Xilin CQDH Series User manual

CQDH Reach Electric Stacker
Operation Manual
Spare parts catalogue
2009-11

Welcome to choose “XILIN” Fork Reach Electric Stacker.
We hope our fork reach electric stacker will bring great
convenience to your work.
Please read the manual carefully before operation.
This manual is a common manual. We reserve the right to modify technology of the
reach electric stacker. If there is anything in the manual that is not consistent with the
actual truck, the actual truck should be considered correct and the manual is only for
reference.
Warning!
According to ISO 3691:1980 “Safety Norm of Motor Industrial Vehicles”, Load and lifting height of our CQDH fork reach
electric stacker are stipulated as follows:
When the lifting height of CQDH stacker is below 3000mm (including 3000mm), the maximum bearing capacity is the
rated bearing capacity. Overload is prohibited.
When the lifting height of CQDH stacker is above 3000mm (excluding 3000mm), the bearing capacity is less than the
rated bearing capacity. And you can take height curve as a reference.
When the center of gravity is not in accordance with standards, you can take load center curve as a reference.
Fig. 1
Note:
When the lifting height of the forks exceeds 500mm, the stacker must travel at the lowest speed and the continual travel
distance must not exceed 2m. Inconformity with the regulation may result in:
a. Injury of the driver or other people
b. Damage of the stacker and goods

Table of Contents
1. Configuration diagram…………………………………………………………………………………………1
2. Main technical parameters…………………………………………………………………………………..2
3. Use and scope……………………………………………………………………………………………………4
4. Brief introduction of structure……………………………………………………………………………..4
5. Using and operation instructions………………………………………………………………………….4
6. Maintenance and upkeep…………………………………………………………………………………….6
7. Common faults and trouble shooting……………………………………………………………………7
8. Maintenance and charge of the storage battery…………………………………………………….9
9. List of accessories, spare parts and vulnerable parts……………………………………………..10
10. Package and transportation……………………………………………………………………………… 11
11. Warning (notes)……………………………………………………………………………………………… 11
12. Structure diagram (explosion diagram) and principle diagram of the major parts……11
13. Packing list……………………………………………………………………………………………………….12

1
1. Configuration diagram

2
2.1 CQDH10AMain technical parameters
Feature
1.2 Model CQDH10A
1.3 Driving mode Electric
1.4 Driving mode Stand driving
1.5 Rated load Q(kg) 1000
1.6 Load center distance c (mm) 500
1.8 Front overhang x (mm) 375
1.9 Tread Y (mm) 1290 1380
Weight
2.1
Service weight(with storage
battery) kg 1350 1385 1420 1450 1480 1850 1950 2050
2.3 Axleloading,unladen front/rear kg 810/570 830/590 880/600 1130/720 1210/740 1280/770
2.4 Axleloading,fork
advanced,laden front/rear kg 530/1870 540/1880 550/1930 1000/1850 1040/1910 1080/1970
2.5 Axleloading,fork
retracted,laden front/rear kg 1000/1390 1020/1420 1040/1440 1230/1620 1280/1670 1330/1510
Chassis
3.1
Wheels (rubber, high
elasticity, pneumatic tyre,
polyurethane wheel)
polyurethane
3.2 Front wheel dimension mm 250x82
3.3
Rear wheel dimension
mm 150x82
3.5 Wheel number,
front/rear (x=driving wheel) 1+2
3.6 Tread, front b
10(mm)
650 790
3.7 Tread, rear b
11(mm)
980
Dimension
4.1
Tilt of mast/fork carriage
forward/backward Grad 2/5
4.2
Height, mast lowered
h
1(mm)
1635 1885 2135 2385 2635 2235 2395
2560
4.3 Free lift height h
2(mm)
～～～～～1575 1700 1825
4.4 Lift height h
3(mm)
2000 2500 3000 3500 4000 4500 5000 5500
4.5
Height, mast extended
h
4(mm)
3070 3570 4070 4570 4920 5570 6070 6570
4.19 Overall length l
1(mm)
2185 2235
4.20
Length to fork face
l2 (mm) 1125
4.21 Overall width of truck body b
1
Ib
2(mm)
950/1200
4.22 Fork dimension s/e/l(mm) 40ｘ100ｘ950
4.28 Reach distance l
4(mm)
500
4.32 Wheelbase ground distance m
2(mm)
65
4.33
Aisle width for pallets
1000 1200
Ast (mm) 2650 2680
4.34 Aisle width for pallets
800x1200 lengthways
Ast (mm) 2650 2680
4.35
Turning radius
W
a(mm)
1750 1780
Performance Data
5.1 Travel speed，laden/unladen Km/h 4.5/5 4.8/5
5.2 Lift speed，laden/unladen m/s 0.095/0.12
Loweringspeedladen/unladen
m/s
0.2/0.15
5.3
5.8 Max.gradeability,laden/unladen % 5/12
5.10 Traveling brake Electromagnetic brake

3
Motor
6.1 Drive motor power kW 0.9 1.2
6.2
Lift motor power
kW 3
6.4 Batteryvoltage/nominal
capacity
V/Ah 24/320
6.5
Battery weight
kg 275
Battery dimension（LXWXH）mm 812x270x535
8.4 Noise level at operator’s
ear, according to DIN12053 dB(A) 70
2.2CQDH12AMain technical parameters
Feature
1.2 Model CQDH12A
1.3 Driving mode 电动
1.4 Driving mode 站驾式
1.5 Rated load Q(kg) 1250
1.6 Load center distance c (mm) 500
1.8 Front overhang x (mm) 375
1.9 Tread Y (mm) 1290 1380
Weight
2.1
Service weight(with storage
battery) kg 1370 1405 1440 1470 1500 1870 1970 2070
2.3 Axleloading,unladen front/rear kg 830/570 840/600 890/610 1140/730 1250/720 1280/790
2.4 Axleloading,fork
advanced,laden front/rear kg 630/2020 640/2050 650/2080 1110/2010 1160/2060 1180/2140
2.5 Axleloading,fork
retracted,laden front/rear kg 1100/1640 1120/1570 1140/1590 1330/1790 1380/1840 1440/1680
Chassis
3.1
Wheels (rubber, high
elasticity, pneumatic tyre,
polyurethane wheel)
polyurethane
3.2
Front wheel dimension
mm 250x82
3.3 Rear wheel dimension mm 150x82
3.5 Wheel number,
front/rear (x=driving wheel) 1+2
3.6 Tread, front b
10(mm)
650 790
3.7 Tread, rear b
11(mm)
980
Dimension
4.1
Tilt of mast/fork carriage
forward/backward Grad 2/5
4.2
Height, mast lowered
h
1(mm)
1635 1885 2135 2385 2635 2235 2395 2560
4.3 Free lift height h
2(mm)
～～～～～1575 1700 1825
4.4
Lift height
h
3(mm)
2000 2500 3000 3500 4000 4500 5000 5500
4.5 Height, mast extended h
4(mm)
3070 3570 4070 4570 4920 5570 6070 6570
4.19 Overall length l
1(mm)
2185 2235
4.20
Length to fork face
l2 (mm) 1125
4.21 Overall width of truck body b
1
Ib
2(mm)
950/1200
4.22
Fork dimension
s/e/l(mm) 40ｘ100ｘ950
4.28 Reach distance l
4(mm)
500
4.32 Wheelbase ground distance m
2(mm)
65
4.33
Aisle width for pallets
1000 1200
A
st
(mm)
2650
2680

4
4.34 Aisle width for pallets
800x1200 lengthways
Ast (mm) 2650 2680
4.35 Turning radius W
a(mm)
1750 1780
Performance Data
5.1 Travel speed，laden/unladen Km/h 4.5/5 4.8/5
5.2 Lift speed，laden/unladen m/s 0.095/0.12
Loweringspeedladen/unladen
m/s
0.2/0.15
5.3
5.8 Max.gradeability,laden/unladen % 5/12
5.10 Traveling brake Electromagnetic brake
Motor
6.1 Drive motor power kW 0.9 1.2
6.2
Lift motor power
kW 3
6.4
Batteryvoltage/nominal
capacity
V/Ah 24/320
6.5 Battery weight kg 275
Battery dimension
（
LXWXH
）mm 812x270x535
8.4 Noise level at operator’s
ear, according to DIN12053 dB(A) 70
3. Use and scope
CQDH reach electric stacker adopts storage batteries as the dynamic source and a DC or AC motor as the driving force,
traveling through gear transmission. The lifting and forward/backward movement of the fork relies on the DC motor and
the hydraulic transmission system. The up-and-down movement of the cylinders lifts the fork and the goods. As the
traveling and lifting of the truck are electrically driven, it possesses the characteristics of energy saving, high efficiency,
stable operation, easy operation, safety and reliability, low noise and no pollution, etc.
The most important character of fork reach forklift is that not only can it lift-descend and handle goods, but also it can
move the goods forward and backward with the movement of forks. In this way it overcomes the inconvenience of
“straddle leg”. Meanwhile, it is more suitable to operate this stacker in narrow aisle, as it is possesses the feature of smaller
volume and more flexible operation comparing the same type of balance weight forklift.
The fork reach electric stacker is applicable for goods piling and handling operation on hard and flat ground.
Allowed environment for using:
a. Height above sea level shall not be over 1200m;
b. Ambient temperature shall not be higher than +40℃ and lower than -25℃;
c. When the ambient temperature reaches +40℃, the relative humidity shall not exceed 50%; at a lower temperature,
higher relative humidity is allowed;
d. Hard and flat ground
e. It is prohibited to use the stacker in a flammable, explosive or corrosive environment with acid and alkali.
4. Brief introduction of Structure
(See also the structure diagram and the principle diagram of the major parts)
The stacker mainly consists of frame, mast, fork carriage, fork, lifting oil cylinder, forward movement oil cylinder,
inclination oil cylinder, operating handle, steering device, drive wheel, storage battery pack, hydraulic power unit, control
system for electrical equipment, etc.
As for detailed structure, please refer to explosion diagrams of different parts, which are added behind this instruction.
5. Use and operation instructions
The CQDH fork reach electric stacker adopts storage batteries as the power supply for short distance goods handling and
stacking. Correct use and operation will bring you great convenience in your work but incorrect use and operation will
damage the stacker and pose risk to your safety and goods.

5
5.1 Before operation
5.1.1 Before operation, please check if the truck is in normal condition: Is there any oil leakage in the hydraulic pipes? Are
the supporting wheels able to operate normally? Is there any block? Faulty stackers are strictly prohibited.
5.1.2 Check if there is any electric power in the batteries with the method indicated in Fig, I. Pull the general power supply
switch out to turn on the general power supply, unlock the electric lock on the handle, and check the electric energy
meter on the instrument panel of the truck. If one grid at the zero end is bright, it indicates that there is no electric
power in the batteries and charging should be conducted at once. It is prohibited to operate the stacker without
electricity as that will greatly reduce the service life of the batteries and even damage the batteries.
5.1.3 Check if the stacker brake is normal. Check the lifting, lowering, forward and backward extension of fork, and
forward and backward traveling of the truck to see if the actions are normal. Check if the emergency reverse action
of the stacker is normal with the method indicated in Fig. II:
Fig II
Operating handle is located as indicated in Fig II. Move the steering switch on the accelerator of the operating handle to
see if the stacker can travel forward and backward. Operate the handle of multi-way valve to see if the lifting, lowering and
forward/backward movement of fork is normal.
After the above check, if there is no failure in the stacker, it can be put into use; if there is some failure, please repair at
once. It is prohibited to use faulty trucks.
5.2 In operation
5.2.1 Note: A side-magnetic brake is installed on the shaft end of the driving wheel motor and there is a cam and an
inching switch installed on the rotary shaft of the operating rotary arm. Only when the rotary arm is at 30°±20°
(as indicated in Fig. II), can the truck get power and operate. Larger or less than the angle, the truck has no power
and is braked. In that case, the truck can lift, lower and move the goods forward and backward. When lifting,
lowering and moving the goods, the truck cannot travel as indicated in Fig. II.
Turn on the power supply
Turn off the power supply
Electric door lock
There is no electric power in the
batteries if the grid is bright
Fig. I

6
5.2.2 Operation of handling and stacking
As indicated in Fig. I, pull out the general power supply switch, unlock the electric door lock, and drive the stacker to
goods pile nearby (the tip of the fork is 30cm from the goods pile). Turn lifting-lowering handle of multi-way valve so
as to adjust the height of the fork to a proper position; turn fork reach handle to insert the fork slowly and as deep
as possible into the goods pallet. Turn the lifting-lowering handle of multi-way valve to lift the fork until it is 20-30cm
from the ground. Turn extension handle of multi-way valve to return the fork. Drive the truck to the location of the
goods shelf and slowly stop until the tip of the fork (or the front end of goods) is 20cm from the goods shelf. Turn
lifting-lowering handle until the fork rises to a proper height of the shelf (The bottom of the pallet is about 10cm
higher than the shelf). Move the goods slowly to the accurate position of the shelf and turn fork reach handle to
move the fork forward slowly to a proper position. Turn lowering handle of multi-way valve to put the goods
carefully on the shelf. Turn extension handle of multi-way valve to return the fork inside the truck to lower the fork
until it is about 30mm from the ground to drive the stacker away from the goods shelf. During operation, please pay
attention to obstacles around and slow down when turning around.
5.2.3 Operation of taking goods down from shelves
As indicated in Fig. I, pull out the general power supply switch, unlock the electric door lock, drive the truck to the
goods shelf nearby (the tip of the fork is 30cm from the goods shelf). Turn lifting-lowering handle of multi-way valve
so as to adjust the height of the fork to a proper position. Turn extension handle of multi-way valve to insert the fork
slowly and as deep as possible into the goods pallet. Turn lifting-lowering handle of multi-way valve to lift the
goods (the bottom of pallet is 10mm from the goods shelf). Turn extension handle of multi-way valve to move the
goods slowly from goods shelf. Turn lifting-lowering handle of multi-way valve to lower the fork until it is 20mm
to 30mm from the ground. Drive the stacker away from the goods shelf until it reaches a desired position and then
slowly stop it. Turn the extension handle of multi-way valve to reach the goods wholly outside the fork leg. Turn the
lifting-lowering handle of multi-way valve to make the fork completely away from the goods. Turn extension handle
of multi-way valve and move the fork slowly out of the goods pallet.
5.3 Abnormal situation handling in operation
5.3.1 When the handle of multi-way valve returns to the middle position from some working position, if it is still during
operation, press down the general power supply switch to cut off the power supply at once. Meanwhile move the
stacker to a safe place and lower the goods manually so as to repair the stacker.
5.3.2 If the brake is out of function when the stacker is in operation, the operation must be stopped at once and repair the
truck.
5.3.3 When the truck is moving backward and pushing the operator against a wall or other objects, press the emergency
reverse button on top of the control handle and the stacker will automatically move forward to avoid injuring the
operator.
5.4 After operation
After operation, the stacker should be parked in a fixed parking position and routine maintenance should be
conducted according to the stipulations in clause 6 and charging should be carried out.
6. Maintenance
Note: It is prohibited for untrained personnel to maintain the truck.
6.1 Whether the truck can operate satisfyingly depends on the efficient maintenance. When maintenance is ignored, the
truck may pose a threat to human lives and cause property damage. Routine inspection should be conducted, when
the truck is in operation, to eliminate abnormal conditions in time. Never use a faulty truck to ensure safety and to
prolong the service life of the stacker.
6.2 Maintenance: The maintenance of the truck is divided into three levels, i.e. routine maintenance, level I
maintenance and level II maintenance.
Routine maintenance: Daily maintenance is to clean the surface of the stacker body and the surface of the
storage battery and to examine the firmness of the power supply line and whether the elasticity of the chain is
normal.
Level I maintenance: Level I maintenance should be performed once every week. Besides what should be done
in daily maintenance, the operation situation of all the parts should be carefully inspected to see whether the
operation is normal; whether there is any loose of the fasteners; whether the elasticity of the chain is appropriate;
whether the connecting pin of the chain connection is bending or twisting; whether the up and down movement of

7
the internal and external door frames is normal; is there any oil leakage at the hydraulic connection; is there any
abnormal wearing and tearing in the mechanical parts; is there any abnormal temperature rise or sparks in the
electric part, etc. If there is any abnormal situation, adjustment or trouble-shooting should be conducted promptly.
Level II maintenance:Level II maintenance should be carried out as planned. Overall inspection should be
performed for the truck according to the following requirements.
a. Maintenance for mechanical system: Once half a year. The major content is to add lubricant to the
transmission gears and bearings of the drive wheel and the rotary joints, examine the firmness of the fixing fittings,
the flexibility of the wheels, as well as whether the forks can be lifted and lowered normally. The operation noise of
the truck shall not exceed 70 dB.
b. Maintenance for hydraulic system: Once every 12 months. Examine if the oil cylinder is normal, if there is
any leakage externally or internally, if the hydraulic connection and the hose are reliable with no leakage. The
hydraulic oil should be kept clean and generally it should be replaced every 12 months. ISO oil product standard is
adopted for the hydraulic oil. When the ambient temperature is –5~ 40℃, HL-N46 or HL-N68 should be used; when
the ambient temperature is –35~ –5℃, HV-N46 or HV-N68 should be used. The replaced waste oil should be treated
according to the local rules and regulations.
c. Maintenance for electric equipment: Once every three months. First examine whether the specific gravity of
the electrolytic solution of the storage battery [specific gravity at 1.24 (at 25℃) in tropical areas and 1.26 (at 25℃)
in other areas] fits and the terminals are clean. Otherwise, the specific gravity of the electrolytic solution should be
adjusted as required and the terminals should be cleaned and painted with Vaseline and tightened. Then examine if
the connections of the electrical devices are reliable, the switches are normal and the insulation is ok (The insolating
resistance between the electrical devices and the truck body should be above 0.5MΩ).
6.3 Adjustment of brake clearance
After a period of use, braking performance of the brake will decline due to the
wearing of the brake. Therefore, it is necessary to adjust the brake’s
clearance. As indicated in drawing on the right, check the clearance between
brake plate and magnetic steel with feeler, if the clearance is bigger than
0.5mm, clearance should be adjusted. Before adjustment, loosen the
tightening screws, adjust the length of the adjusting screws, and then screw
down the tightening screw. After the adjustment, the clearance between
brake plate and magnetic steel should be kept at 0.2-0.3mm. During the
adjustment, please pay attention to the balance adjustment of three lock
screws so as to ensure that clearance between brake plate and magnetic steel
is distributed evenly around.
7. Common faults and trouble shooting
No. Trouble Cause Shooting
1
The stacker cannot
be started (The
contactor does not
work either.)
①
The fuse of the control circuit is burnt out.
Replace
②
The power switch contact is bad or damaged.
Repair or replace
③
The fuse of the major circuit is blown.
Replace
④
The contact of the electric lock switch is bad or damaged.
Repair or replace
⑤The connection of the storage batteries is loose or has
fallen off.
Tighten
The stacker cannot
be started (The
contactor works.)
①The side-magnetic brake of the drive wheel does not suck
and the stacker is in a braked condition.
Repair or replace
②The walking motor carbon brush is worn or bad contact
between the steering device and the carbon-brush.
Repair or replace
③The magnet-exciting coil of the stepper motor is broken or
bad contact at the wire end.
Repair or replace
④
Bad contact
Repair or replace
⑤
There is a trouble at the MOSFET tube type circuit board.
Repair or replace
2
The stacker can
①
Bad or broken contact.
Repair or replace
Steel magnet
Lock screw
Adjusting screw

8
only move forward
(or backward)
②There is a trouble in the circuit board. Repair or replace
3 The stacker can not
stop while traveling Broken contact. The moving contact cannot be reset.
Cut off the power supply at
once and replace the head of
contactor.
4 The brake does not
work
①The erection bolt of the inching
switch looses or is
damaged.
Adjust or tighten the bolt or
replace the inching switch.
②The connecting wire of the side-magnet brake is loose or
damaged
Tighten the bolt or repair the
side-magnet brake.
③The braking plates of the side-magnet brake are worn. Replace the braking plates.
5 The steering is
blocked.
①The bearing of the steering device is damaged. Replace the bearing
②The bearing of the steering device lacks lubricant or there
is too much dust
Clean the bearing
6
Difficult steering of
the drive wheel,
noise and the
motor is
overloaded.
①The gear or bearing has is blocked because of foreign
matters.
Clean or replace the bearing
②There is a gap in the bearing installed or the fixing ring
has come off.
The fixing ring has come off.
Reinstall the ring and adjust
the gap.
③The front wheel bearing is damaged. Replace the bearing
7 The forks cannot be
lifted
①
Overload
Reduce the load
②
The pressure of the overflow valve is too low
Adjust the pressure higher
③
Internal abnormal leakage in the lifting oil cylinder
Replace the seals
④Insufficient hydraulic oil
Add appropriate quantity of
filtered hydraulic oil
⑤
Insufficient voltage of the storage battery
Charge the battery
⑥The control handle is not horizontal or vertical, the motor
of oil pump has not been turned on.
Improper operation
⑦
Damaged oil pump motor
Repair or replace
⑧
Damaged oil pump
Repair or replace
⑨
Damaged lifting button
Repair of replace
⑩
The electric lock is not unlocked or is damaged.
Repair or replace
○
11
Seriously insufficient voltage in the cell.
Recharge
8 The forks cannot be
lowered
①
The internal doorframe is overloaded and deformed
Repair or replace
②
The external doorframe is overloaded and deformed
Repair or replace
③
Frame roller is blocked.
Repair or adjust
④
Frame guiding rode is curved
Repair or straighten
⑤
The oil return hole is blocked
Clean
⑥The electromagnetic valve of hydraulic station is out of
control
Shoot the trouble
9
Voltage at the
storage battery
reduces. (after
charging)
①
Damage of individual battery
Repair or replace
②
Low level of the electrolytic solution
Add electrolytic solution
③Foreign matters in the electrolytic solution Replace electrolytic solution
8. Use, maintenance and charge of the storage batteries

9
8.1 Initial charge
Note: The charging environment requires good ventilation and there should be no
open flame, otherwise explosion may occur.
8.1.1 Initial charge should be conducted for batteries that have never been used. Before the initial charge, the surface of
the batteries should be cleaned and the batteries should be examined for damage. The bolts should be tightened to
ensure reliable connection.
8.1.2 Pull out the sealing cover and replace it with the open cover type liquid hole plug and open the cover.
8.1.3 When the charging equipment is able to operate normally, pour the sulfuric acid electrolytic solution with a density
of 1.260±0.05 (25℃) and a temperature of lower than 30℃into the batteries. The liquid surface should be
15-25mm higher than the protective board. In order to reduce the temperature rise caused by chemical reaction of
the electrolytic solution and let the electrolytic solution fully penetrate into the pores of the polar plates and the
baffles, the batteries should be placed still for 3-4 hours but not exceeding 8 hours. The initial charging can only be
conducted when the temperature of the solution reduces to below 35℃. (When necessary, the batteries can be put
into cold water for temperature reduction). After the still placement, if the surface of the solution reduces,
electrolytic solution should be added.
8.1.4 The sulfuric acid electrolytic solution is prepared with battery sulfuric acid complying with the state standard
GB4554-84 and distilled water. Never use industrial sulfuric acid and running water. The standard temperature and
density of the electrolytic solution can be converted as follows:
D25 = Dt+ 0.0007 (t-25)
Where: D25: the density of the electrolytic solution at 25℃
Dt: the actual density of the electrolytic solution at a temperature of t ℃.
t: temperature of the electrolytic solution when testing the density.
8.1.5 Sweep the electrolytic solution on the surface of the batteries and connect the positive and the negative poles of the
battery pack respectively with the positive and the negative ends of the DC power supply (charger). Turn on the
power supply. First charge with 18A (the first stage current,); when the voltage reaches 28.8V (12 ×2.4V = 28.8V),
change to the second stage current 9A and continue to charge. The temperature of electrolytic solution during the
process of charging must not exceed 45℃and when it is close to 45℃, the charging current should be reduced by
50% or the charging should stop temporarily. Wait till the temperature drops to 35℃to continue the charging. The
charging time, however, should be properly prolonged.
8.1.6 Fully charged basis: When the voltage during the second stage charging reaches 31.2V (12 ×2.6V = 31.2V), the
variation of the voltage is no greater than 0.005 (V); the density of the electrolytic solution reaches 1.280 ±0.005
(25℃), no obvious variation in 2 hours and there are fine air bubbles appear violently, it can be deemed that the
batteries are fully charged. The charged power capacity is 4-5 times of the rated capacity and the charging time is
about 70 hours.
8.1.7 In order to accurately control the sulfuric acid content of the electrolytic solution, the electrolytic solution density of
the batteries should be examined during the last period of charging. If there is inconsistence, adjust with distilled
water or sulfuric acid with a density of 1.40. The electrolytic solution density and the liquid surface should be
adjusted to the stipulated value within two hours in the charging state.
8.1.8 After the initial charging is completed, the surface of the batteries should be cleaned. Close the cover of the open
cover type liquid hole plug and then the batteries can be used.
8.2 Use and maintenance
8.2.1 In order to guarantee the service life of the batteries, the batteries in use should be fully charged. Insufficiently
charged batteries must not be used. During the process of use, close attention should be paid to the discharge
extent. Over discharge is prohibited---the voltage reduces to 1.7V per battery (when the total voltage reduces to
1.7V×12 = 20.4V ). When the density of the electrolytic solution reduces to 1.17, discharging should be stopped
and charging should be conducted at once. The batteries should not be placed idle for a long period of time. The
supplementary charging frequently conducted during the process of use is called common charge.
8.2.2 Common charge: The first stage current of common charge is 26A and that of the second stage is 13A. The charging
method is the same as that of initial charge. The charged volume is 130-140 % of the discharged volume and the
charging time is about 15 hours.
8.2.3 The batteries in normal use should avoid over-charge, but over-charge must be properly conducted for the batteries

10
in the following situation, i.e. equalizing charge.
a. The “lag-behind” batteries--- batteries with a voltage lower than that of the other batteries in the charging and
discharging process and the batteries having been repaired for failure. (When equalizing charge is conducted, the
positive and negative poles of the “lag-behind” battery should be respectively connected with the positive and
negative ends of the charger, the DC power supply, and the charge should be conducted independently.).
b. Equalizing charge should be conducted for the batteries in normal use every 2-3 months.
c. Equalizing charge should be conducted for the batteries that have not been used for a long period of time before
use.
8.2.4 Equalizing charge
a. Charge with a 4A current.
b. When the charge voltage reaches 31.2V (12 ×2.6V = 31.2V) and air bubbles occur in the electrolytic solution,
the current should be reduced by 50% (2A) and continue to charge.
c. When the batteries are fully charged, stop charging for 0.5 hour and charge again with a 1A current for one more
hour.
d. Stop charging for another 0.5 hour and charge with a 1A current for another one hour.
e. Repeat according to item d till air bubbles occur violently in the batteries once the charger is switched on.
8.3 Storage
8.3.1 Batteries should be stored in a clean, dry and well ventilated warehouse with a temperature of 5-40℃. The valid
shelf life is 2 years. The batteries should be kept according to the following requirements during storage:
a. No direct sunlight on the batteries and at least 2m away from heat source.
b. Avoid contacting with any harmful substances. No metallic matters are allowed to drop into the batteries.
c. The batteries should not be placed upside down and should not be hit mechanically or heavily pressed.
d. The batteries must not be stored with electrolytic solution. When it is required in special situation that the
batteries must be stored with electrolytic solution, the batteries should be fully charged and the density and the
liquid surface of the batteries should be adjusted to the stipulated values. When the storage period comes to one
month, the batteries should be complementarily charged with the common charge method.
9. List of accessories, spare parts and vulnerable pasts
No. Name Use position Type & specification Quantity Remarks
1 Key to the electric lock Unlock the electric lock 2
2 Charging plug and socket Matched with the charger 1 set
3 Fuse Electric equipment 10A 1
4 Fuse Electric equipment 160A 1
5 Sealing ring Lifting oil cylinder UHS38 2
6 O type sealing ring Lifting oil cylinder 3.55X50 1
7 Sealing ring Tilting oil cylinder UHS30 1
8 Sealing ring Tilting oil cylinder UHS63 1
9 O type sealing ring Tilting oil cylinder 2.56X58 1
10 sealing ring Forward reach oil cylinder UHS28 1
11 sealing ring Forward reach oil cylinder UHS40 1
12 O type sealing ring Forward reach oil cylinder 2.65x45 1
13 Dustproof ring Forward reach oil cylinder DH28 1
14 Dustproof ring Tilting oil cylinder DH30 1
15 Dustproof ring Lifting oil cylinder DH38
10. Package & transportation

11
The stacker is packed with a tray. During transportation, turnover and upside-down are not allowed. Collision is not allowed
when lifting and loading onto the truck. Do not damage the outward surface of the stacker when opening the package.
11. Warning (points for attention)
11.1 Read the manual carefully before operation so as to know the performances of the stacker.
11.2 It is forbidden to press and frequently switch the lifting or lowering, otherwise it might damage the stacker and the
goods.
11.3 Do not shake the handle rapidly or with high frequency.
11.4 It is not allowed to rapidly put heavy goods onto the forks.
11.5 The stacker should not be overloaded. When overloaded, the stacker will not be able to operate normally.
11.6 The center of gravity of the goods should be placed between the two forks, otherwise, the forks will be damaged and
the goods will fall down in the process of operation.
11.7 Loose and unstable goods are not allowed to load onto the truck.
11.8 Do not put the goods on the forks for a long period of time.
11.9 Turning rapidly on narrow road is forbidden. In order to ensure the safety of the people and goods, the truck should
turn slowly in this situation.
11.10 When the truck is not in use, the forks should be lowered to the lowest position.
11.11 Never put any part of human body under heavy goods and forks.
11.12 The truck is applicable for use on plane ground and should never be parked on slope for a long period of time.
11.13 Over-load or over-slope operation is forbidden. Otherwise the wheel will slip, damaging the wheel and the motor.
The safety of people and goods will be affected as well.
11.14 It is forbidden to repair the stacker without training.
11.15 Operation of the stacker under the stipulated voltage 20.4V is forbidden.
11.16 It is forbidden to directly connect the plug with AC power supply for charge.
11.17 When lifting height of forks exceeds 500mm, the truck must travel at the minimum speed and the continual traveling
distance must not exceed 2m.
12. Structure diagram (explosion diagram) and principle diagram of
the major parts
See Electric Instructions for “Instruction of the electric system”
See attached diagrams for “The explosion diagram”
13. Packing list
Packing List of CQDH Fork Reach Electric Stacker

12
Consignee: Ex-work No.:
Contract No.: Ex-work date:
No. Name Quantity Net
weight
Dimension
(L
×
W
×
H)
Remarks
1 CQDH Fork Reach Electric Stacker 1 A complete set.
2 Accessory box 1
Technical documents, accessories
and spare parts.
Note: 1. The following documents are in the file bag:
①Operation manual of CQDH Fork Reach Stacker 1 volume
②Packing list 1 copy
③Qualification certificate 1 copy
2. Accessories and spare parts
No.
Name
Use position
Type & specification
Quantity
Remarks
1
Key to electric lock
Unlock the electric lock
2
2
Charging plug and socket
Matched with the charger
1 set
3
Fuse
Electric equipment
10A
1
4
Fuse
Electric equipment
160A
1
5
Sealing ring
Lifting oil cylinder
UHS38
2
6
O type sealing ring
Lifting oil cylinder
3.55X50
1
7
sealing ring
Tilting oil cylinder
UHS30
1
8
sealing ring
Tilting oil cylinder
UHS53
1
9
O type sealing ring
Tilting oil cylinder
2.65X58
1
10
sealing ring
Forward Reach oil cylinder
UHS28
1
11
sealing ring
Forward reach oil cylinder
UHS40
1
12
O type sealing ring
Forward reach oil cylinder
2.65X45
1
13
Dustproof ring
Forward reach oil cylinder
DH28
1
14
Dustproof ring
Tilting oil cylinder
DH30 1
15
Dustproof ring
Lifting oil cylinder
DH38
1
Consigner:Ningbo Ruyi Joint Stock Co., Ltd

13
J 1- 1
1 0#
+
Z 2
Z1 3
Z 5
SA4-6
FU2
200 A
M 1
BATT
24V
X 8 B +
Z 4
Z1 2
Z 3
B -
M1
J2-1
J2-5
J2-2
J 2 -4
KM 2
B+
FU1
100 A
J 1 -1
J1-2
J1-14
J1-13
J1-16
Z 10
Z11
J1-11
J1-15
J1-12
J1-6
J1-3
J1-22
Z 9
BATT-
J2 - 3
J 2 -6
J1-23
J1-9
J1-24
CURTIS
1311/1314
PROGRAMMER
J 3- 3
J 3- 1
J3-4
J3 - 2
+
-
F+
U
V
W
GROUND
FU3
10A
KM 1
4
4
BATT-
（+）
Z 1
+
H T
CZ
X 3 X 2
X6
X 4
X 5 B -
J1-1
X 4
X 3
2 #
S A 7
CURTIS803
CURTIS 1230 CONTROLLER;REMA TILLER
SA2 Keyswitch
SA1 Em erge ncy st op swit ch
Lift motor
Travel motor
Decoder
Decoder B
Decoder A
Decoder_
Decoder+12v
Coulometer
Rapid reveres
Rapidreverse Rapid reverse
X 3
Liftrequestinput
Lift request input
Acceleration adjustment0-5V
Slow down Slowdown
HOMHorn Horn
C ircuit p an c e l o
f o pera t
i o nh a ndl e
RAMA hand le
He
i g ht l i m
it s w i tch
Multi-way valveswitch
KM2 Lift contactorcoil
Lift contactorcoil
Decline electromagnetic valve
Receive
Se n d
Hand unitinterface
YB brakecoil
Main contactor coil KM1 Main contactor coil
Safetyswitchinput
Decline request input
Declinerequestinput
Hackward
Forward
SA3 Handle safety switch
Backward
Forward
TMlogic card
1230-200A 2402CONTROLLER
Key switchinput

14
急 停 开 关
CURTIS 1207 CONTROLLER;REMA TILLER
SA2 Key switch
SA1 Emergency stop switch
Main contactor
Lift contactor
Forward contactor
Backward contactor
Handle switch
Controller
Lift motor
T
ravel motor
Direction contactor
Direction contactor
Main contactor
Acceleration adjustment 0-5V
Operation handle
YB brake coil
Multi-way valve switch
KM1 lift c ontact or
Backward
Forward
Backward
Forward
Belly SW Rapid reverse
Cutbackspeed Slow input

15
A2
A2
D1
D2
M1
A1
KM3 KM4
KM4
VMN
13
M2
A1
-SH
SHUNT
B+
2
KM2
FEEDER 12V A14
A3
A4
A11
V3
FR
B-
FU2
125 A
FU3
10A
10
CZ
CZ
A12
A 3
A4
A 11
V4
A3
YV
V7
A8
A3
SA3
A13
A5
20k
A1
+
-
+
-
A2
1
4
12
3
A13
11
10
V6
13
KM2
急反
A10
A9
A 10
13
X3 X2
X6
X4
X5 B-
A5
V5
DL
3 0
X7 B+
X4
X3
A5
28
A5
A5
SA4
SA5
SA6
SA7
BATT
24V
2
5
13
9
KM3
D1 D2
CURTIS803
TM HO 200A
FU1
180A
ZAPI H0 200A REMA TILLER RUDDER
SA2 Key switch
SA1 Emergency stop switch
SA1 Emergency stop switch
Lift contactor
M
ulti-way valve switch
Multi-way valve switch
Multi-way valve switch
Main contactor
Lift motor
Tr
ave
l motor
Main contactor
Forward contactor
KM3
Backward contactor
Acceleration adjustment 0-5V
contactor
Rapid reverse
Rapid reverse
Acceleration adjustment 0-5V
Operation handle
Height li mit switch
Coulometer
Handle safety switch
Power
Contactor
KM4
YB Brake coil
KM1 Lift contactor
Forward
Backward
Backward
Forward
A2
A1
A9
2 9
13
30
Lift
Cathode
Horn
Decline
Slow down
Controller