Ep Ept20-15et-Service-Manual

Service Manual
EPT20-15ET
EPT20-15ETL
Electric Pallet Truck
Service Manual
EPT20-15ET
EPT20-15ETL
Electric Pallet Truck
Release Date Version No. Changes (Serial number)
2016-09-27 SM-1115 09.16 New Version
* 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.
This manual applies to:
Model Specifications
EPT20-15ET 1,500 kg Capacity
EPT20-15ETL 1,500 kg Capacity, Ultra-low Placement
Some sections of the manual only involve certain model, please refer to the manual
according to the actual configuration of the vehicle.
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.
Safety signs and instructions:
Please strictly adhere to these safety instructions to avoid personal injury.
Please pay attention to the important safety instructions.
i Instructions.
Copyright
Copyright of Service Manual belongs to EP Equipment Co., Ltd.
EP Equipment Co., Ltd.
EP Industrial Park, Xiaquan Village,

Dipu Town, Anji County, Zhejiang Province
www.ep-zl.com
REV. SM-1115 09.16

TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION PAGE
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 .....................................................................16
3. STRUCTURE & FUNCTIONS ........................................ 19

3.1 Structure & Functions ................................................. 21
3.1.1 Travel Switch .................................................................21
3.1.2 Lifting/Lowering Switch ..................................................21
3.1.3 Emergency Reverse Switch ..........................................21
3.1.4 Horn Switch ...................................................................21
3.1.5 Emergency Stop Switch ................................................22
3.1.6 Key Switch .....................................................................22
3.1.7 Charge Gauge ...............................................................22
3.1.8 LED Charging Indicator .................................................22
3.1.9 Buzzer ..........................................................................23
3.1.10 Fuse.............................................................................23
3.1.11 Controller .....................................................................23
3.1.12 Charger........................................................................23
3.1.13 Lifting Limit Switch .......................................................24
3.1.14 Interlock Switch ...........................................................24
3.1.15 Pump Motor .................................................................24
3.1.16 Gear Pump ..................................................................24
3.1.17 Pump Contactor...........................................................25
3.1.18 Solenoid Valve .............................................................25
4. CHASSIS SYSTEM ........................................................ 27

4.1 Load Wheel ................................................................ 29
4.1.1 Removal and Installation ...............................................29
4.1.2 Faults and Causes.........................................................30
4.2 Cover .......................................................................... 30
REV. 09/2016
1-5
TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION PAGE
4.3 Lifting Mechanism....................................................... 31
4.3.1 Fork Inspection ..............................................................31
4.3.2 Connecting Rod Adjustment ..........................................31
5. DRIVE SYSTEM ............................................................. 33

5.1 Drive Assembly ........................................................... 36
5.2 Electromagnetic Brakes.............................................. 36
5.2.3 Checking and Testing ....................................................38
5.2.4 Control Circuit Troubleshooting .....................................39
5.3 Drive Wheel ................................................................ 40
5.4 Drive Motor ................................................................. 41
5.5 Gearbox ...................................................................... 43
6. OPERATING SYSTEM................................................... 45
6.1 Control Lever .............................................................. 47
6.2 Button Switch.............................................................. 47
6.3 Travel Switch .............................................................. 51
7. HYDRAULIC SYSTEM................................................... 53
7.1 Overview..................................................................... 55
7.1.1 Hydraulic Schematic Diagram ......................................56
REV. 09/2016
2-5
TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION PAGE
7.2 Pump and Motor Assembly......................................... 57
7.2.2 Component ....................................................................58
7.3 Pump Motor ................................................................ 58
7.4 Pump Contactor.......................................................... 60
7.5 Solenoid Valve ........................................................... 62
7.6 Reach Cylinder ........................................................... 64
7.6.1 Cylinder Removal Precautions ......................................64
7.6.2 Cylinder Installation Precautions ...................................65
7.7 Hydraulic Troubleshooting .......................................... 68
7.8 Hydraulic Symbol........................................................ 69
8. ELECTRICAL SYSTEM ................................................. 71

8.1 Controller .................................................................... 73
8.1.2 Controller Interface Function .........................................73
8.2 Fuse............................................................................ 75
8.2.1 Location of Fuses ..........................................................75
8.3 Key Switch .................................................................. 77
8.4 Charge Gauge ............................................................ 78
8.5 LED Charging Indicator .............................................. 79
REV. 09/2016
3-5
TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION PAGE
8.6 Lifting Limit Switch ...................................................... 80
8.7 Interlock Switch .......................................................... 81
8.8 Speed Mode Switch (Optional) ................................... 82
8.8.2 Connection Mode ..........................................................82
8.9 Handheld Unit (Optional) ............................................ 84
8.9.1 Handheld Unit Connection.............................................84
8.9.2 Handheld Unit Main Menu .............................................84
8.9.3 Parameter Settings ........................................................85
8.9.4 TESTER Menu ..............................................................87
8.10 Controller Error Message ......................................... 88
8.10.1 Traction Controller .......................................................88
8.11 Electrical Schematic Diagrams ................................. 91
8.12 Cable Wiring Diagrams............................................. 94
8.13 Wiring Harness and Connectors............................... 95
9. TROUBLESHOOTING ................................................... 97
9.1 Preparation Before Troubleshooting ........................... 99
9.1.1 Check the Voltage of Battery .........................................99
9.2 Troubleshooting Solutions of Common Faults .......... 100
APPENDIX ................................................................ 103
B SERVICE MANUAL - BATTERY ................................. 105

B1 Lead-acid Battery ...................................................... 107
B1-1 Safety and Warnings .............................................. 107
REV. 09/2016
4-5
TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION PAGE
B1-2 Use of Battery ........................................................ 107
B1-2.1 Pre-use Checks ........................................................107
B1-2.2 Discharging ...............................................................107
B1-2.3 Charging ...................................................................108
B1-2.4 Temperature ..............................................................108
B1-3 Maintenance & Care ............................................. 108
B1-3.1 Daily Maintenance ....................................................108
B1-3.2 Weekly Maintenance.................................................108
B1-3.3 Monthly Maintenance ................................................109
B1-3.4 Care ..........................................................................109
B1-4 Storage .................................................................. 110
B1-5 Troubleshooting ..................................................... 110
B2 Maintenance-free Battery ......................................... 113

B2-1 Safety and Warnings .............................................. 113
B2-2 Use of Battery ........................................................ 113
B2-2.1 Pre-use Checks ........................................................ 113
B2-2.2 Discharging ............................................................... 113
B2-2.3 Charging ................................................................... 114
B2-3 Maintenance & Care .............................................. 114
C SCHEDULE ................................................................. 115
REV. 09/2016
5-5
TABLE OF CONTENTS
REV. 09/2016
SAFETY WARNING
For your own safety and that of others, please observe the following safety instructions:
Thorough and normative maintenance is one of the most important prerequisites to ensure
stable and reliable operation of truck. Neglecting regular maintenance could easily lead
to the truck malfunction and failure, and potential threats to staff and operational safety.
Therefore, there must be adequate maintenance equipment, professional maintenance
personnel and a comprehensive maintenance plan in place.
Please perform the maintenance and inspections according to the following provisions:
1. To strictly enforce the truck maintenance, lubrication and inspection plans.
2. Truck maintenance, lubrication and inspection personnel must be approved by accredited
certification or evaluation agency.
3. The following operations shall be performed before you leave the truck:
- No parking on slopes.
- Fully lower the forks.
- Cut off the power supply.
- Turn the switch lock to “STOP” and remove the key.
4. Prior to truck maintenance:
- Raise the drive wheel off the ground, or cut off the power supply connection.
- Use wooden wedges or other effective fixtures.
- When performing maintenance underneath the vehicle, make sure that the lifting device
or jack leg is secure.
- Park your vehicle in a safe and secure area.
5. Never use an open flame to check level of electrolyte, other oils or fluids for leaks.
6. Keep the parking lot clean, well-ventilated and dry.
7. Regular checks and maintenance should be conducted to braking, steering, control, warning
and safety devices to keep them in good condition.
8. All nameplates and safety signs on the truck should be cleaned regularly to make them
clearly visible.
9. Regular checks and maintenance should be conducted to all the devices of lifting system to
ensure them to be safe for use.
10. The hydraulic system should be checked regularly based on usage. Hydraulic cylinders,
hydraulic valves and other hydraulic components should be ensured to be without leakage.
11. Regular checks and maintenance should be conducted to batteries, motors, controllers,
limit switches, protective devices, wires and connectors, and so on. Please pay particular
attention to the electrical insulation.
12. Park the truck in a clean environment to minimize the risk of fire.
13. Without the permission of the manufacturer, users are not allowed to change or increase
the capacity of the truck. After having been changed under permission, the nameplates and
safety signs on the truck should also be changed accordingly.
1. INFORMATION & SPECIFICATIONS 1
1
NOTE:
2
INFORMATION & SPECIFICATIONS
1.1 After-sales Service Platform

Claims/Replacement Parts Service Platform: After-sales Maintenance Service Platform:
1
Customer Customer
Claim Form Claim Form
[email protected] [email protected]
Customer service to input Customer service to input

into After-sales System. into After-sales System.
After-sale Engineer to After-sale Engineer to call
call back to confirm the back to confirm about the
accuracy of the information specific fault information.
about the components.
Maintenance service Within two business

specialist will provide days after the mainten-
Components on-site service at the ance, customer service
Warehouse appointed time. will call back and close
the claim.
Shipped within
24 hours
Customer Customer
i NOTE
In order to provide you with a fast and efficient
after-sales service, when you claim / order spare
parts or after-sales service upon maintenance,
please provide accurate truck model, vehicle
body serial number and part number.
REV. 09/2016
3
1.2 Introduction
No. Name No. Name

1 Control Lever 8 Battery
2 Emergency Stop Switch 9 Chassis
3 Charge Gauge 10 Balance Stand / Caster Wheel
4 LED Charging Indicator 11 Drive Wheel
5 Key Switch 12 Lower Cover
6 Upper Cover 13 Lift Cylinder
7 Charging Plug
REV. 09/2016
4
This series are electric pallet trucks. Its import-

ant structure is as shown in Figure 10001.
WARNING 1
- Please refer to the nameplate for rated load
capacity of the vehicle.
- The vehicle can only be used on the level gro-
und indoors, never use it on mezzanine or
balcony area.
WARNING
Truck can only be operated by single operator;
other personnel is forbidden from riding.
1.3 Common Tools
No. Name Remark

1 Hex Wrench 2#~14# One Set
2 Hex Head Socket Wrench 10#~27# One Set
3 Phillips Screwdriver 2# One Piece
4 Slotted Screwdriver 2# One Piece
5 Circlip Pliers One for holes and one for shaft
6 Hammer One Piece
7 Spreader, Crane One Pair
8 Cylinder Wrenches For removal and installation of cylinders
9 Diagonal Pliers One Piece
10 Cylinder Pliers One Piece
11 Grease Gun One Piece
12 Tiger Tooth Wrench 22#/27# One of Each
REV. 09/2016
5
1.4 General Tightening Torques

Screws or bolts used on the truck are of 8.8
1 grade or higher performance level.
When you are conducting truck maintenance,
you can refer to Table 1.4.1 and Table 1.4.2 to
select the suitable screws or bolts for replace-
ment.
Table 1.4.1 Screws/Bolts Performance Levels

Performance Level Material Specification (mm)
5.8 5.8 grade Low carbon steel M6 ~ M48
Quenched and tempered medium

8.8 8.8 grade M6 ~ M48
carbon steel

10.9 10.9 grade M6 ~ M48
carbon alloy steel

12.9 12.9 grade M6 ~ M48
carbon alloy steel
CAUTION
- The performance levels of screws or bolts are
marked on the heads of the screws or bolts.
- If you find the screws or bolts used on certain
position are not marked with performance
level, please select spare parts with perform-
ance level of at least 8.8 grade or higher level
forreplacement.
REV. 09/2016
6
Table 1.4.2 Metric Screws/Bolts Tightening Torque Table (n•m)
Nominal Diameter 5.8

Performance Level
8.8 10.9 12.9
1
(mm) Proof Stress (MPa)
380 600 830 970
M6 7~8 10~12 14~17 17~20
M8 16~18 25~30 34~41 41~48
M8×1 17~20 27~32 37~43 43~52
M10 31~36 49~59 68~81 81~96
M10×1 35~41 55~66 76~90 90~106
M12 55~64 86~103 119~141 141~167
M12×1.5 57~67 90~108 124~147 147~174
M14 87~103 137~164 189~224 224~265
M14×1.5 144~170 149~179 206~243 243~289
M16 136~160 214~256 295~350 350~414
M16×1.5 144~170 228~273 314~372 372~441
M18 186~219 294~353 406~481 481~570
M18×1.5 210~247 331~397 457~541 541~641
M20 264~312 417~500 576~683 683~808
M20×1.5 294~345 463~555 640~758 758~897
M22 360~431 568~680 786~941 918~1099
M22×1.5 395~473 624~747 803~1034 1009~1208
M24 457~547 722~864 998~1195 1167~1397
M24×2 497~595 785~940 1086~1300 1269~1520
M27 669~801 1056~1264 1461~1749 1707~2044
M27×2 723~865 1141~1366 1578~1890 1845~2208
M30 908~1087 1437~1717 1984~2375 2318~2775
M30×2 1005~1203 1587~1900 2196~2629 2566~3072
M36 1587~1900 2506~3000 3466~4150 4051~4850
M36×3 1680~2011 2653~3176 3670~4394 4289~5135
M42 2538~3039 4088~4798 5544~6637 6479~7757
M42×3 2731~3269 4312~5162 5965~7141 6921~8345
M48 3813~4564 6020~7207 8327~9969 9732~11651
M48×3 4152~4970 6556~7848 9069~10857 10598~12688
REV. 09/2016
7
REV. 09/2016
8
2. MAINTENANCE
9
NOTE:
10
MAINTENANCE
2.1 Overview
i NOTE
Only by performing regular vehicle maintenance - Under harsh working conditions: such as, the
and repair, can ensure the continuous and external temperature is too high or too low,
reliable use of the truck. dusty, or implementing multiple shifts per day,
Only specially trained and qualified personnel the maintenance and care interval should be
are capable of maintenance and repair shortened.
operations of the equipment. If you want to
perform the maintenance and repair on your
- Prior to lubrications, replacement of filters or
operating the hydraulic system, please clean
2
own, it is recommended that on-site training the external parts carefully and use a clean
should be conducted to your maintenance container.
personnel by the service representative of the
- Only compliant lubricants can be used See
vendor.
Table 2.2 Lubricants.
Working conditions:
- Truck must be parked on the level ground
reserved for maintenance (such area needs
to be clean and with less dust), block the
wheels with wooden wedges, disconnect
the key switch and disconnect the battery
connections.
- When lifting the truck, the lifting tools can
only be installed on the fixed positions as
specified.
- When jacking up the truck, appropriate tools,
such as wedge blocks, wooden blocks, and
so on, must be used to secure the truck to pr-
event the occurrence of accidental rolling or
tipping over.
WARNING
When lifting load components or during the
operations under the cabin, sufficiently strong
chains or safety device must be used to secure
the vehicle.
CAUTION
Without the supplier's consent, it is strictly
forbidden to make modifications to truck, espe-
cially to the safety devices. It is strictly forbidden
to change the various working speeds of the
truck.
REV. 09/2016
11
MAINTENANCE
2.2 Maintenance Regular inspection and maintenance under

harsh conditions of use:
2.2.1 Cleaning Under harsh working conditions, especially:
- Dusty environment
- Do not use flammable liquids to clean the - Corrosive environment
truck. - Cold storage environment
- Before starting to clean, all necessary
2 security measures must be taken to prevent
sparking (short circuit) during operation. If the
The maintenance intervals should be shortened
by half.
truck is powered by battery, battery plug must

be pulled out.
- When cleaning electrical and electronic com-
ponents, you should use low-intensity suction
gas or compressed dry air. Meanwhile, clean
the dust on the surface of components with
non-conductive and antistatic brush.
- Do not use vapor steam to clean the equipm-
ent.
2.2.2 Inspection
Regular inspection and maintenance under
normal conditions of use:
Operating
Requirements
Hours (h)
50 At least once per 7 days
1000 At least once every 6 months
2000 At least once per year
CAUTION
When the truck is at running-in phase (after
approximately 100 hours of operation), the
equipment user must check the fastening of
wheel nuts and bolts and re-tighten them if
necessary.
REV. 09/2016
12
MAINTENANCE
Table 2.1 Inspection & Maintenance List

Interval in days/months/years 7d 60 d 90 d 6m 1y
Interval in hours 50 250 500 1000 2000
Functions and Control
Check the functions of the operation switches and
display
A 2
Check alarm system functions A
Check interlock switch functions A
Check the emergency switch functions A
Check the cables for damage and if the terminals are
A
secure
Check the lifting limit switch functions A
Check and tighten the controllers and contactors A
Check fault information records and operating hours A
Power Supply & Drive System
Check the battery cables for damage and replace if
A
necessary
Check the battery charge connector A
Check if the cable connections between battery mon-
omers are secure, apply some grease to electrodes if A
necessary
Check the position of various bearings for noise A
Clean or add the gear grease A/L
Check the gearbox for abnormal noise or leaks A
Check and lubricate the bearings between drive motor
A/L
and gearbox
Check the drive wheel and load wheel for worn or
A
damage
Check the wheel bearings and fixation A
A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the
vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.
REV. 09/2016
13
MAINTENANCE
Table 2.1 Inspection & Maintenance List (Continued)

Power Supply & Drive System
2 Check the bearing bridge for damage or crack

Check the travel speed
A
A
Hydraulic System
Check the functions of hydraulic system A
Check if the hoses, pipes and interfaces are fastened
A
or sealed securely, and check if there is damage
Check the cylinders for leaks A
Check the cylinders for damages and check the fixation A
Check the oil tank fixation and check for leaks A
Check the hydraulic oil level A
Replace after 100 hours of early operation.
Clean or replace the hydraulic oil
Then replace once every 2000 hours
Check the function of emergency pressure relief
A
valve
Check and clean oil tank air filter A
Replace the oil tank air filter and filter A
Check the relief pressure A
Breking System
Check the braking functions of electromagnetic brake A
Check the air gap of electromagnetic brake A
Check the installation and connection of electromagn-
A
etic brake
Check the braking distance of electromagnetic brake A
A = Check / Adjust
vehicles.
L = Lubrication
REV. 09/2016
14
MAINTENANCE
Table 2.1 Inspection & Maintenance List (Continued)

Lifting Mechanism
Check the connecting rod mechanism for wear or
damage
A 2
Check whether the pin shaft is fixed securely A
Check and lubricate the moving parts of connecting
A/L
rod mechanism
Check the lifting and lowering speed A
Other
Check if the signs are clear and complete A
Check the chassis for cracks or damages A
Check the connections of bolts and nuts A
Checking covering parts for damages A
Check if the optional features are functioning properly A
A = Check / Adjust
vehicles.
L = Lubrication
REV. 09/2016
15
MAINTENANCE
2.2.3 Lubrication Please see Table 2.2 for the lubricants used in
this truck.
Lubricant
CAUTION
- Improper operations may constitute hazards
to the operator's health and life, as well as to The use and disposal of lubricants must be
the surrounding environment. carried out in strict accordance with the manufa-
2 - When storing or adding lubricant, use clean

containers. It is strictly forbidden to mix
cturer's regulations.
different types and specifications of lubricants

with each other (except for those can be
mixed under clear statement).
Sliding surface
Hydraulic oil injection nozzle
Gear oil injection nozzle
REV. 09/2016
16
MAINTENANCE
Table 2.2 Lubricants
Code Type Specification Amount Position
Anti-wear hydraulic oil L-HM46

Hydraulic
A Low temperature anti-wear 0.65 L
L-HV32 System
B
hydraulic oil (cold storage)
Multi-purpose grease Polylub GA352P Appropriate amount

Sliding surface 2
(See Table 2.3)
C Grease (MoS2) - 100 grams Gearbox
Table 2.3 Sliding Surface

Lubrication Table
Code Position
L1 Mounting Shaft
L2 Steering Bearing
L3 Drive Wheel
L4 Long Shaft
L5 Load Wheel
REV. 09/2016
17
MAINTENANCE
REV. 09/2016
18
3. STRUCTURE & FUNCTIONS
19
NOTE:
20
STRUCTURE & FUNCTIONS
3.1 Structure & Functions

3.1.1 Travel Switch
Location: control lever;
Function: to output travel speed signal to the
drive controller;
Description: when the vehicle is powered on,
the travel switch is at Middle position;
Note: Unserviceable.
Travel Switch
3
3.1.2 Lifting/Lowering Switch
Function: to lift / lower the fork;
Description: the lifting/lowering switch is nor-
mally-open. When pressing, the switch is on;
after release, the switch will automatically reset;
Lifting/Lowering Switch
3.1.3 Emergency Reverse Switch Emergency Reverse Switch

Function: press the switch, the vehicle will
travel in reverse direction;
Description: reverse switch is normally-open.
When pressing, the reverse switch is on; after
release, the switch will automatically reset;
3.1.4 Horn Switch

Function: to press the horn;
Description: the horn switch is normally-open.
When pressing, the horn switch is on; after re-
lease, the switch will automatically reset;
Horn Switch
REV. 09/2016
21
3.1.5 Emergency Stop Switch Emergency Stop Switch

Location: electrical mounting plate;
Function: to disconnect the circuit and switch
off all electrical functions, achieving emergency
braking;
Description: under normal circumstances,
switch cover is at high position, and the circuit is
connected, when pressing this switch, the circuit
is disconnected;
3 Note: Unserviceable.
3.1.6 Key Switch

Function: for operator to switch on or off the
truck;
Description: remove the key to prevent opera-
tions to the truck by unauthorized operator;
Key Switch
3.1.7 Charge Gauge

Function: display battery power, working hours
(this function is available on the component with
timer function);
Description: 24V operating voltage;
Charge Gauge
3.1.8 LED Charging Indicator

Function: to determine the charging state by
the color displayed;
Description: can display three colors, red,
yellow and green;
LED Charging Indicator
REV. 09/2016
22
3.1.9 Buzzer
Function: can provide sound alarm through the
operation to horn switch operation;
Buzzer
3.1.10 Fuse 3
Function: overcurrent protection;
Description: fusing current is 100A;
Fuse
3.1.11 Controller
Function: to control the truck through the signal
input ;
Description: 24V operating voltage, to control
the circuit;
Controller
3.1.12 Charger
Function: charge the battery;
Description: 100V~240V operating voltage,
Charger
REV. 09/2016
23
3.1.13 Lifting Limit Switch

Location: bracket;
Function: limit the lifting height of the fork;
Description: lifting limit switch is normally
closed. When the fork is lifted in higher position
(that is to trigger the limit switch to disconnect),
lifting will be limited;
Lifting Limit Switch
3
3.1.14 Interlock Switch
Location: at handle joint;
Function: the truck cannot be operated if the
interlock switch is not closed;
Description: to prevent misuse of truck;
Interlock Switch
3.1.15 Pump Motor

Function: to provide power for gear pump for
lifting the loading rack;
Description: upon receiving the signal input by
control switch, traction controller to control the
power transmission of pump motor;
3.1.16 Gear Pump

Location: below the valve body;
Function: to provide pressure for hydraulic sys-
Pump and Motor Assembly
tem of the entire vehicle;
Description: N/A;
REV. 09/2016
24
3.1.17 Pump Contactor

Location: outside of the pump motor;
Function: to connect and disconnect circuit of
pump motor, and to control the power trans-
mission of pump motor;
Description: the signal obtained by drive
controller from lifting switch controls the ON/
OFF of pump contactor;
3
3.1.18 Solenoid Valve
Pump Contactor Solenoid Valve
Location: on valve body at pump and motor as-
sembly;
Function: to realize the lowering of fork, con-
troller gets signal from the lowering switch to
control the absorption of solenoid valve, forming
a hydraulic circuit;
REV. 09/2016
25
REV. 09/2016
26
4. CHASSIS SYSTEM
27
NOTE:
28
CHASSIS SYSTEM
4.1 Load Wheel

4.1.1 Removal and Installation
Removal
- Lift the vehicle carefully with lifting equipment
through the lifting holes at back;
WARNING
Make sure the lifting equipment is solid and
secure, and the load capacity should be greater
than the total weight of the vehicle.
Single Wheel (see Figure 10103)

- Remove the coiled elastic cylindrical pin (1)
within the wheel bracket with an ejector pin;
4
- Knock out the wheel pin shaft (2) from side
and remove load wheel and bearing assem-
bly;
- Remove the bearing (3) of load wheel (4) with
hammer and jacking equipment.
- Place a wooden wedge under the chassis
near load wheel, make the load wheel off the
ground;
WARNING
When replacing wheels, be sure that the truck
won't tilt.
Double Wheels (see Figure 10102)

- Remove the coiled elastic cylindrical pin (2)
within the wheel bridge (1) with an ejector pin;
- Turn the wheel bridge to vertical direction,
knock out the wheel pin shaft (3) from side,
and remove the load wheel and bearing Installation and Commissioning
assembly; - Install according to the reverse order of rem-
- Remove the bearing (5) of load wheel (4) with oval;
hammer and jacking equipment. - Run the truck to see if the load wheel is fun-
ctioning properly. If there is blocking or noise,
please install again.
REV. 09/2016
29
CHASSIS SYSTEM
4.2 Cover
CAUTION
When installing, please apply appropriate 4.2.1 Removal and Installation
amount of grease on the axle first.
(See Section 2.2.3 for specifications)
Removal
Quality of tyres directly affects the stability and - Unscrew the two large flat-head screws (1),
driving performance of the device. and pull out the upper cover (2);
If you need to replace the factory-fitted tyres, - Unscrew the six screws (3) with a wrench
please use original spare parts provided by the and remove the upper drive cover (4) and the
equipment manufacturer to reach the original lower drive cover (5).
design performance of the truck.
4.1.2 Faults and Causes
4 1
Fault Bearing noise or jammed
Cause Bearing fatigue damage or foreign
Abnormal tyre wear, cracking or
Fault
2 degumming
Cause Improper use
CAUTION
The covers are all made of plastic materials,
even force must be applied when pulling, be
sure not to concentrate the force on one spot to
prevent the covers from being damaged.
Installation
- Install according to the reverse order of rem-
oval.
REV. 09/2016
30
CHASSIS SYSTEM
4.3 Lifting Mechanism

4.3.1 Fork Inspection
Lower the forks completely down: Lift the forks completely:
The truck is equipped with batteries, the height The truck is equipped with batteries, the height
from fork surface at center of load wheel to the from fork surface at center of load wheel to the
ground (h1): ground (h2):
- Single Wheel : 75 mm ~ 78 mm - Single Wheel : 190 mm ~ 193 mm
- Double Wheels : 83 mm ~ 87 mm - Double Wheels : 198 mm ~ 202 mm
- Ultra-low Placement : 42 mm - Ultra-low Placement : 117 mm
4.3.2 Connecting Rod Adjustment

WARNING
- Fully lower the forks and switch off the power
supply; Make sure the lifting equipment is solid and
- Lift the vehicle carefully with lifting equipment than the total weight of the vehicle.Lifting height
through the lifting holes at at front and back; of not more than 400mm, to prevent the hazards
to the maintenance personnel working under
the vehicle for connecting rod adjustment.
- Loosen the retaining nut, adjust the relative

distance between long rod and connector;
- Turn the connector for 180° according to the
arrow direction in the figure, the forks can
then be lowered for 3 mm, whereas can be
Retaining Nut lifted for 3mm;
- Adjust the fork surface distance to standard
Connector Long Rod value, tighten the retaining nut.
REV. 09/2016
31
CHASSIS SYSTEM
4.2.3 Removal and Installation - Tap the coiled elastic cylinder (11) into the
short axis (12), and tap the short axis (12)
Removal out from the side to separate the lower
connecting rod with the bearing bridge;
- Lift the vehicle carefully with lifting equipment
through the lifting holes at at front and back; - Remove the circlip (8) from the holes at both
sides of front chassis, tap out the support
WARNING shaft (7) and remove the lower connecting
rod (10);
Make sure the lifting equipment is solid and
- Remove the shaft circlip (9), and the
adjustable long connecting rod can then be
than the total weight of the vehicle.Lifting
removed from the lower long connecting rod
height of not more than 400mm, to prevent the
(6).
hazards to the maintenance personnel working
under the vehicle for connecting rod removal - Tap the coiled elastic cylinder (3) out, tap the
and installation. long connecting rod pin shaft (4) out from the
side, and remove the wheel frame assembly
4 (5).
CAUTION
When replacing the long connecting rod, the
connecting rod must be adjusted so that the fork
surface height can reach the specified value.
Installation
oval.
CAUTION
Before going on with the next step, please fix
the wheel bracket first. Be sure to avoid the
falling of wheel bracket during removal, resulting
in personal injury.
- Tap the coiled elastic cylinder (1) into the axle
(2), and tap the axle (2) out from the side
to separate the wheel frame from the front
chassis;
- Remove the drive cover; (see Section 4.2)
REV. 09/2016
32
5. DRIVE SYSTEM
33
NOTE:
34
DRIVE SYSTEM
Drive System
No. Name
1 Drive Assembly
2 Electromagnetic Brakes
3 Gear Cover
4 Gear Case
5 Drive Wheel
6 Drive Motor
REV. 09/2016
35
DRIVE SYSTEM
5.1 Drive Assembly 5.2 Electromagnetic Brakes

5.1.1 Removal and Installation The truck is braked through electromagnetic
brake. When the truck is powered off, the
Removal electromagnetic coil (6) doesn't absorb the
- Remove the drive cover (see Section 4.2); pressure plate (8), the friction force generated
- Disconnect the connections between elbow between brake pads (2), pressure plate and
friction plates (5) will prevent the drive motor
wiring harness, interlock switch, positive and
from rotating, thus to brake the vehicle.
negative elec-trode cables of motor and the
controller.
- Unscrew the five screws (4) with a wrench,
and remove the handle assembly (5) off from
the drive assembly (3);
- Unscrew the bolt (1) and knock the drive
assembly (3) down with a hammer to remove
it from the bearing bridge (2).
WARNING
5 When knocking, be sure to protect the wire

harness cable from being damaged.
No. Name
1 Mounting screws
2 Brake pads
3 Brake gear
4 Dust cover
5 Friction plate
Installation 6 Electromagnetic coil
- Install according to the reverse order of rem- 7 Spring

oval. 8 Pressure plate
REV. 09/2016
36
DRIVE SYSTEM

CAUTION
Removal
When installing the brake gear (7), make sure
The brake is installed on the drive motor. See the flat key is installed on the shaft of drive
Figure 30204 motor (8).
Adjustment
The electromagnetic brake used in this series of
truck is an air gap adjustment-free brake. After
the normal installation is completed, the air gap
between electromagnetic coils and pressure
plate should be standard gap distance.
As shown in the following table:
Air gap Standard value Maximum value

s 0.2 mm 0.4 mm
- Switch off the truck power connections and CAUTION

pull out the brake connectors; When the air gap s exceeds 0.4mm, replace the
- Remove the drive cover;(see Section 4.2) brake pads (2, Figure 30203)
- Remove the three mounting screws (1) with
wrench. Remove the electromagnetic coil (2)
and dust cover (3);
- Remove the brake pads (4) and friction plates
(5) by order; After the coil is energized, the
Fault
- Remove the circlip (6) on the shaft with circlip pressure plate does not absorb
pliers and remove the brake gear (7). a. Mechanical part failure;
1 b. Foreign body blocking;
Installation Cause c. Coil failure;
d. Coil supply voltage less than
- Install according to the reverse order of rem- 24V
oval.
REV. 09/2016
37
DRIVE SYSTEM
After the coil is powered off, the Air Gap Checks

Fault
2 pressure plate won't release
- Switch off the truck power connections and
Cause Foreign body blocking pull out the brake connectors;
Fault Abnormal noise after absorption - Check the air gap between electromagnetic
coil and pressure plate with feeler gauge:
3 a. Fully absorbed, but plate not measurement method is as shown in Figure
Cause flat. 50208;
b. Mechanical resistance - Determine if the air gap is normal according
Fault Brake temperature is too high to the gauge measurements.
4 Pressure plate does not fully
Cause absorb, overcurrent of the coil, or Air gap distance Judgment
energized too frequently
0.2~0.4mm Normal
The air gap is too large
5.2.3 Checking and Testing > 0.4mm
(replace brake pads)
Electromagnetic Coil Checks
i NOTE
5 - Switch off the truck power connections and
pull out the brake connectors; After a period of use, brake pads of the electr-
omagnetic brake will wear. After being worn
- Check the resistance of the coil with a multi-
meter: measurement method is as shown in too much, the air gap between electromagnetic
Figure 30206; coil and pressure plate may exceed the
predetermined maximum value, which may
cause electromagnetic absorption failure.
Foreign Body Checks

Foreign bodies stuck in the brake may affect the
normal absorption of pressure plates.
Check if there is foreign body in the air gap that
may affect the absorption or bouncing off of the
pressure plates.
Spring Checks
- Identify if the electromagnetic coil is normal Deformation or foreign bodies stuck in the
according to the readings of resistance on the spring may affect the normal absorption of
multimeter. pressure plates.
Check if the distribution of the springs on the
Resistance electromagnetic coil is correct, and check if
Judgment
Measurement there is foreign body in the spring hole.
Approx. 30 Ω Normal
Coil shorting i NOTE
0Ω
(replace the brake) After a period of time of use, the springs may
be deformed due to the effect of radial force,
Coil breaking
∞Ω such case may result in abnormal air gap of the
(replace the brake)
brake, and the spring must be replaced.
REV. 09/2016
38
DRIVE SYSTEM
5.2.4 Control Circuit Troubleshooting

Brake Control Circuit (Figure 30207)
Check if the circuit is broken by using a multi-
meter:
- Set the multimeter to ON-OFF;
- Check if #6 circuit (circuit between brake and
controller) is conducted;
- Check if #7 circuit (circuit between brake and
controller) is conducted;
REV. 09/2016
39
DRIVE SYSTEM
5.3 Drive Wheel - Loosen the six screws (9) with a wrench, and
dismantle the large ring gear (10), bearing (11)
5.3.1 Removal and Installation and drive wheel (12) by order.
Removal
Installation
- Remove the brake (see Section 5.2.1);
(See Figure30208) - Install according to the reverse order of rem-
oval.
CAUTION
Tyre wear can affect the stability of the truck,
adjust the caster with minor wear on a regular
basis, or replace the caster with heavy wear.
Quality of tyres directly affects the stability and
driving performance of the device. If you need
to replace the factory-fitted tyres, please use
original spare parts provided by the equipment
manufacturer to reach the original design
performance of the truck.
5
- Dismantle the motor cable mounting base (1), 5.3.2 Faults and Causes
and remove the motor cables (2);
Fault Drive wheel slipping or jumping
- Loosen the eight screws (3) with a wrench, 1
and remove the gearbox cover (4) and gear Cause Wear
set (5); Drive wheel cracking or degumm-
Fault
- Unscrew the five screws (6) and knock out 2 ing
the assembly (7) from the gearbox;
Cause Improper use
Fault Vehicle sways while running
3
Cause Drive wheel lock nut loosening
(See Figure30209)
- Knock out the drive motor (13), and remove
the oil seal (8);
REV. 09/2016
40
DRIVE SYSTEM
5.4 Drive Motor - After replacing carbon brush, running opera-

tion must be carried out to the carbon brush:
This truck obtains drive force through DC motor. By running the motor with repeated lifting,
letting the carbon brush to be fully running,
making its surface smooth to fit the rotor.
Drive Motor
See Section 5.3.1 . 5.4.2 Faults and Causes
Carbon Brush Fault Motor does not rotate

- Unscrew the three screws (1) and remove a. Negative electrode cable
motor end cover (2) ; broken;
- Unscrew the two screws (5) and remove the b. Motor positive and negative
carbon brush (7) on the holder (6). electrode with loose terminals;
1 c. Armature winding with broken
- Install according to the reverse order of rem- Cause
circuits;
oval. d. Motor bearing damaged and
blocked;
e. Serious wearing of carbon
Fault
brush.
Motor speed is turning slow
5
a. Insufficient voltage of battery;
b. Carbon brush worn or carbon
brush spring pressure
2 decreases;
Cause c. Bearing wear or lack of
lubricating oil;
d. Armature winding has short
circuit elements;
e. Carbon brush winding grounded.
CAUTION Motor sometimes can start,
Fault
When replacing the carbon brush, replace the sometimes cannot
complete set of carbon brushes. a. Motor positive and negative
3 electrode with loose terminals
WARNING and poor connection;
Cause
Due to magnetic force, the rotor and the stator b. Carbon brush wear and tear;
may pull each other, therefore, when disman- c. Armature winding has circuit
tling motor rotor, do not hold your hand between broken unit.
the rotor and the stator to avoid pinch hazard!
Motor with abnormal noise or
Fault
vibration
Adjustment a. Uneven clearance between
4 stator and rotor;
- After replacing the motor or carbon brush,
conduction test must be carried out to the Cause b. Bearing failures;
motor (see Section 5.4.3). c. Loosening fixing screws on
motor housing.
REV. 09/2016
41
DRIVE SYSTEM
Fault Motor smoking or burning smell Circuit of drive motor

5 Stator winding short circuit, motor
Cause
burnt
Fault Excessive temperature rise
a. Stator winding short circuit;

b. Motor positive and negative
6 electrodes with surface
Cause oxidation, resistance increases
and results in heating;
c. Bearing failure, resulting in
severe heating. Positive
Negative
5.4.3 Checking and Testing

Checking
- Check if the drive motor and appearance of
5 cables are in good condition, and if the plug
connection is secure;
- Check if the circuit is connected.
Testing
- Remove the cables on the drive motor;
- Carry out ON/OFF test to motor positive and
negative electrodes with a multimeter:
If connected, the motor is normal;
If not connected:
1) Broken circuits in rotor coils (replace the
motor);
2) Carbon brush wearing, move on to the
next step.
- Replace the carbon brush .
(See Section 5.4.1)
CAUTION
When replacing the carbon brush, replace the
complete set of carbon brushes.
REV. 09/2016
42
DRIVE SYSTEM
5.5 Gearbox
See Section 5.3.1 .
CAUTION
Please add gear oil to the grease nipple on the
gearbox cover (see Section 2.2.3 for specifica-
tion and filling amount)
Fault Gearbox Abnormal Noise
1 a. Supporting bearing wear;

Cause b. Gear wear, the gap is too big;
c. Foreign objects in gear oil.
Fault Gearbox Oil Leaks
2
Cause Oil seal wear or aged 5
Fault Gearbox Stuck
a. Gear fastening screws or nuts
3 loosening;
Cause
b. Support bearing damage
c. Foreign objects in gear oil.
REV. 09/2016
43
DRIVE SYSTEM
REV. 09/2016
44
6. OPERATING SYSTEM
45
NOTE:
46
OPERATING SYSTEM
6.1 Control Lever 6.2 Button Switch

Control lever is used to control the travel, lifting, Push button switch is the switch that makes
lowering, horn and emergency reverse of the the dynamic and static contacts ON or OFF to
vehicle. achieve the switching of circuits through push-
button drive mechanism. In the electrical control
Removal circuits of this truck, the push button switch is
used for manual emitting of control signals to
Control lever is mounted on control arm (5, Fig- control the vehicle lifting, lowering, horn and
ure 30301). emergency reverse.
- Remove four screws (1) , lift up cap assem-
By function:
bly (2);
- Lifting Button Switch
- Disconnect control lever wiring harness from - Lowering Button Switch
wiring harness; - Horn Button Switch
- Unscrew two screws (4), remove the control - Emergency Reverse Switch
lever (3).
Lifting/Lowering/Horn Switch
(See Figure 30302)
- Remove pin (6&18) securing switches (16) ;
- Unscrew three screws (11), remove the wire
clamps (12) and remove the lifting-lowering-
horn switch wiring harness (15).
6
oval.
Lifting-Lowering Button
Lifting-Lowering Button
Installation
oval.
Horn Button
CAUTION Lifting Switch
Lowering Switch
When removing or installing, please pay attent-
ion to protect the cables from being damaged.
Horn Switch
REV. 09/2016
47
OPERATING SYSTEM
Lifting/Lowering Button 6.2.2 Faults and Causes

(See Figure 30302)
Operate the push button switch,
- Remove switch assembly (5 or 9) form cap Fault but the vehicle responds with no
(1); action
- Remove pin (6) securing buttons and remove 1
a. Push button switch failure;
the lifting button (2 or 7) , the lowering button Cause b. Push button switch circuit not
(3 or 8) and springs (4). conducted.
Push button switch not operated,
oval.
Fault but the vehicle responds with
2 action
Horn Button
Cause Pushbutton switch failure
(See Figure 30302)
- Unscrew three screws (11) and remove bra-
cket (20) and springs (19) and horn button 6.2.3 Checking and Testing
(17).
Checking
oval. - Check if the pushbutton switch and the
appearance of cables are in good condition,
and if the plug connection is secure.
Emergency Reverse Switch
(See Figure 30303) Testing
6 - Remove pin (5) securing button and remove

the emergency reverse button (1) and springs
- Check if the push button switch circuit is
connected;
(2) from bracket (4). - Carry out ON/OFF test to the push button
- Remove pin (3) and remove the emergency switch with a multimeter:
reverse switch (6).
oval. Emergency Reverse
Button
Emergency Reverse
Switch
REV. 09/2016
48
OPERATING SYSTEM
Lifting Switch
(See Figure 30304)
- Carry out ON/OFF test to the circuit between
#1 and #2 with a multimeter:
push button switch at original position, broken
circuit;
press the button , the circuit is conducted.
Lowering Switch
(See Figure 30304)
- Carry out ON/OFF test to the circuit between
circuit;
press the button , the circuit is conducted.
Horn Switch press the button :

#1 - #12 : broken
(See Figure 30304) #1 - #13 : conducted
- Carry out ON/OFF test to the circuit between #1 - #12 : broken
circuit;
press the button , the circuit is conducted. 6.2.4 Control Circuit Troubleshooting
6
Lifting Switch Control Circuit
Emergency Reverse Switch
(Figure 30305)
(See Figure 30308)
- Carry out ON/OFF test to the circuit with a meter:
multimeter:
push button switch at original position:
#1 - #12 : conducted - Check if #1 circuit (circuit between lifting
#1 - #13 : broken switch and key switch) is conducted;
#1 - #12 : broken - Check if #2 circuit (circuit between lifting
switch and pump contactor) is conducted.
Pump Contactor
Key Switch
REV. 09/2016
49
OPERATING SYSTEM
Lowering Switch Control Circuit Emergency Reverse Switch Control

(Figure 30306) Circuit (Figure 30311)
Check if the circuit is broken by using a multi- See Section 6.3.4 .
meter:
- Check if #1 circuit (circuit between lowering
switch and key switch) is conducted;
- Check if #3 circuit (circuit between lowering
switch and solenoid valve) is conducted.
Key Switch
Solenoid Valve
6 Horn Switch Control Circuit

(Figure 30307)
meter:
- Check if #1 circuit (circuit between horn swit- Buzzer Checks
ch and key switch) is conducted; Energize the buzzer with a voltage of 24V:
Buzzer sounds, it is working properly;
- Check if #4 circuit (circuit between horn swit- Buzzer does not sound, it failure, needs to be
ch and buzzer) is conducted. replaced.
Buzzer
Key Switch
REV. 09/2016
50
OPERATING SYSTEM
6.3 Travel Switch 6.3.2 Faults and Causes

Travel switch provides forward or backward in- Operate travel switch, the vehicle
put signals for the vehicle. Fault
cannot go forward or backward
1 a. Travel switch failure;
6.3.1 Removal and Installation Cause b. Travel switch circuit not
conducted.
Removal
Travel switch not operated, the
(See Figure 30309) Fault vehicle goes forward or backward
- Remove four screws (1), lift up cap assem- 2 automatically
bly (2);
Cause Travel switch failure;
- Remove the emergency reverse button;(See
Section 6.2.1)
- Unscrew the screw(4 & 5) and remove the 6.3.3 Checking and Testing
travel switch (9).
Checking
- Check if the appearance of travel switch and
its wiring harness are in good condition, and
if the connectors are connected securely.
Testing
- Enter Monitor Menu to check the status of the
switch:
"Throttle", toggle the switch forward / back-
6
ward, if the display does not change, then it
indicates the travel switch or its circuit failure;
- Turn off the vehicle to check the travel swit-
ch and its wiring harness. (See Figure 30310)
- Energize the travel switch with a voltage of
24V and check the voltage of each port with
a multimeter;
Installation
oval.
CAUTION
When removing or installing, please pay attent-
ion to protect the cables from being damaged.
REV. 09/2016
51
OPERATING SYSTEM
- Place the travel switch at Middle position.

Respectively, measure the voltage of pin (11),
pin (12) and pin (22) of the travel switch:
if the voltage is not 0, it indicates the travel
switch failure, needs to be replaced;
if the voltage is 0, indicating the switch is
normal, move to the next step.
- Toggle the travel switch forward, measure the
voltage of pin (11), pin (12) and pin (22) of
the travel switch:
Pin(11) : 24V . Normal
Pin(22) : 0V~5V, the maximum value is
4V~5V. Normal
- Toggle the travel switch backward, measure
the voltage of pin (11), pin (12) and pin (22)
of the travel switch:
Pin(22) : 0V~5V, the maximum value is
4V~5V. Normal
6 6.3.4 Control Circuit Troubleshooting

Travel Switch Control Circuit
(Figure 30311)
meter:
- Check if #1/#9/#10/#11/#12 circuit (circuit
between travel switch and controller) is con-
ducted.
Potentiometer
Emergency Reverse Key Switch

Switch
Forward
Backward
Travel Switch
REV. 09/2016
52
7. HYDRAULIC SYSTEM
53
NOTE:
54
HYDRAULIC SYSTEM
The system pressure of the entire hydraulic Hydraulic Oil

system pressure is provided by hydraulic power
unit system, which is used for lifting. While the Hydraulic oil for truck:
hydraulic power unit is equipped with a relief Specifications: Anti-wear Hydraulic Oil L-HM46.
valve to ensure that the entire system pressure * For cold storage: Low Temperature Anti-wear
is always within the safety limits that can lift the Hydraulic Oil L-HV32.
maximum load capacity.
Solenoid valve on the valve body is used for the
control of lowering. Throttle valve is used for the Hydraulic Seals
control of lowering speed. Inlet is equipped with The seals installed within the cylinder are made
a filter to prevent the impurities in the hydraulic of rigid polyurethane. The deformation during
oil from entering into the pump. assembly due to compression will not cause a
Hydraulic Schematic Diagram is as shown in permanent deformation.
Figure 10401; When assembling, pay attention to prevent the
See Section 7.8 for hydraulic symbol descripti- seals from being broken, rolled and undercut.
ons.
Assembly Instructions
7.1 Overview The tools used to install the seals must be made
of soft metal or suitable plastic, without burrs
- Lower the fork to the bottom, remove the air and sharp edges on surfaces. It is prohibited
filter on cylinder, observe the oil level with the to use the tools that can easily damage the
oil dipstick. When adding hydraulic oil, please surface of seals, such as, screwdriver or other
use hydraulic oil of the same specifications. similar tools with hard front edges.
- When the fork occasionally jitters, that may Where the hydraulic seals to be installed should
be leaks in the cylinder, or there could be be free of burrs, sharp edges and cracks. If the
leaks on the valve body. Dismantle and clean
7
installation of seals needs to cross sharp edges,
(to clean with hydraulic oil of the same spe- grooves or cuts, protective devices must be
cifications) the valve on the valve body, disch- used for protection. Before installing, lubrication
arge the foreign bodies within the valve body should be performed to the seals and the
through repeatedly lifting and lowering of the mounting positions first.
mast.
- If hydraulic oil is becoming less, please tho- CAUTION
roughly check the hydraulic system for leaks. The lubricant used during assembly must be of
- Disassembly of cylinder needs to be perfor- the same specifications with the hydraulic oil
med in a clean environment. Before removing used in the vehicle.
the cylinder, the stains on the cylinder must
be removed first. Carefully remove the piston
rod to prevent the cylinder wall from being
scratched by its end surface or damaged
part. Every time when replacing the cylinder,
also replace the cylinder seals.
REV. 09/2016
55
HYDRAULIC SYSTEM
7.1.1 Hydraulic Schematic Diagram
REV. 09/2016
56
HYDRAULIC SYSTEM
7.2 Pump and Motor Assembly - Unscrew the two screws (3) with a wrench
and remove the hydraulic station from the
7.2.1 Removal and Installation electrical mounting plate.
Installation
Removal oval.
- Remove the upper cover; (see Section 4.2)
- Unscrew the articulated joint (1) with a wren- CAUTION
ch and disconnect the connection between When removing the tubing and pump and
the tubing and the cylinder; motor assembly, the system will lose some
- Remove wiring harness and cables between hydraulic oil, please refer to Section 2.2.3 for
electrical board assembly and the battery; supplementary adding of hydraulic oil.
- Unscrew the four bolts (2) with wrench and
remove the electrical board assembly from
the chassis;
7
- Remove the positive and negative electrode

cables from the pump contactor and the wires
from the solenoid valve;
REV. 09/2016
57
HYDRAULIC SYSTEM
7.2.2 Component 7.3 Pump Motor

Removal
- Remove the pump and motor assembly;

- Remove the 2 long screws (1) on the motor
end cover, and remove the pump motor (2)
from the valve block (3);
- If you need to replace carbon brush (4). Re-
move motor end cover, replace the carbon
brush on the holder.
7 No.
1 Pump Motor
Name CAUTION
2 Carbon Brush
3 Pump Contactor Installation
4 Solenoid Valve - Install according to the reverse order of rem-
5 Valve Body oval.
6 Gear Pump
CAUTION
7 Filter
When installing the pump motor, make sure the
8 Tank shaft and the coupling on motor rotor are mated
in place. (Rotate the motor around to make the
end surface of motor be in full contact with valve
block).
WARNING
Due to magnetic force, the rotor and the stator
may pull each other, therefore, when disman-
tling motor rotor, do not hold your hand between
the rotor and the stator to avoid pinch hazard!
REV. 09/2016
58
HYDRAULIC SYSTEM
Adjustment Motor with abnormal noise or

Fault
- After replacing the steering motor or carbon vibration
brush, conduction test must be carried out to a. Uneven clearance between
the motor (see Section 7.3.3). 4 stator and rotor;
- After replacing carbon brush, running opera- Cause b. Bearing failures;
tion must be carried out to the carbon brush: c. Loosening fixing screws on
By running the motor with repeated lifting, motor housing.
letting the carbon brush to be fully running,
Fault Motor smoking or burning smell
making its surface smooth to fit the rotor.
5 Stator winding short circuit, motor
Cause
burnt
7.3.2 Faults and Causes Fault Excessive temperature rise
Fault Motor does not rotate a. Stator winding short circuit;

b. Motor positive and negative
a. Negative electrode cable electrodes with surface
6
broken; Cause oxidation, resistance increases
b. Motor positive and negative and results in heating;
electrode with loose terminals; c. Bearing failure, resulting in
1 c. Armature winding with broken
Cause severe heating.
circuits;
d. Motor bearing damaged and
blocked;
e. Serious wearing of carbon 7.3.3 Checking and Testing
brush.
Checking
Fault Motor speed is turning slow
- Check if the pump motor and appearance of
cables are in good condition, and if the plug
7
b. Carbon brush worn or carbon connection is secure;
brush spring pressure - Check if the circuit is connected.
2 decreases;
Cause c. Bearing wear or lack of Testing
lubricating oil;
d. Armature winding has short - Remove the cables on the pump motor;
circuit elements; - Carry out ON/OFF test to motor positive and
e. Carbon brush winding grounded. negative electrodes with a multimeter:
Motor sometimes can start, If connected, the motor is normal;
Fault If not connected:
sometimes cannot
1) Broken circuits in rotor coils (replace the
a. Motor positive and negative motor);
3 electrode with loose terminals 2) Carbon brush wearing, move on to the
and poor connection; next step.
Cause
b. Carbon brush wear and tear; - Replace the carbon brush (See Section
c. Armature winding has circuit 7.3.1).
broken unit.
CAUTION
REV. 09/2016
59
HYDRAULIC SYSTEM
Circuit between pump motor and pump 7.4 Pump Contactor

contactor
This truck is using DC contactor with normally-
open contacts. And the ON/OFF of the
Negative contactors is controlled through controller, thus
to achieve the control of ON/OFF of the vehicle.
When the contactor coil (Between A and B) is
energized, the coil current will create a magnetic
field, making the static stator core produce a
steady magnetic force to absorb the core and
Positive drive the contactor actions: normally-opened
contact (C and D) connected, so the circuit is
disconnected.
When the contactor coil is powered off, the
magnetic force disappears, the pressure plate
is released along with the release of spring,
and the contact recovers: normally-opened con-
tact (C and D) disconnected, so the circuit is
disconnected.
7
Fault Contact adhesion or slow release

a. Contact fusion welding;
b. Contact spring pressure is too
1 low;
Cause
c. Mechanical moving parts
blocked, shaft rusted or crooked;
d. Anti-force spring damaged.
Contact not absorbed or not fully
Fault
absorbed
2 b. Main contactor coil open circuit;
Cause c. Mechanical moving parts
blocked, shaft rusted or crooked;
d. Control contact poor contact.
REV. 09/2016
60
HYDRAULIC SYSTEM
7.4.2 Checking and Testing Resistance

Judgment
Measurement
Checking
Approx. 22 Ω Normal
- Check if the pump contactor and appearance
of cables are in good condition, and if the Coil shorting
0Ω
plug connection is secure; (replace the contactor)
Coil breaking
Testing ∞Ω
(replace the contactor)
- Switch off the power supply of the vehicle;
If the coil is normal, move on to the next step.
- Carry out ON/OFF test to contacts of pump
contactor with a multimeter: - Energize the contactor coil between end point
If connected, but with contactor adhesion, A and B (24V):
replace the contactor; If the contact is not absorbed (without the
If not connected, move on to the next step; sound of absorption), the contactor is having
mechanical failure with its contact, replace
the contactor;
If the contact is absorbed (with the sound
of absorption), and contact C and D are
conducted, then the contactor is working pro-
perly.

Pump Contactor Control Circuit
(Figure 10301)
- Measure the resistance between pump

meter:
7
contactor coil end point A and B to identify if
the coil is normal; - Check if #5/#9 circuit is conducted.
Pump Contactor
Lifting Limit Switch
Key Switch
REV. 09/2016
61
HYDRAULIC SYSTEM
7.5 Solenoid Valve Fault Internal leakage

When solenoid valve coil is energized (there 3 Damaged seals or spring
Cause
is voltage between coil end A and B), the deformations
electromagnetic coil generates electromagnetic
Fault External leakage
force, and the spool will move, the valve will
open, and the vehicle will be lowered. 4 Loose connections or damaged
Cause
When the contactor coil is de-energized, the seals
closing part will be released under the effect Fault Noisy when energized
of the released spring, the hydraulic oil cannot
form a loop, thus the lifting mechanism cannot a. Unstable supply voltage;
5 b. Impurities on absorption surface
be lowered. Cause
or uneven surface of core,
needs cleaning.
Spool
Checking
Electromagnetic Coil - Check the solenoid valve connector for loos-
ening or poor connection of leads.
7.5.1 Faults and Causes Testing

- Switch off the power supply of the vehicle;
Solenoid valve does not work after
Fault - Measure the resistance between solenoid
energized
valve coil end point A and B to identify if the
a. Different power supply circuits; coil is normal;
7 b. Insufficient power supply

voltage;
as shown in the following table:
Resistance
c. Short circuit; Judgment
Measurement
1 d. Unsoldering coil (coil short
circuit); Approx. 32 Ω Normal
Cause
e. Main spool and moving core Coil shorting
of the solenoid valve blocked by 0Ω
(replace the solenoid valve)
impurities;
f. High viscosity of hydraulic oil; Coil breaking
∞Ω
g. High frequency of use, service (replace the solenoid valve)
life has expired already. If the coil is normal, move on to the next step.
Fault Solenoid valve cannot be closed - Check the solenoid valve for blocking:
a. Main spool or core seals broken the fitting clearance between slide valve
or aged; sleeve and spool is very small, when there
b. Main spool and moving core is impurity entering or too less lubricant, it is
of the solenoid valve blocked by easily blocked.
2 impurities; Handling method:
Cause
c. Spring deformation;
- Insert a steel wire from the small hole at va-
d. Balancing hole blocked by
lve end to make the spool rebound;
impurities;
e. High frequency of use, service
life has expired already.
REV. 09/2016
62
HYDRAULIC SYSTEM
- Remove the solenoid valve, take out the

spool and spool sleeve, clean with CCI4 to
enhance the flexibility of the moving of spool
within the spool sleeve. During disassembly,
pay attention to the sequence of assembly
and position of external wiring for correct re-
assembly and wiring, also check the oil mist
spray orifice for blockage and if the lubricant
is sufficient.
CAUTION
If the solenoid valve is found with the above
mechanical failures, it is recommended to re-
place the solenoid valve directly.

Solenoid Valve Control Circuit
(Figure 30306)
meter:
- Check if #3/#9 circuit is conducted.
7
Key Switch
Solenoid Valve
REV. 09/2016
63
HYDRAULIC SYSTEM
7.6 Reach Cylinder - Upon removal, the damage to cylinder

threads, oil port threads, cylinder cap threads,
7.6.1 Cylinder Removal Precautions piston rod surface and inner cylinder wall
should be prevented.
- Before removing the cylinder, be sure to reli-
eve the hydraulic circuit first, which is to lower In order to prevent piston rod from bending or
the lifting mast to the bottom. Otherwise, deformation, support it wooden block when
when removing the tubing connected with the placing.
cylinder, the pressured hydraulic oil within When removing seals, the use of sharp
the circuit may be sprayed out at high speed tools should be avoided, so as not to stab
along with the tubing, and there is risk of the seals. For the seals that are difficult to
causing personal injury. remove, soak them with boiled water, remove
Turn off the power source, so that the entire them when getting softened.
hydraulic system will stop functioning, then - Before removing, try to create conditions
the connecting tubing can be loosened; in
to prevent the cylinder parts from being
order to avoid the residual pressure within the
contaminated by the surrounding dust and
circuit, the tubing joint should be loosened
impurities. For example, try to disassemble
slowly, loosen the joint by half and shake the
the equipment in a clean environment; after
tubing to see if there is overflow of pressured
the disassembly, all parts should be covered
oil, and then go on with the removal;
with plastic, do not cover with cotton cloth or
- Cylinder is the powered actuator in hydraulic other cloth used during operation;
system. Therefore, before removing the - For the cylinder which is found with internal
cylinder from the equipment, the connection or external leakage during use, if the piston
part must be supported with appropriate rod or cylinder tube is not scratched, such
supporting to avoid personal injury or damage case may be due to wear or aged seals.
to the equipment;
- Cylinder is the powered actuator in hydraulic CAUTION
system. Therefore, before removing the
7 cylinder from the equipment, the connection
part must be supported with appropriate
When the seals need to be replaced, replace
with the complete set of seals in the cylinder
supporting to avoid personal injury or damage repair kit.
to the equipment;
- For the cylinder which is found with internal
- Upon disassembly of the cylinder, you should or external leakage during use, if the piston
know the main structure of the cylinder to rod or cylinder tube is not scratched, such
avoid sightless removal. Due to the different case may be due to wear or aged seals (when
size, structure, purpose of use of the replacing seals, replace with the complete set
cylinders, the sequences and methods used of seals in the cylinder repair kit).
for removal are also different;
Pay special attention to the cylinder tube,
- When removing each part, do not hammer piston rod and other moving parts for bumps
forcefully, it such case cannot be avoided, and scratches. If only minor damage, sand
please lay a copper rod to avoid damage the edge point around the damaged part with
to the parts; special tools must be used for fine stone and then polish the part smooth
the parts having such requirements, do not with metallographic sandpaper.
hammer forcefully or pry. Fine pitch threaded
cylinder cap, after being shaken loose,
loosen it with cylinder wrench with even force,
copper rod can be used to hammer the part
that cannot easily deform, do avoid violent
shocks.
REV. 09/2016
64
HYDRAULIC SYSTEM
CAUTION
Cylinder Cap
- O-ring is quite flexible and easy to install,
but it must not be pulled up to the extent of
permanent deformation, nor scroll it while
installing;
Cylinder Wrenches - Y-ring or X-ring needs to be identified if it is
for shaft or hole to avoid misplacement;
- The removed O-rings and dust rings should
be replaced with new ones.
Piston Rod
- Cylinder parts must not be arbitrarily repla-
ced, the original products provided by the
manufacturer should be used;
- After maintenance and assembly of the cylin-
Cylinder Tube der is completed, pressure leak testing must
be carried out before it can be put operation
once again.
Before the testing, discharge the air within
the cylinder, run the cylinder in a small range
of movement for several times, and pay
attention if it is moving without blocking and if
there is uneven resistance during the moving.
Upon the pressure testing, raise the pressure
7.6.2 Cylinder Installation Precautions slowly and observe carefully for leaks.
- All parts should be cleaned up before asse-
mbly, then to be assembled after being
dried;(during assembly, apply appropriate
amount of hydraulic oil for lubrication)
7
- The tools used to install the seals must
be made of soft metal or suitable plastic,
without burrs and sharp edges on surfaces.
It is prohibited to use the tools that can
easily damage the surface of seals, such as,
screwdriver or other similar tools with hard
front edges.
Where the hydraulic seals to be installed
should be free of burrs, sharp edges and
cracks. If the installation of seals needs to
cross sharp edges, grooves or cuts, protective
devices must be used for protection. Before
installing, lubrication should be performed to
the seals and the mounting positions first with
hydraulic oil.
REV. 09/2016
65
HYDRAULIC SYSTEM
7.6.3 Removal and Installation - Install the cylinder according to the reverse
order of removal ;
- Add hydraulic oil of the same specifications
into the tank, see Section 2.2.3;
- Pull out emergency stop switch and turn on
the key switch;
- Repeat Lift - Lower cylinder to discharge the
air within the tubings and cylinder;
- Check the hydraulic oil level and make sure
that the liquid is at standard level.
Cylinder Maintenance
- Lower the forks completely down, press the

emergency stop switch and turn off the key
switch;
- Remove the upper cover; (see Section 4.2.1)
- Turn the handle tube (2) to the right till the
end;
- Unscrew the articulated joint (1) and remove
7 the tubing from the cylinder;
CAUTION
Hydraulic oil may damage truck parts and cont-
aminate the environment. When removing joints
or tubings, place a clean container under it for
discharge of hydraulic oil.
- Unscrew two screws (4) and the screw (5);
CAUTION
Before going on with the next step, please fix
the cylinder properly first. Be sure to avoid the
falling of cylinder during removal, resulting in
personal injury.
- Hold the cylinder (6) by hand, tap out the
pin shaft (3) from the side and remove the
cylinder;
REV. 09/2016
66
HYDRAULIC SYSTEM
CAUTION
- Use suitable hose clamps to avoid cylinder
deformation caused by severely tight hose
clamp.
- Carry out the maintenance work in a clean
environment to prevent impurities from
entering into cylinder, causing cylinder
damage.
- During the installation, hydraulic oil of
the same specifications must be used for
cleaning or lubrication.
- Secure the cylinder to hose clamp and gently

clamp the cylinder bottom;
- Unscrew the cylinder cap (4, Figure 10409)
with cylinder wrench;
- Remove the dust ring (2), O-ring (3) from the
cylinder cap;
- Remove the guide bush (8) from the cylinder
tube (5);
- Pull out the piston rod (1) from the cylinder
tube;
- Remove the support ring (6) and seal (7)
from the piston rod;
- Clean with hydraulic oil of the same specifica-
tions;
- Replace the problem parts and assembly in
7
reverse steps.
CAUTION
If the piston rode or cylinder tube is damaged,
please replace the entire cylinder.
If the seals are aged or damaged, please
replace the complete set of seals.
REV. 09/2016
67
HYDRAULIC SYSTEM
7.7 Hydraulic Troubleshooting
Fault Symptom Failure Causes Troubleshooting Measures
a. Insufficient oil; 1. Check the hydraulic oil level.

b. High viscosity of oil; 2. Replace the hydraulic oil.
c. Oil suction pipe air leak; 3. Check the oil suction pipe.
1 Noisy pump
d. Filters clogged by impurities; 4. Clean the oil inlet piping,
replace the filter, if necessary.
e. Hydraulic oil with foam; 5. See Fault 2.
1. Check the amount of oil;

2. Check if the viscosity of
a. Pump cavitation; hydraulic oil is normal;
2 Hydraulic oil with foam b. There is water in the oil. 3. Check the oil inlet piping for air
leaks;
4. Discharge and clean, and
replace with new hydraulic oil.
1. Discharge and clean, and add

a. Oil is too thin; new hydraulic oil;
Pump or oil
3 b. Pump cavitation; 2. Check the oil inlet piping for air
temperature is too high c. Valve body internal relief. leaks;
3. Replace the valve body.
a. Insufficient oil; 1. Check the hydraulic oil level;

4 Low System Pressure b. Relief valve failure. 2. See Fault 6;
c. Pump wear, internal leakage. 3. Replace the gear pump.
7 5 On load, declined a. Solenoid valve failure.
1. Check and clean the solenoid
valve spool.
a. Pressure adjustment screw too 1. Adjust to proper pressure

loose; through hydraulic pressure
Relief valve pressure b. Relief valve spring breakage or gauge.
6
unstable or too low deformation; 2. Replace the relief valve.
c. Relief valve spool wear or 3. Clean or replace the relief
blocked. valve.
REV. 09/2016
68
HYDRAULIC SYSTEM
7.8 Hydraulic Symbol
Symbol Description Symbol Description
Tank
Pipe end below liquid
Explosion-proof valve
level
Tank
Pipe end above liquid
Check valve
level
Cylinder
Filter Single-acting direction
Service line
(Supply line or return
Relief valve
line)
Control line Throttle valve

(Drain line) With pressure
compensation device
7
Solenoid Valve
Connecting pipe Two-way two-pass
Port
(Test port)
Motor
Hydraulic pump
REV. 09/2016
69
HYDRAULIC SYSTEM
REV. 09/2016
70
8. ELECTRICAL SYSTEM
71
NOTE:
72
ELECTRICAL SYSYTEM
8.1 Controller 8.1.2 Controller Interface Function

Traction Controller (1212)

Removal
- Remove the upper cover; (See Section 4.2.1) J1 Interface
- Remove the wiring harness and cables on the
controller;
- Unscrew the two screws (1) with a wrench
and remove the controller (2) and cooling fin
(3);
J1 Interface 8
Pin No. Description
J1#1 Pot wiper
Installation J1#2 -
- Apply appropriate amount of thermal grease J1#3 -
on the back of controller; J1#4 Mode switch (open=M1,closed=M2)
- Place the controller onto the electrical moun-
J1#5 Keyswitch input (KSI)
ting plate, tighten the two screws with a
wrench; J1#6 Speed inhibit
- Plug the wiring harness and cables into cor- J1#7 -
responding ports.
J1#8 -
J1#9 -
J1#10 Status LED
REV. 09/2016
73
ELECTRICAL SYSYTEM
J1 Interface - Continued J3 Interface
Pin No. Description

J1#11 -
J1#12 Reverse switch
J1#13 -
J1#14 -
J2 Interface
(Handheld unit communication interface)
J3 Interface
Pin No. Description
Positive of electromechanical brake
J3#1
coil.
Negative of electromechanical brake
J3#2
coil.
Terminal stud
J2 Interface
8
Pin No. Description
J2#1 Rx
J2#2 B-
J2#3 Tx / Charge inhibit
J2#4 Mode switch (open=M1,closed=M2) Terminal stud
Pin No. Description
M1 Negative of the motor.
M2 Positive of the motor.
B- - Batt.
B+ +Batt.
REV. 09/2016
74
ELECTRICAL SYSYTEM
8.2 Fuse
The entire vehicle is installed with two fuses
altogether. When there is fuse failure, the truck
may not be able to run properly due to that.
Status
Function
Fuse 1 Fuse 2
Fuse 1 150A × Ο
Fuse 2 10A Ο ×
1 Drive × ×
2 Lifting / Lowering × ×
3 Steering Ο Ο
4 Traction Controller × ×
5 Charge Gauge × ×
6 Horn × ×
× : Failure
Ο : Normal
8.2.1 Location of Fuses
Fuse 1: installed on electrical mounting plate

Fuse 2: installed on main harness
★ Fuse position in electrical schematic diagram
CHARGER INTERLOCK SW. 8

KEY SW.
FUSE 2 10A
MOTOR P.C.
FUSE 1 100A
REV. 09/2016
75
ELECTRICAL SYSYTEM

Checking
- Check the fuses for damage, check the
connectors at terminal lugs for loosening or
poor connection of leads.
Testing
- Turn the key switch to "OFF", remove key;
pull out the battery plug and disconnect the
power supply.
- Set the multimeter to resistance measure-
ment: with black probe (-) connected to one
end of the fuse; red probe (+) connected to
another end of the fuse.
- Identify if the fuse is normal according to the
readings of resistance on the multimeter.
Resistance
Judgment
Measurement
0Ω Normal
Failure
∞Ω
(replace the fuse)
REV. 09/2016
76
ELECTRICAL SYSYTEM
8.3 Key Switch 8.3.2 Faults and Causes

Key switch is used to START / STOP the truck. Turn the key switch to “ON”, the
Fault
vehicle won’t start
1
8.3.1 Removal and Installation a. Key switch failure;
Cause
b. Key switch circuit not conducted.
Removal
Turn the key switch to “OFF”, the
- Remove the upper cover ;(See Sention 4.2) Fault
vehicle won’t stop
2
a. Key switch failure;
Cause
b. Key switch shorted (short circuit)

Checking
- Check if the appearance of key switch its
wiring harness are in good condition, and if
the connectors are connected securely.
Testing
- Check if the key switch circuit is conducted;
- Carry out ON/OFF test to the key switch with
a multimeter:
key switch at “OFF” position, open circuit;
- Disconnect the key switch connector from place the key switch at “ON” position, the
main wiring harness; circuit is conducted.
- Unscrew the nut and remove the key switch
from the mounting plate. 8.3.4 Control Circuit Troubleshooting
Key Switch Control Circuit
Installation (Figure 30517)
oval.
meter: 8
REV. 09/2016
77
ELECTRICAL SYSYTEM
8.4 Charge Gauge 8.4.3 Checking and Testing

Charge gauge is used to display remaining Checking
battery power of forklift, working hours (this
- Check if the appearance of charge gauge its
function is available on the component with
wiring harness are in good condition, and if
timer function).
the connectors are connected securely.
- Check if the charge gauge gear is in the
8.4.1 Removal and Installation correct position. (Charge gauge with timer)
Removal
- Remove the upper cover ;(See Sention 4.2)
Charge gauge
with timer Needle
Charge gauge Charge gauge

without timer with timer
M: for lead-acid battery

Q: for maintenance-free battery
- Disconnect the charge gauge connector from

main wiring harness;
- Unscrew the nut and remove the charge gau-
ge from the mounting plate. Charge gauge
8 Installation
without timer

oval.
Fault No display on the charge gauge 8.4.4 Control Circuit Troubleshooting
1 a. Charge gauge failure; Charge Gauge Control Circuit

Cause b. Charge gauge circuit not (See Electrical Schematic Diagrams )
conducted.
Power capacity display not
Fault meter:
accurate
2 - Set the multimeter to ON-OFF;
a. Charge gauge wrong gear;
Cause - Check if #0/#1/#9/(#8) circuit is conducted.
b. Charge gauge failure.
REV. 09/2016
78
ELECTRICAL SYSYTEM
8.5 LED Charging Indicator 8.5.2 Faults and Causes

LED charging indicator is used to display Fault No display from indicator
charge status, which can display in three colors:
red, yellow and green. 1 a. Indicator failure;
Cause b. Indicator circuit not connected;
Display Description c. Charger failure.
Solid Red Battery is charging

Solid Green The charging is completed
Solid Yellow Battery failure Checking

Flashing Yellow Charger failure - Check if the appearance of LED charging
indicator its wiring harness are in good con-
No output current from the dition, and if the connectors are connected
Flashing Red
charger securely.
NO Lighting Charger failure
Testing
- Check if LED charging indicator circuit is
conducted;
8.5.1 Removal and Installation - Energize the LED charging indicator with a
Removal voltage of 24V:
If the light is on, then it is normal;
- Remove the upper cover ;(See Sention 4.2) if the light is not lit, then the light is faulty.
- Disconnect the LED charging indicator con-
nector from main wiring harness;
- Remove the indicator (2) from the indicator 8.5.4 Control Circuit Troubleshooting
holder (1) on mounting panel. LED Charging Indicator Control Circuit
(Figure 30513)
meter:
- Check if the circuit is conducted.
8
LED
Installation CHARGER
oval.
REV. 09/2016
79
ELECTRICAL SYSYTEM
8.6 Lifting Limit Switch Lifting limit switch pressed, lifting

Fault
8.6.1 Removal and Installation mechanism does not stop
2 a. Lifting limit switch failure;
Removal
Cause b. Lifting limit switch shorted
(short circuit).

Checking
- Check if the appearance of limit switch and
its wiring harness are in good condition, and
if the connectors are connected securely;
- Repeatedly press the limit switch to check if it
can reset properly.
- Normally-closed (NC):
Terminal (1) and Terminal (2) for connection
of wiring harness connector.
- Unscrew the two screws (1) with a wrench,
(see Figure 10509)
and remove the mounting plate (3) from the
bracket (2);
Testing
- Remove the lifting limit switch (4) from the
mounting plate (3); - Check if the limit switch circuit is conducted;
- Disconnect the connection between lifting - Carry out ON/OFF test to limit switch with a
limit switch and drive wiring harness. multimeter:
Reset the limit switch (original position), the
Installation circuit is connected;
press the limit switch, the circuit is discon-
- Install according to the reverse order of rem- ducted.
oval.
8 8.6.2 Faults and Causes 8.6.4 Control Circuit Troubleshooting

Lifting Limit Switch Control Circuit
Fault Lifting mechanism cannot lift (Figure 10509)
1 a. Lifting limit switch failure;
Cause b. Lifting limit switch with broken
meter:
circuit.
Lifting Switch Key Switch
REV. 09/2016
80
ELECTRICAL SYSYTEM
8.7 Interlock Switch Interlock switch pressed, the

Fault
8.7.1 Removal and Installation vehicle cannot travel
2 a. Interlock switch failure;
Removal
Cause b. Interlock switch with broken
circuit.

Checking
- Check if the appearance of interlock switch
and its wiring harness are in good condition,
and if the connectors are connected securely;
- Repeatedly press the interlock switch to che-
ck if it can reset properly.
Testing
- Disconnect the connection between interlock switch: “Inhibit”, press the interlock switch, if
switch and main wiring harness; the display does not change, then it indicates
- Unscrew the two screws (1) with a wrench, the interlock switch or its circuit failure;
and remove the mounting plate (2) from the (see Section 8.9)
joint holder (3); - Check if the interlock switch circuit is condu-
- Unscrew the two screws (4), and remove the cted;
interlock switch (5) from the mounting plate - Carry out ON/OFF test to interlock switch
(2). with a multimeter:
Reset the interlock switch (original position),
Installation the circuit is disconnected;
press the interlock switch, the circuit is con-
ducted.
oval.
8.7.2 Faults and Causes Interlock Switch Control Circuit
(Figure 30516)
8
Interlock switch not pressed, the
Fault
vehicle can still travel Check if the circuit is broken by using a multi-
1 meter:
a. Interlock switch failure;
Cause b. Interlock switch shorted - Set the multimeter to ON-OFF;
(short circuit). - Check if #1/#8 circuit (circuit between inter-
lock switch and controller) is conducted.
Key Switch
REV. 09/2016
81
ELECTRICAL SYSYTEM
8.8 Speed Mode Switch (Optional) Normally-opened (NO):
8.8.1 Removal and Installation Terminal (2) and Terminal (3) for connection of
wiring harness connector to switch base
Removal
When left or right steering angle ≥

Fault 45°, but travel speed of forklift is
not reduced
1
a. Speed mode switch failure;
Cause b. Speed mode switch with broken
circuit.
When speed mode switch is activ-
Fault
ated, the speed is not reduced
2 a. Speed mode switch failure;
Cause b. Speed mode switch shorted
(short circuit).
- Unscrew the two screws (1) with a wrench,
and remove the mounting plate (2) from the
bearing bridge;
- Remove the speed mode switch (3) from the 8.8.4 Checking and Testing
mounting plate (2);
- Disconnect the connection between speed
mode switch and drive wiring harness.
Installation
oval.
8 8.8.2 Connection Mode

Speed mode switch has 3 terminals.
The switch can be switched between open and
close by toggling the roller lever to achieve the
control of connection and disconnection of the
circuit. Checking
- Check the switch for damage and check the
roller for deformation;
- Check if the handwheel is working smoothly
and if there is foreign body blockage.
- Check if the half-speed rail is in the initial
position.(see Figure10512)
REV. 09/2016
82
ELECTRICAL SYSYTEM
Testing
switch:
"Mode Input", press the switch, if the display
does not change, then it indicates the switch
or its circuit failure;
- Turn the key switch to "OFF", remove key;
pull out the battery plug and switch off the
power supply.
- Check the ON/OFF normally-opened (NO)
terminal with a multimeter: with handwheel
at natural position, Terminal (2) and (3) not
conducted; toggle the handwheel, Terminal (2)
and (3) conducted.
- Check the ON/OFF normally closed (NC)
terminal with a multimeter: with handwheel
at natural position, Terminal (1) and (3) con-
ducted; toggle the handwheel, Terminal (1)
and (3) not conducted.

Speed Mode Switch Control Circuit
(Figure 10513)
meter:
- Check if #1/#24 circuit (circuit between switch
and controller) is conducted.
Key Switch
REV. 09/2016
83
ELECTRICAL SYSYTEM
8.9 Handheld Unit (Optional) - Turn on the key switch, pull out emergency
stop switch, the display of handheld unit will
Handheld unit must be used together with con- be flashing:
troller, if necessary, it can be purchased from if the connection is successful: The program-
our company or dealer. mer automatically powers up, and displays
this screen while it loads information from the
controller.Once the programmer has upload-
ed the information from the controller, it
displays the Main Menu.
If the controller is not turned on when the pro-
grammer is connected, you can power up
the programmer by pressing the Power key;
the message “No System detected” will be
Display displayed.
Softkeys
8.9.2 Handheld Unit Main Menu
Parameter
Arrow keys adjustment
button
Power ? Help
Favorites Main menu
Connectors Figure 30520

- With Arrow keys (Figure 30520), you can
carry out menu switching;
8
8.9.1 Handheld Unit Connection - “Select”, select ENTER the menu.
- Remove upper cover;(See Section 4.2) Parameters : parameter change

- Plug the handheld unit communication Monitor : vehicle running test
cable into the handheld unit communication Diagnostics : error alrms
interface of the controller; * See “Handheld Unit Operation Manual” for
detailed operations
J2 Interface - Handheld unit

communication interface
REV. 09/2016
84
ELECTRICAL SYSYTEM
8.9.3 Parameter Settings

THROTTLE MENU
CAUTION
Paramete Setting
Without the written permission of equipment
manufacturer or its agent, it is strictly prohibit- 1 Type
ed to change any of the parameters in "PARA- 2 Neutral Input
METERS".
3 PotHigh
Traction Controller Parameter Settings 4 PotLow
5 Neutral Deadband
DRIVE MENU
6 Throttle Max
Paramete Setting
1 Accel Max Speed 7 HPD
2 Accel Min Speed 8 Speed Limit Pot
3 Decel High Speed 9 Throttle Map
4 Decel Low Speed 10 Tremor Suppression
5 Rev Accel Max Speed 11 Calibration
6 Rev Accel Min Speed

CURRENT MENU
7 Rev Decel High Speed
Paramete Setting
8 Rev Decel Low Speed
9 Key off Decel 1 Main Current Limit
10 E Stop Decel 2 Braking Current Limit

11 E Stop Pause 3 Boost Current
12 Soft Start 4 Boost Time
13 Gear Soften
14 Creep Speed INHIBIT MENU 8
15 Soft Stop Speed Paramete Setting
Speed 1 Type
Max Speed 2 Speed
Mode 1 Min Speed
( Full
speed ) Rev Max Speed BRAKE MENU
16 Rev Min Speed Paramete Setting
Max Speed 1 Delay
Mode 2 Min Speed 2 Fault Check

( Slow) Rev Max Speed
3 Hold Voltage
Rev Min Speed 4 Brake Light
REV. 09/2016
85
ELECTRICAL SYSYTEM
HORN MENU COMPENSATION MENU

Paramete Setting Paramete Setting
1 Reverse Beep 1 IR Comp
2 Beep Constant 2 Anti-Rollback Comp
MOTOR MENU EMERGENCY REVERSE MENU

1 System Resistance 1 Speed
2 Resistance Auto Comp 2 Time Limit
3 Auto Comp Current Limit 3 Decel Rate
4 Speed Scaler 4 Accel Rate
5 Current Rating 5 Max Braking Current
6 Max Current Time 6 Switch Normally Closed
7 Cutback Gain 7 EMR Interlock
BDI MENU MISCELLANEOUS MENU

1 Full Voltage 1 Sleep
2 Empty Voltage 2 Reset Drive Time
3 Full Charge Voltage 3 Emergency Stop
4 Start Charge Voltage 4 Pump SRO
5 Reset Voltage
8 6 Discharge Factor
7 Charge Factor
8 Low BDI Level
9 Low BDI Max Speed
10 External Lift Lockout
11 Lift Lockout Enable
12 Lift Lockout Threshold
13 Lift Lockout Output Type
REV. 09/2016
86
ELECTRICAL SYSYTEM
8.9.4 TESTER Menu

The parameters in Monitor Menu are real-
time presentation of the running status of the
equipment.
Traction Controller (1212)
Parameters Description Remark
Temp Check the temperature of controller Display the current temperature ( ℃ )
Battery Voltage Check the voltage of storage battery Display the current voltage ( V )
Motor Voltage Check the voltage of motor Display the current voltage ( V )
Motor Thermal Cutback Check the capacity of motor current Display the current capacity ( % )
Armature Current Check the motor current Display the current value ( A )
Current Limit Check the maximum limit current Display the current value ( A )
Resistance Check the resistance of system Display the current resistance ( mΩ )
Throttle Check the input of accelerator Display the current capacity ( % )
Speed Limit Pot Check the input of limit speed Display the current capacity ( % )
If the function is triggered properly,

Mode Input Check the status of speed mode switch
the value will change
Reverse Input Check the backward status of travel switch
Inhibit Check the status of interlock switch
Push Input Check the status of push switch
Main Contactor Check the status of main contactor

8
Brake Check the status of brake
BDI Check the capacity of battery Display the current capacity ( % )
Drive Time Check the working time Display the current working time ( h )
REV. 09/2016
87
ELECTRICAL SYSYTEM
8.10 Controller Error Message to the vehicle, LED will twinkle and indicate the
The error message can be obtained in two ways: fault code; LED won’t restore to the extinguish-
1) By reading the appropriate display on the ing state until the fault is eliminated.
handheld unit ; LED indicates two digit codes: for example, digit
2) By observing the fault codes issued by the code “1, 4” — UNDERVOLTAGE FAULT, the dis-
LED fault indicator. play mode is as follows:
Handheld Unit Diagnostics

The fault information is shown in the Diagnos-
tics menu of the handheld unit.
LED Blinks 1 Second Stop
LED Fault Indicator Diagnostics
When the truck is in normal use, LED fault indi-
cator is always going on; When any fault occurs
8.10.1 Traction Controller
Error Message
LED LED
BLINKS BLINKS Explanation Possible cause
digit 1 digit 2 Error text
1. Temperature >80°C or <

-10°C.
2. Excessive load on vehicle.
over-/under-temperature
1 1 THERMAL FAULT 3.Operation in extreme
cutback
environments.
4.Electromagnetic brake not
releasing.
1.Throttle input wire open or

8 1 2 THROTTLE FAULT
PotLow and/or PotWiper
out of range
shorted.
2.Throttle pot defective.
3.Wrong throttle type
selected.
1.Speed limit pot wire(s)

speed limit pot wiper out
1 3 SPEED POT FAULT broken or shorted.
of range
2. Broken speed limit pot.
1. Battery voltage <17 volts.

UNDERVOLTAGE
1 4 battery voltage too low 2. Bad connection at battery
FAULT
or controller.
REV. 09/2016
88
ELECTRICAL SYSYTEM
Error Message
LED LED
BLINKS BLINKS EXPLANATION Possible cause
1. Battery voltage >31 volts.

2. Vehicle operating with
OVERVOLTAGE
1 5 battery voltage too high charger attached.
FAULT
3.Intermittent battery
connection.
main contactor driver Off 1.Main contactor driver failed

2 1 MAIN OFF FAULT
fault open.
1.Main contactor welded or

2 3 MAIN FAULT main contactor fault stuck open.
2. Main contactor driver fault.
main contactor driver On 1.Main contactor driver failed

2 4 MAIN ON FAULT
fault closed.
1.Misadjusted throttle.
HPD fault present >10
3 1 WIRING FAULT 2.Broken throttle pot or
sec.
throttle mechanism.
1.Electromagnetic brake
driver shorted.
3 2 BRAKE ON FAULT brake On fault
2.Electromagnetic brake coil
open.
3 3 PRECHARGE FAULT precharge fault

1. Brake driver shorted.
2. Precharge circuit damaged.
8
3. MOSFET failure.
1.Electromagnetic brake
driver open.
3 4 BRAKE OFF FAULT brake Off fault
2.Electromagnetic brake coil
shorted.
1. Improper sequence of
HPD (High Pedal throttle and KSI,push, or
3 5 HPD FAULT
Disable) inhibit inputs.
2. Misadjusted throttle pot.
1.Short in motor or in motor

CURRENT SENSE current sense out of
4 1 wiring.
FAULT range
2. Controller failure. ★
REV. 09/2016
89
ELECTRICAL SYSYTEM
Error Message
LED LED
BLINKS BLINKS EXPLANATION Possible cause
1.Motor voltage does not

correspond to throttle request.
HARDWARE motor voltage out of
4 2 2.Short in motor or in motor
FAILSAFE range
wiring.
3. Controller failure. ★
EE CHECKSUM
4 3 EEPROM fault 1. EEPROM failure or fault.
FAULT
1. Battery not connected.

BATTERY
4 5 battery disconnected 2.Poor connection to battery
DISCONNECT FAULT
terminals.
REV. 09/2016
90
ELECTRICAL SYSYTEM
8.11 Electrical Schematic Diagrams

Charge Gauge with Timer + Emergency Reverse External Control
FAN
PUMP
CONTACTOR Lifting SW.
Lifting Limit SW.
Lifting SW.
E-VALVE Lowering SW.
Lowering SW.
HORN Horn SW.
BELLY
CMD
FWD
POTLOW REV
ACCEL
REV.
CMD
E-BRAKE LED
LED Speed Mode SW.
CHARGER Interlock SW.

8
Key SW.
Fuse 10A
Pump Motor Pump Contactor
Emergency SW.
Fuse 150A
REV. 09/2016
91
ELECTRICAL SYSYTEM
Charge Gauge without Timer + Emergency Reverse External Control
FAN
PUMP
Lifting Limit SW.
Lifting SW.
Lowering SW.
HORN Horn SW.
BELLY
CMD
FWD
POTLOW REV
ACCEL
REV.
CMD
E-BRAKE LED
LED Speed Mode SW.
8 CHARGER Interlock SW.

Key SW.
Fuse 10A
Emergency SW.
Fuse 150A
REV. 09/2016
92
ELECTRICAL SYSYTEM
Charge Gauge with Timer + Emergency Reverse Internal Control
FAN
PUMP
Lifting Limit SW.
Lifting SW.
Lowering SW.
HORN Horn SW.
CMD
FWD
POTLOW REV
CMD
E-BRAKE BELLY SW.
LED
Speed Mode SW.
CHARGER
8
Interlock SW.
Key SW.
Fuse 10A
Emergency SW.
Fuse 150A
REV. 09/2016
93
ELECTRICAL SYSYTEM
8.12 Cable Wiring Diagrams
No. Name No. Name

1 Cable C2 6 Cable B-
2 Power Cable BATT+ 7 Pump Motor Cable PA-
3 Cable M2 8 Pump Motor Cable PA+
4 Cable M1 9 Cable C3
5 Cable B+
REV. 09/2016
94
MAIN WIRE
LIFTING HARNESS
SPEED
LIMIT SW. PUMP
E-BRAKE MODE SW. CONTACTOR
Interlock SW.
CHARGER
+BATT FAN
-BATT
CONTROLLER
DRIVE WIRE SOLENOID

HARNESS VALVE COIL
8.13 Wiring Harness and Connectors
95
LED
ELBOW WIRE
HARNESS LED
HORN
CHGRGE KEY SW.

REVERSE SW. LIFT/LOWER SW. GAUGE
POTENTIONMETER
TRAVEL SW.
REV. 09/2016
ELECTRICAL SYSYTEM
8
ELECTRICAL SYSYTEM
REV. 09/2016
96
9. TROUBLESHOOTING
97
NOTE:
98
TROUBLESHOOTING
9.1 Preparation Before Troubleshooting

CAUTION
- Park the truck on level ground and block the
If the battery voltage is still abnormal after being
wheels with wooden wedges;
charged: open the battery compartment, check
- Fully lower the fork and press the emergency the voltage of each battery and its connection
stop switch. circuit respectively:
- Turn off the key switch;
1) Check if the voltage of single battery is
- Open the cover and check the controller.
normal;
(See Service Manual : Maintenance-free
CAUTION 2) Battery)
Check if the cables for connections between
- Even if key switch is turned off, the controllers
each battery are normal, check for open circ-
are still energized.
uit and if the connection between connectors
- Before checking or repairing the controllers, is secure.
make sure the battery plug has been
unplugged and the electrical circuit is - Battery leakage check: disconnect the battery
disconnected. connection, black probe (-) connected to
(-) terminal of battery plug; red probe (+)
connected to the chassis. Read the voltage
9.1.1 Check the Voltage of Battery reading on the meter.
No voltage (0V): normal;
- Unplug the battery plug;
With voltage: battery leakage (remove battery
- Measure the battery voltage with a multim- compartment, check each battery and cables)
eter: black probe (-) connected to (-) terminal
of battery plug; red probe (+) connected to
the (+) terminal of battery plug. Read the
voltage reading on the meter.
- Identify if the battery voltage is normal
according to the measured voltage.
Battery Voltage Judgment
Greater than 24V Normal

24V Needs to be
Less than 24V
charged
9
i NOTE
Enter Monitor Menu to check the battery
voltage.(see Section 8.9)
REV. 09/2016
99
TROUBLESHOOTING
9.2 Troubleshooting Solutions of Common Faults

Table 9.1 lists the common faults that may occur and handling
methods. Mainly consists of the following items:
Table 9.1 Troubleshooting of Common Faults
Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures

Power supply 1. Whole vehicle a. Power supply failure 1) Check the voltage of storage
failure power outrage b. Fuse failure battery (see Section 9.1.1)
2) Check the fuses
c. Emergency stop switch or circuit (see Section 8.2)
failure 3) Check key switch and its circuit
d. Key switch or circuit failure (see Section 8.3)
4) Check emergency stop switch
and its circuit
Travel Fault 1. Forward and rever- a. Interlock switch or its circuit Controller failure error, carry out
se moving failures of connection failure troubleshooting according to the
the vehicle, but other b. Electromagnetic brake locked fault code information on the
functions are normal (Non-mechanical failure, the instrument (see Section 8.10).
instrument will display fault code) 1) Check if the interlock switch or
the connection of its circuit is
c. Travel switch or its circuit normal; (See Section 8.7)
connection failure 2) Electromagnetic brake and its
d. Drive motor or its circuit connecting circuit;
connection failure (see Section 5.2)
e. Drive motor carbon brush 3) Check the travel switch and its
connection circuit;
failure
(see Section 6.3)
f. Controller failure 4) Check the drive motor and its
connection circuit;
(see Section 5.3)
5) Replace the controller.
2. The vehicle can Failures due to external factors: Controller failure error, carry out
travel at low speed, a. Electromagnetic brake locked troubleshooting according to the
but cannot travel at (Non-mechanical failure, the fault code information on the
instrument will display fault code) instrument (see Section 8.10).
high speed
b. Motor bearing blocked 1) Check the voltage of storage
battery (see Section 9.1.1)
c. Gearbox bearing blocked 1) Check if the motor rotation is
9 Failures due to internal factors:
a. Battery voltage deficiency
normal;
2) Check the electromagnetic
brake or its connection circuit
b. Speed mode switch failure (see Section 5.2)
b. Controller failure 3) Check speed mode switch and
its connection circuit;
(see Section 8.8)
4) Remove the gearbox, check if
the gear rotation is smooth and
if there is blocking;
(see Section 5.5)
5) Replace the controller
* Carry out trouble shooting in accordance with the order listed
in the table, it can help you quickly identify problems and
resolve accordingly.
REV. 09/2016
100
TROUBLESHOOTING
Table 9.1 Troubleshooting of Common Faults (continued)

Hydraulic 1. The vehicle cannot 1. Pump motor does not work: 1. Pump motor does not work:
Failure lift a. Pump motor or its circuit 1) Check the pump motor and its
connection failure connection circuit;
b. Pump contactor or its circuit (see Section 7.3)
connection failure 2) Check the pump contactor and
c. Lifting switch or its circuit (see Section 7.4)
connection failure 3) Check the lifting switch and its
d. Lifting limit switch or its circuit connection circuit;
connection failure (see Section 6.2)
4) Check the lifting limit switch
and its connection circuit;
(see Section 8.6)
2. Pump motor works: 2. Pump motor works:

a. Overload 1) Refer to the rated capacity
b. Insufficient hydraulic oil marked on the nameplate;
2) Lower the mast to the bottom,
c. Hydraulic pipeline leakage check if the amount of oil in the
d. Pump motor reverse rotation oil tank can meet the requireme-
e. Cylinder failure (blocked) nts (see Section 2.2.3);
3) Check the pipe and hydraulic
f. Solenoid valve blocked and components for oil leaks;
cannot reset 4) Check the pump motor wiring;
g. Valve body failure: 5) Check the cylinder for damage
excessive wear of gear pump, or deformation, remove the
serious internal leaks, insufficient cylinder to check for wear or
pressure of relief valve or aged seals inside;
blocked, check valve blocked (see Section 7.6)
6) Wash or replace the solenoid
spool (see Section 7.5)
7) Wash or replace the valve body
2. The vehicle cannot a. Solenoid valve or its circuit 1) Check the lowering button and
be lowered connection failure its connection circuit;
(see Section 6.2)
9
b. Lowering switch or its circuit
connection failure 2) Check the solenoid valve and
c. Valve failure; (see Section 7.5)
d. Cylinder deformation or blocked 3) Check the cylinder for
deformation, remove the
cylinder to check if the internal
assembly is normal ;
(see Section 7.6)
4) Clean or replace the valve;

REV. 09/2016
101
TROUBLESHOOTING
Table 9.1 Troubleshooting of Common Faults (continued)

Lift Failure 3. Slow Lifting of a. Overload 1) Refer to the rated capacity
Vehicle b. Hydraulic pipeline leakage marked on the nameplate;
2) Check the pipe and hydraulic
c. Valve failure: components for oil leaks;
Gear pump wear, internal 3) Wash or replace the valve body
leakage occurs
Insufficient relief valve pressure
or blocked
4. Slow Lowering of a. Solenoid valve blocking 1) Wash or replace the solenoid
Vehicle b. Valve body failure: throttle valve spool (see Section 7.5)
failure or blocked 2) Wash or replace the valve body
5. Unstable Lifting / a. Lifting mechanism loosening or 1) Check if the lifting mechanism

Lowering of Vehicle wear; is normal;
b. Poor lubrication of lifting (see Section 4.3)
mechanism;
Other Failures 1. Horn does not a. Horn switch or its circuit 1) Check the horn button and its
sound connection failure connection circuit;
b. Horn failure (see Section 6.2)
2) Check the horn and its
connection circuit.
(see Section 6.2)

REV. 09/2016
102
APPENDIX
103
NOTE:
104
B SERVICE MANUAL - BATTERY
105
NOTE:
106
SERVICE MANUAL - BATTERY
B1 Lead-acid Battery As for failure to comply with instructions

for use, maintenance without using
B1-1 Safety and Warnings original parts, user corruption, or viola-
tion of provisions when adding electrolyte
- When operating on battery, you must wear and other circumstances, the quality
protective glasses and protective clothing! assurance will automatically void.
- Electrolyte contains sulfuric acid and is highly
corrosive. If it accidentally comes into contact
with the skin, wash immediately with plenty of B
water, if the situation is serious, immediately B1-2 Use of Battery
seek medical advice.
B1-2.1 Pre-use Checks
- The battery will produce hydrogen during
charging, which may produce an explosive - Check if the battery status is normal and also
mixture. Smoking or ignition is prohibited check for mechanical failures;
near the battery that is being charged or just
- Connect the battery connectors, make
completes charging, there should not be
sure the contact is solid, the electrodes are
flame or a hot wire, otherwise there may be
connected properly, otherwise may cause
fire or explosion hazards!
damage to the battery, truck or charger;
- Check if the electrode bolt of each battery
CAUTION interface is tightened;
To avoid accumulation of hydrogen gas, keep - Check electrolyte fluid level. It must be
the battery cover open during charging, charge ensured that the electrolyte level is higher
the battery at a cool, well-ventilated place. than the upper edge of overflow outlet or
separator;
- To avoid short circuit. Metal parts of the
battery cell are live; it is prohibited to place - Charge the battery according to the
metal objects on the battery to avoid the instructions on the operation manual;
occurrence of short circuit. - Refill the electrolyte with distilled water to
- Dumping of battery is prohibited. Only use make the electrolyte level reach standard
proper lifting equipment to lift or transport the level.
battery.
WARNING B1-2.2 Discharging

- It is necessary to add water regularly, other- - Do not close or cover the ventilation openings
wise may cause damage to the battery due to with objects;
water loss. - When connecting or disconnecting the battery
- The water must be added after the battery is connector (such as, plug), the power supply
fully charged, adding water before charging must be disconnected first;
can cause electrolyte overflow. - In order to meet or exceed the rated batt-
- The amount of water to be added must be ery service life, the battery should avoid
strictly controlled, excessive adding of water excessive discharge during runtime (capacity
may lead to electrolyte overflow. less than 20% of the rated capacity);
- Only distilled water can be added, the adding - Re-charge the battery immediately after
of tap water or mineral water is prohibited. discharging without delay.
As for the decrease of battery capacity, or
even damage to the battery due to failure
to comply with the above provisions, the
quality assurance will automatically void.
REV. 09/2016
107
B1-2.3 Charging B1-3 Maintenance & Care

- When charging, only DC can be used. B1-3.1 Daily Maintenance
Connect the battery with proper charger for
specification and size to avoid overload of - Charge the discharged battery;
circuit and interface, and to avoid electrolyte - Visual inspection for excessive dirtiness and
foaming or overflow from the cell; mechanical damage after the charging.
B - The charger purchased separately must

be checked by the after-sales service
department of our company before it can be B1-3.2 Weekly Maintenance
used;
- Control the electrolyte fluid level. Check the
- When connecting the battery with the charg- electrolyte fluid level when the charging is
er, the circuit switch should be at “OFF” about to complete. If necessary, add distilled
position, make sure the connection is correct. water into the electrolyte when the charging
It is prohibited to connect the battery with live is about to complete to make the fluid level
charger. reach the rated standard.
- Before battery charging, make sure the elec-
trolyte temperature is within the range of CAUTION
10 ° C~ 45 ° C;
- Lower fluid level may reduce the battery
- When charging, the cover or cover plate of capacity, and thus reduce the service life of
the battery compartment must be opened or battery.
removed to ensure that the gas generated
- Higher liquid level may lead to electrolyte
during charging can be smoothly discharged.
overflow when charging, which may cause
- When the concentration of the electrolyte and corrosion to the battery compartment or even
battery voltage remain constant (for more the vehicle.
than 2 hours), it indicates that the charging is
completed.
There are two types of battery filler cap used on
battery cell:
1) Filler cap with buoy
B1-2.4 Temperature
- Rated temperature of electrolyte is 30 °C.
proper
合适的电electrolyte
- If the temperature is too high, it will reduce
liquid
解液液位 leveL
the service life of the battery; too low may
reduce the battery capacity. Battery
电瓶
- When the temperature reaches the limit
temperature of 55 ° C, it is prohibited to run
the battery.
Add distilled water, red buoy will float until while

rod appears under the red scale.
REV. 09/2016
108
- As for a group of normal batteries, when the

WARNING battery is discharged for 80% (the instrument
- Add only distilled water. alarms and prompts low battery, you should
recharge in a timely manner), the open circuit
- Before adding distilled water, check if the
voltage should be around 1.93V, specific
buoy can move up and down properly to
gravity of electrolyte (under 30°C) should be
prevent the buoy from failing to float up and
around 1.14.
B
resulting in excessive filling.
CAUTION
2) Filler cap without buoy And you can identify if the battery is fully
When adding water, stop filling when the discharged according to the specific gravity of
electrolyte level is higher than the protective battery electrolyte when the instrument alarms,
plate for 15~20 mm. and identify if the capacity indicated on the
instrument is accurate.
CAUTION
If there is fault, please notify ser vice
Please operate the electric watering device in personnel for repairs.
accordance with its operating manual.
B1-3.4 Care
B1-3.3 Monthly Maintenance 1. Keep it clean
- Before the charging is completed (while - Battery surface should be clean and dry to
the charger is still energized), measure and prevent the occurrence of leakage currents;
record the voltage of battery cell the entire - Battery cables, terminals and connectors mu-
battery;
st be tightened and clean, a small amount of
- After the charging is completed, measure special grease should also be applied.
and record the electrolyte concentration and
temperature of the battery cell. WARNING
- Do not use a dry cloth or fabric to clean the
How to tell if the battery is normal?
surface of the battery, so that to prevent the
- As for a normal set of fully charged batteries, occurrence of static electricity, resulting in
the voltage of each of the battery cell explosion;
should be around 2.08V, specific gravity of - Unplug the power plug;
electrolyte should be around 1.28; - Wipe clean with a damp cloth;
CAUTION - Please wear goggles, rubber boots and
rubber gloves.
After being fully charged, if the voltage of
battery cell is lower than 1.85V or the specific
gravity of electrolyte is less than 1.05, then that 2. Make sure that the cable insulation is not da-
battery cell has been damaged and needs to be maged and the connection layer has no signs
replaced. of heating.
REV. 09/2016
109
3. Make sure that the "+" and "-" output termin- B1-4 Storage
als are not sulfated (with white salt).
- When the battery is not used for a long time,
- Slight sulfation: clean top of the element with the battery should be filled up and stored in a
a damp cloth. dry, frost-free space.
- Severe sulfation: the battery must be remov- - Regular equalizing charge may help extend
ed for powerful cleaning; the battery base the service life of battery and ensure that the
B should also be cleaned.

- Very severe sulfation (or a large amount
capacity won't be reduced.
of electrolyte overflow): please contact the

after-sales service department as soon as
possible. B1-5 Troubleshooting
- Upon battery or charger failure, please prom-
DO NOT arbitrarily discharge acidic wast-
ptly notify the after-sales service department.
ewater after cleaning, dispose such water
in accordance with national laws and - Refer to battery failure analysis to facilitate
regulations! troubleshooting and elimination.
Battery Fault Analysis

Fault Negative Phenomena Cause Handling Methods
Insufficient 1. Low static voltage 1. Charger voltage and current 1. Adjust and repair the
Battery 2. Low density, cannot meet are set too low charger
Charge the requirements after being 2. Insufficient initial charge 2. Battery supplemental
charged 3. Charger failure charge
3. Short working time 3. Battery needs to be
4. When running, the instrume- replaced in severe situations
nt displays quick drop of
capacity
Electrolyte - In case of high intensity: 1. Initial adding of electrolyte 1. Replace the battery
has been 1. Electrolyte density is not with excessive high or low electrolyte
improperly less than 1.300g/cm3 after density 2. Battery needs to be
added to the charging 2. Liquid level reduces, adding replaced in severe situations
battery 2. Battery static voltage is errors, failed to add pure water
higher in accordance with provisions,
3. Initial capacity is good, but but mistakenly adding dilute
reduced after a period of use acid
4. Electrolyte is turbid 3. Initial adding of liquid is
impure (containing impurities
- Low density: and with odor)
1. Electrolyte density is still
lower than the specified
value after charging
2. Battery capacity is low
- Adding impure liquid:

1. Battery capacity is low
2. Electrolyte is turbid and of
abnormal color
3. Battery with severe self-
discharge
REV. 09/2016
110

Electrode 1. Battery capacity drops 1. Insufficient initial charge 1. Over-discharge method
plate sulfation during normal discharge 2. Long time of storage under 2. Repeated charging method
2. Density drops to be lower the state of discharge 3. Water treatment method
B
than normal value 3. Long-term insufficient
3. Voltage drops quickly when charged
discharging 4. Electrolyte density is too high
4. Start charging under high 5. Electrolyte level is too low,
voltage the upper part of electrode
5. Bubbles generated during plate is exposed outside of
charging the electrolyte
6. Coarse crystallization of 6. Impure electrolyte
PbSO4 7. Internal short circuit
Excessive 1. There is gray-brown 1. Brown precipitation is due to 1. Clean up the precipitation

shedding substance rising from the excessive large charging 2. Adjust the density
of active bottom when charging current 3. Battery needs to be
substances 2. Battery capacity reduced 2. White sediment is due to replaced if necessary
over-discharge
3. Battery electrolyte is impure
Battery 1. Color of battery filling cap 1. Charger voltage and current 1. Adjust and repair the
overcharged becomes yellow, and then are set too high charger
red 2. Charging time is too long 2. Adjust the charging system
2. Battery casing deformation 3. Frequent charging 3. Battery needs to be
3. Battery spacers 4. Less discharging, but much replaced in severe situations
carbonization, deformation charging
4. Positive electrode corrosion, 5. Charger failure
broken
5. Electrode pole rubber
bushing raised, aged and
cracked
6. Frequent water-adding,
electrolytic turbidity during
charging
7. Evenly shedding of active
substances from electrode
plate
8. Positive electrode plate
detonation
Battery Over- 1. Low static voltage 1. Go on using the battery 1. Supplementary charging
discharge 2. Electrolyte density is still despite of insufficient charge 2. Repair the vehicle
low after charging 2. Battery pack short circuit 3. Battery needs to be
3. Positive and negative 3. Small current long time replaced in severe situations
electrode plates curved or discharge
fractured
REV. 09/2016
111

Battery Short 1. Low static voltage below 2V 1. Electrode plate deformed and Battery needs to be replaced
Circuit 2. Electrolyte density is too low short circuit
3. High temperature during 2. Spacer missing or broken
B
charging during assembly
4. Truck is with short working 3. Positive electrode active
time substances shedding, short
circuit at bottom
Broken 1. Abnormal and unstable 1. Poor welding during assembly 1. Battery needs to be repaired
circuits voltage upon external of electrode pole or electrode 2. Battery needs to be
connection with load plate replaced if necessary
2. Current fails to input when 2. External short circuit
charging 3. Large current discharge
4. Poor wiring connection or
disconnected
5. Electrode plate corrosion
Battery 1. Negative voltage values Wrong connections of positive 1. Reverse charging is
Reverse 2. Electrolyte density is lower and negative electrodes during allowable
Electrodes than 1.20g/cm3 after charging 2. Battery needs to be
charging replaced in severe situations
3. Positive and negative
electrode lugs, colors of
electrode plates are
reversed
Battery Leaks 1. Filling hole leaks 1. Tank, filling cap with poor 1. Repair
2. Leaks at sealing seams of heat sealing 2. Battery needs to be
tank and filling cap 2. Electrode lug rubber ring replaced if necessary
3. Drainage problems
4. Marks of bumps on external 3. Sealing compound cracked
surface of tank 4 External impact due to
negligence during use
REV. 09/2016
112
B2 Maintenance-free Battery B2-2 Use of Battery

B2-1 Safety and Warnings B2-2.1 Pre-use Checks
- The battery should be away from heat source - Check if the fixing bolts on the bracket for the
and the place that is easy to produce sparks, battery are tightened, insecure installation
the safety distance should be greater than may cause damage to the case due to the
shock during the travel of the vehicle.
0.5m.
- The battery should avoid direct sunlight, Metal objects should not be placed on the
battery to prevent short circuits;
B
and cannot be placed in the environment
with large amount of radioactivity, infrared - Check if the poles and wiring connections are
radiation, ultraviolet radiation, organic solvent reliable from time to time. In order to prevent
gas and corrosive gases. oxidation of terminals, you can apply Vaseline
or other protective agents;
- Due to the high voltage of battery componen-
ts, there is risk of electrical shock; therefore, - DO NOT check the capacity of battery
insulated tools should be used when through direct ignition (short circuit test), such
installing or removing the conductive straps, method may damage the battery;
wear insulated gloves, aprons and protective - There will often be yellow white paste around
goggles when installing or handling batteries. the battery poles and cover, which is caused
During installation or handling of the batteries, by the corrosion of sulfuric acid to the poles,
only non-metallic sling can be used, wire wire clips and holders, etc. These substances
ropes cannot be used. are of very large resistance and must be
- Dirty strap or loose connection may cause removed in a timely manner;
battery ignition, or even damage the battery - When you need to use two batteries in
group, so double-check and remove the dirt series, the capacities of the two batteries are
on the strap when installing, and tighten the preferably to be equal. Otherwise it will affect
strap. the service life of the battery.
- DO NOT clean the battery case with organic
solvent, DO NOT use carbon dioxide fire
extinguisher to extinguish electrical fires, B2-2.2 Discharging
carbon tetrachloride fire extinguisher is
- When connecting or disconnecting the battery
available.
connector (such as, plug), the power supply
- When the battery is connected to the charger must be disconnected first;
or the load, circuit switch should be at "OFF" - In order to meet or exceed the rated bat-
position, and make sure the connection is
tery service life, the battery should avoid
correct: positive electrode of the battery
excessive discharge during runtime (the
is connected to the positive electrode of
remaining capacity is less than 20% of the
the charger, and negative electrodes are
rated capacity);
connected with each other.
- Re-charge the battery immediately after
- During the use of battery, be sure to tighten
discharging without delay;
the bolts of the terminals, so as to avoid
sparks and poor contact. - The normal load voltage of battery is 20.8V
~24.4V, if the voltage is lower than this range,
As for failure to comply with instructions it indicates that the battery already has
for use, maintenance without using origi- capacity loss, the circumstance of long time
nal parts, user corruption, or violation of under load voltage may reduce the service
provisions when adding electrolyte and life of the battery.
other circumstances, the quality assurance
will automatically void.
REV. 09/2016
113
B2-2.3 Charging B2-3 Maintenance & Care

- When charging, only DC can be used. Con- - Compared to lead-acid batteries, mainten-
nect the battery with proper charger for ance-free battery eliminates the maintenance
specification and size to avoid overload of to electrolyte.
circuit and interface, and to avoid electrolyte
foaming, leading to swollen battery;
Daily Maintenance
B - The charger purchased separately must be
checked by the after-sales service depart- - Charge the discharged battery;
ment of our company before it can be used; - Visual inspection for excessive dirtiness and
- When connecting the battery with the charg- mechanical damage after the charging.
er, the circuit switch should be at “OFF”
position, make sure the connection is correct. Supplementary Charging
It is prohibited to connect the battery with live
charger. - If the vehicle is not used for more than two
months, supplementary charging must be car-
- Before charging the battery, the charging spa-
ce should be ensured with good ventilation ried out to the battery to prevent permanent
without open flames and combustibles; battery damage;
when the temperature of electrolyte exceeds - Charging method is in accordance with the
40 degrees during charging, reduce the requirements of normal charging.
current or take physical cooling measures,
the charging must be stopped when the
temperature reaches 45 degrees; How to tell if the battery is normal?
- When the battery voltage remains constant General diagnostic method for the quality of
(for more than 2 hours), and the load voltage battery is to fully charge the battery with good
of the battery is within the specified range charger, and then measure the load voltage with
between 20.8V~24.4V, it indicates that the a multimeter to check if the voltage is between
charging is completed. 20.8V~24.4V.
REV. 09/2016
114
C SCHEDULE
115
NOTE:
116
Operator's Daily Checklist
Date Operator
TruckNo. No.
Department
Runtime
MeterReading
DailyCheckItems O.K.( √ ) Remark
DriveWheel
LoadWheel/Casters
Horn
Lifting/LoweringControlFunctions
OptionalFeatures
Forward/ReverseControlFunctions
Steeringcontrolfunctions
BrakingFunctions
Checkhydraulicsystemforleaks:
cylinders,fittings,tubings,oiltank,etc.

Ep Ept20-15et-Service-Manual

Uploaded by

Copyright:

Available Formats

Ep Ept20-15et-Service-Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ep Ept20-15et-Service-Manual

Uploaded by

Copyright:

Available Formats

Service Manual

This manual applies to:

Safety signs and instructions:

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

Please pay attention to the important safety instructions.

Copyright of Service Manual belongs to EP Equipment Co., Ltd.

EP Equipment Co., Ltd.

EP Industrial Park, Xiaquan Village,

REV. SM-1115 09.16

3. STRUCTURE & FUNCTIONS ........................................ 19

4. CHASSIS SYSTEM ........................................................ 27

5. DRIVE SYSTEM ............................................................. 33

8. ELECTRICAL SYSTEM ................................................. 71

APPENDIX ................................................................ 103

B SERVICE MANUAL - BATTERY ................................. 105

B2 Maintenance-free Battery ......................................... 113

C SCHEDULE ................................................................. 115

1.1 After-sales Service Platform

Claim Form Claim Form

Customer service to input Customer service to input

Maintenance service Within two business

No. Name No. Name

This series are electric pallet trucks. Its import-

1.3 Common Tools

No. Name Remark

1.4 General Tightening Torques

Table 1.4.1 Screws/Bolts Performance Levels

5.8 5.8 grade Low carbon steel M6 ~ M48

Quenched and tempered medium

Quenched and tempered medium

Quenched and tempered medium

Table 1.4.2 Metric Screws/Bolts Tightening Torque Table (n•m)

Nominal Diameter 5.8

2.2 Maintenance Regular inspection and maintenance under

truck is powered by battery, battery plug must

Table 2.1 Inspection & Maintenance List

Table 2.1 Inspection & Maintenance List (Continued)

2 Check the bearing bridge for damage or crack

Table 2.1 Inspection & Maintenance List (Continued)

2 - When storing or adding lubricant, use clean

different types and specifications of lubricants

Hydraulic oil injection nozzle

Gear oil injection nozzle

Table 2.2 Lubricants

Code Type Specification Amount Position

Anti-wear hydraulic oil L-HM46

Multi-purpose grease Polylub GA352P Appropriate amount

Table 2.3 Sliding Surface

3.1 Structure & Functions

3.1.3 Emergency Reverse Switch Emergency Reverse Switch

3.1.4 Horn Switch

3.1.5 Emergency Stop Switch Emergency Stop Switch

3.1.6 Key Switch

3.1.7 Charge Gauge

3.1.8 LED Charging Indicator

LED Charging Indicator

3.1.13 Lifting Limit Switch

3.1.15 Pump Motor

3.1.16 Gear Pump