICAL SYSTEM ................................................. 93

8.1 Controller.................................................................... 95

8.1.1 Removal and Installation ...............................................95

8.1.2 Controller Interface Function .........................................97

8.2 Fuse.......................................................................... 107

8.2.1 Location of Fuses ........................................................107

8.2.2 Checking and Testing ..................................................108

8.3 Main Contactor ......................................................... 109

8.3.1 Removal and Installation .............................................109

8.3.2 Faults and Causes.......................................................109

8.3.3 Checking and Testing .................................................. 110

8.3.4 Control Circuit Troubleshooting ................................... 110

8.4 Height Display (RVF/NRVF) ......................................111

8.4.1 Removal and Installation ............................................. 111

8.4.2 Faults and Causes....................................................... 111

8.4.3 Checking and Testing .................................................. 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 Control Circuit Troubleshooting ................................... 114

8.6 Accelerator Pedal ..................................................... 116

8.6.1 Removal and Installation ............................................. 116

8.6.2 Faults and Causes....................................................... 116

8.6.3 Checking and Testing .................................................. 116

8.6.4 Control Circuit Troubleshooting ................................... 117

8.7 Foot Switch............................................................... 118

8.7.1 Removal and Installation ............................................. 118

8.7.2 Faults and Causes....................................................... 118

8.7.3 Checking and Testing .................................................. 118

8.7.4 Control Circuit Troubleshooting .................................. 119

8.8 DC-DC Converter ..................................................... 120

8.8.1 Removal and Installation ............................................120

8.8.2 Faults and Causes......................................................120

8.8.3 Checking and Testing .................................................120

8.8.4 Control Circuit Troubleshooting ..................................120

5-9

TABLE OF CONTENTS

SECTION PAGE

REV. 07/2016

TABLE OF CONTENTS

8.9 Warning Light / Headlight ......................................... 121

8.9.1 Removal and Installation ............................................121

8.9.2 Faults and Causes......................................................121

8.9.3 Checking and Testing .................................................121

8.9.4 Control Circuit Troubleshooting ..................................121

8.10 Cooling Fan ............................................................ 122

8.10.1 Removal and Installation ...........................................122

8.10.2 Faults and Causes.....................................................122

8.10.3 Checking and Testing ................................................122

8.10.4 Control Circuit Troubleshooting .................................122

8.11 Seat Switch............................................................. 124

8.11.1 Removal and Installation ...........................................124

8.11.2 Faults and Causes.....................................................124

8.11.3 Checking and Testing ................................................124

8.11.4 Control Circuit Troubleshooting .................................124

8.12 Instrument............................................................... 125

8.12.1 Instrument Operation Schematics .............................125

8.13 Handheld Unit (Optional)........................................ 129

8.13.1 Handheld Unit Connection.........................................129

8.13.2 Handheld Unit Menu Options ....................................129

8.13.3 TESTER Menu ..........................................................131

8.14 Controller Error Message ....................................... 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

8.15.1 Electrical Schematic Diagram RVF/NRVF (1/6) ........149

8.15.2 Electrical Schematic Diagram RVF/NRVF (2/6) ........150

8.15.3 Electrical Schematic Diagram RVF/NRVF (3/6) ........151

8.15.4 Electrical Schematic Diagram RVF/NRVF (4/6) ........152

8.15.5 Electrical Schematic Diagram RVF/NRVF (5/6) ........153

8.15.6 Electrical Schematic Diagram RVF/NRVF (6/6) ........154

8.16 Electrical Schematic Diagrams RV/NRV ................ 155

8.16.1 Electrical Schematic Diagram RVF/NRVF (1/5) ........155

8.16.2 Electrical Schematic Diagram RVF/NRVF (2/5) ........156

8.16.3 Electrical Schematic Diagram RVF/NRVF (3/5) ........157

8.16.4 Electrical Schematic Diagram RVF/NRVF (4/5) ........158

8.16.5 Electrical Schematic Diagram RVF/NRVF (5/5) ........159

8.17 Cable Wiring Diagrams (RVF/NRVF) ..................... 160

8.18 Cable Wiring Diagrams (RV/NRV).......................... 161

6-9

TABLE OF CONTENTS

SECTION PAGE

This manual suits for next models

Table of contents

Other EP Equipment Truck manuals

EP Equipment

EP Equipment EPL152 User manual

EP Equipment

EP Equipment HPL152 User manual

EP Equipment

EP Equipment CQE12R User manual

EP Equipment

EP Equipment LIST JX0 User manual

EP Equipment

EP Equipment LIST JX0 User manual

EP Equipment

EP Equipment J1HD User manual

EP Equipment

EP Equipment HPL152 User manual

EP Equipment

EP Equipment ES16-RS User manual

EP Equipment

EP Equipment EPT20-15ET User manual

EP Equipment

EP Equipment CQD15S-E User manual

EP Equipment

EP Equipment EPT16-ET User manual

Popular Truck manuals by other brands

Sealey

Sealey CST801 quick start guide

RAM

RAM 1500 2019 owner's manual

BT Ergomover 620 AC-TT Operator's manual

Still

Still EXU-16 Original instructions

Lift-Rite

Lift-Rite Titan Series Owner's Manual, Operating Instructions Manual, and Replacement Parts Manual

SAC

SAC TURBO-MAX 6046 Operator's manual

Noblelift

Noblelift PS E12BSL Instruction handbook

Noblelift

Noblelift PTE12N Instruction handbook

Noblelift

Noblelift PT20H Instruction handbook

Daewoo

Daewoo Novus M2SEF manual

jcb

jcb 506-23 Operator's manual

Tico

Tico Pro-Spotter Service manual

Dawson

Dawson Truck Mate Operator's manual

freightliner

freightliner Columbia Driver manual

Mack

Mack M359 manual

Super Products

Super Products Camel 1200 (Ejector Unloading) Operator's manual

Vestil

Vestil CARPET-D instruction manual

STAXX

STAXX EPT15H Operation manual