XCSeries

CPD20/25/30/35-XD4-SI25
CPD20/25/30/35-XD4-SI26

Electric Forklift Truck

Maintenance Manual

Original Instruction

HANGCHA GROUP CO., LTD.

12/ 2018
 FOREWORD
Thanks for your purchasing our Lithium Battery Counterbalanced Forklift Truck
XC series electric four-wheel forklift truck is our company’s new product. It has the character of
small turning radius, beautiful shape, small dimensions, low gravity.
This service manual is about the structure,working principles and maintenance etc. To ensure
safety and exert the truck’s potential, all the personnel that in charge of maintenance and
management must read this manual thoroughly before starting work with the forklift.The driving
speed is over 19km/h, the lifting speed is about 600mm/s, and the performance is the same as the
tonnage XC series internal combustion counterbalanced forklift.
This manual is about 2.0t～3.5t XC series of four support battery counterbalance forklift truck
structure, working principle and maintenance etc. In order to ensure safety and give full play to you
buy the forklift truck performance, relevant operating personnel, equipment management and
maintenance personnel, should carefully read this manual.
Forbid repairing the truck if you haven’t been trained.
Our product design will update and perform better, so the content in this manual may be not the
same as the forklift you owned.
If you have any questions please keep touches with HANGCHA GROUP CO., LTD. sales
department or let the agents know.
This series of forklifts has passed CE certification.

© 12/2018 HANGCHA GROUP CO., LTD.

 CONTENT
1.Drive system ............................................................................................................ 1
1.1 Drive system disassembly and installation...................................................... 1
1.2 Traction motor ................................................................................................. 3
1.3 Gear box ......................................................................................................... 1
1.4 Driving axle ..................................................................................................... 2

2 Steering system ....................................................................................................... 9

2.2 Structure of Steering Device ......................................................................... 10
2.3 Steering Axle................................................................................................. 11
2.4 Steering System Installation Attention .......................................................... 13
2.5 Dismounting and Adjustment of steering axle ............................................... 13
2.6 Troubleshooting and corrections on the steering system .............................. 15
3 Brake System ...................................................................................................... 16
3.1 Foot brake piping system and brake master cylinder .................................... 16
3.2 Hand brake device ........................................................................................ 19
3.3 Foot brake..................................................................................................... 21
3.4 Brake system schematic ............................................................................... 23
4 Hydraulic system ................................................................................................. 24
4.1 Structure of hydraulic .................................................................................... 24
4.2 Working Principle of Hydraulic System ......................................................... 25
4.3Fault and elimination ...................................................................................... 27
4.4Oil pump device ............................................................................................. 29
4.4.1 Gear Pump ................................................................................................ 30
4.4.2 oil pump motor ........................................................................................... 31
4.5 Multi-way valve ............................................................................................. 31
4.6 Hydraulic Steering Gear................................................................................ 34
4.7 Steering Cylinder .......................................................................................... 39
4.8 Tilting Cylinder .............................................................................................. 40
4.9 Lifting Cylinder .............................................................................................. 44
5 LIFTING SYSTEM ............................................................................................... 47
 5.1 General Description ...................................................................................... 47
5.2 Data of assembly and debugging ................................................................. 49
5.3 Trouble shooting and corrective action ......................................................... 50
5.4 Mast Disassembly and Installation ................................................................ 51

6 Electrical system ................................................................................................. 57

6.1 Motor............................................................................................................. 57
6.2meter ............................................................................................................. 59
6.3Controller ....................................................................................................... 68
6.4 Lithium battery .............................................................................................. 70
6.5 Fuse box assembly ....................................................................................... 82
6.6 Lighting System ............................................................................................ 83
6.8 DC fan and others ......................................................................................... 90
6.9 Electrical system principle diagram ............................................................... 93
1.Drive system
The drive system is composed of drive axle assembly 1, reduction gearbox 2, traction motor 3, and
tire assembly.
1.1 Drive system disassembly and installation

Fig.1-1

Dismantle the drive system from the truck：

1、 Remove the mast tilting cylinder, remove the bearing cap bolts connected to the mast
and the drive axle; hoist out the mast
2、 Remove the brake line on the left and right brakes of the drive axle;
3、 Remove three wires of U, V and W on the traction motor;
4、 Lift the drive axle, motor and reduction gearbox integral with the lifting device, bundle
the drive axle left and right, and use the motor hook.
5、 Remove one bolt connecting the reduction gear box to the frame, that is No. 13 in the
figure below;
6、 Loosen 8 bolts of the support plate and the frame, that is No. 2 and No. 5 bolts.

1
 20
19
18
17
13
16 14
15
5
4
2
7
9
8
9
3
10 6 12
4
5

图 1-2
The entire drive system is fastened to the frame by bolts 2, 3 and bolts 13. Note that a seal ring 16
is to be fitted between the gearbox and the motor. The truck is equipped with a high-power traction
motor, which greatly speeds up the vehicle. The reduction gearbox 12 and motor 20 are fastened
by bolts 17.
Decompose the drive system：
1、 The drive axle is laid flat, and the motor side is slightly 1cm high;
2、 Place a container at the bottom of the drive axle housing, loosen the oil drain plug of the
drive axle, and drain the gear oil in the bridge;
3、 3. Loosen No. 17, remove O-ring 16 and motor 20, and place them on a clean tool holder.
Put the fasteners aside.
4、 Loosen No.7, 8 and remove the reduction gearbox 12 and place it on a clean tool holder.

The installation and disassembly of the transmission system are opposite.

Lubrication of transmission system: The axle housing is connected with the reducion gearbox, and
the drive axle is filled with gear oil and gear oil enter the reducion gearbox.
1. Installation and adjustment requirements: The clearance between the supporting plate of axle
and the left and right sides of the frame is not more than 3 mm, and If exceeded, gasket 6 should
be used to adjust
2. Tightening torque：
Tightening torque
No. Connecting part

2 Bolt（M20） Connect support

346～415
3 Bolt（M20） plate and frame

2
 13 Bolt（M20） 346～415 Connect reduction
gearbox and frame
17 Bolt（M14） 140～190 Connect motor
and reduction
gearbox

1.2Traction motor
The traction motor uses a 16.6 kW AC motor. Other parameters are shown in the table below.

Rated Rated Rated Rated Max. Insulati Cooling Protecti Duty Weight
Model Power Voltage Current Speed Speed on Mode ng
kW V A r/m r/m Grade Grade kg

HPQ16.6-4HC 16.6 51 250 3100 5000 H IC00 IP20 60 155

HPQ15-4HC-A 15 55 198 2731 4500 IC00 IP20 102

CAUTION
 AC motor don’t have commutator and brush，not need maintain. You must check and
clear dust everyday.

3
1.3Gear box
Remove the gearbox from the drive axle and remove the motor from the other end.
Gear box is two grades reduce speed gear, one grade straight gear and one grade planet gear. So
the gear box is very small.

pig1-3 Gear box

1. Transmission gear box house 2. Bearing block 3. Locking piece 4.Bolt
5. Differential housing,R.H. 6.Differential housing,L.H. 7. Bolt 8. Pin
9.Gear shaft 10.Gear shaft 11.Washer 12. Half shaft gear
13.Planetary gear 14.Thrust washer 15.Big ring gear 16.Bearing
17.Double gear shaft 18.Bearing 19.Bearing 20.Bush
21.Adjustable pad 22.O-Ring 23.Bearing block 24.Washer
25.Bolt 26.Locknut 27.O-Ring 28.End cap

1
 29.Bolt 30.Bearing 31.Double gear 32.O-Ring
33.Shaft 34.Bearing 35.Pinion 36.Pin
37.Tank cap 38.Washer 39.Bolt 40.Bolt
41. Locating plate 42. Bolt

Trouble Probably cause Method of

troubleshooting
When traveling or Gear clearance is too big. Adjust

change direction Too much worn of gear. Replace

Oil level is low. Add oil

Too much noise when
Gear clearance is too big. Adjust
traveling
Too much worn of gear. Replace

1.4Driving axle
Data
Model 2.0t～2.5t 3.0t～3.5t
Full floating, axle and truck body direct install, front
Driving axle type
wheel driving
Tire pressure MPa 0.9
Wheel hub rotation starting
N 10～29
torque at hub blot
Axial play of wheel bearing mm less than 0.08
Weight kg 195～198 202～208

Trouble diagnoses and corrections

Condition Probable cause Corrective action

Loose driving axle and body connecting blots. Tighten

Abnormal noises Loose wheel nut Tighten

Worn or damaged wheel hub bearing. Replace

2
 Wheel hub bearing not properly adjusted. Adjust

Worn axle shaft spliner. Replace

Insufficient lubrication Lubricate

Loose wheel nut. Tighten

Deformed wheel. Replace

Worn or damaged wheel hub bearing. Replace

Unstable driving
Loose driving axle and body connecting blots. Tighten

Wheel hub bearing not properly adjusted. Adjust

Improper tire pressure. Adjust

Worn or damaged axle shaft oil seal. Replace

Oil leakage Final drive improperly installed. Replace gasket

Loose drain plug. Tighten.

5
6
1 7
3
4

2 12

9
11 8 13,14
10
22 16
15
23 18 17
24 19
20

23
25
26
19 21
18
28
27
29

30

3
 Pig 1-4 Driving axle

1、R.H. Bracket 2、Axle housing 3、Bolt M12×40 4、Washer 5、Air breather 6、Plug 7、Washer
8、Plug9、Washer 10、Plug M16×1.5 11、Washer 12、L.H. Bracket 13、L.H. Brake
14、R.H. Brake 15、BoltM14×1.5×30 16、Washer 1417、Brake drum18、Bolt M6×12
19、Washer 6 20、Stud-bolt 21、Wheel nut 22、SealSD100×140×12
23、Bearing7815 24、Hub 25、Nut 26、Wedge 27、SealPD45×62×12
28、Gasket29、Half shaft 30、Pin D12×35
Tightening torque of each key fastener of the drive axle (see Figure 1-5 Schematic diagram of the
tightening torque of the drive axle)

Figure 1-5 Schematic diagram of the tightening torque of the drive

1. Rim 2. Brake drum 3. wheel hub 4.Wheel nut 5. Wheel hub bolt
6. Bolt 7.Brake assy 8. Wash 9.Bolt 10. Half-axle nut
11. Half axle 12.Bolt 13.Oil seal 14. Taper rollerbearing 15. Adjusting nut
16. Lock nut 17.Pin 18. Paper shim 19. Oil seal 20.Axle case
21. Supporter

4
Tighten torque :Nm
2.0t-3.5t
Axle shaft bolt○
A 73.5-88.3
Trig soleplate bolt○
B 118-147
nut connecting brake drum and hub○
C 324-373
Bolt and nut connecting support plate and
324-373
truck body○
D
Tyre nut○
E 441-588

5
Driving axle assemble removal and installation

WARNING
 Be careful when removal and installation driving axle as it is heavy.
– Raise front end of forklift truck and support frame with wooden blocks.
– Remove mast assembles.
– Slightly raise axle with a hoist and place wooden blacks under differential gear carrier and
transmission case.
– After placing a pan under axle case, loose oil plug, drain oil from axle case.
– Disconnect brake nuts from left and right cylinders.(see fig.1-6）.

CAUTION
 Plug brake tube openings to prevent oil from flowing out.
– Disconnect brake cable at hand brake lever.
– Remove front wheels.
– Remove axle shaft.
– Support driving axle with wire ropes and lifting device.
– Remove bolts securing axle mounting bracket to frame.（see fig.1-7）.
– Remove nuts securing axle case to differential gear carrier.（see fig.1-8）.
– Remove driving axle assemble.

Fig.1-6 Fig.1-7 Fig.1-8

– Remove brake drum，remove wheel hub.
– Remove axle mounting bracket and brake component from axle tube.
– Remove oil seal from axle tube.
– To install driving axle assemble in the reverse order of removal. Observe the following:
a. When installing axle mounting bracket and brake component, apply a coat of calcium
grease to axle tube.
b. Apply 1/3～2/3 of volume of calcium grease to wheel hub，then install them on axle tube.
6
 c. Install oil seal with its part number facing to the inside of forklift truck.
d. attach seal tape （PVC, white）to drain plug then installed after cleaned it.
e. Replenish axle case with gear oil. Tighten vent plug after clearing.
Gear oil GL-5 85W/90
（Cold storage forklift 2.0t～3.5t 4L
selection： GL-5 80W/90）
Axle shaft and wheel hub
Remove
– Raise the front end of forklift truck and support frame with wooden blocks.
– Remove front wheel and axle shaft.
– Remove lock nuts, lock washers, snap ring, felt ring, adjusting nut. Use special tools.
– ；
Remove brake drum（refer to Fig.1-9）
– If brake drum is difficult to remove:
a. Remove adjusting hole plug. Then with flat-blade screwdriver extend adjusting hole, turn
adjusting ratchet wheel by 10 notches. To contract brake shoe lining(refer to Fig.1-10).
b. evenly tapping on brake drum with brass bar or wooden mallet.

Fig.1-9 Fig.1-10
– Remove wheel hub, be careful not to drop bearing inner race.
– Remove oil seal and inner bearing as an assembly by evenly tapping on periphery of seal with
a wooden mallet and brass bar.
– Remove bearing outer race from wheel hub by evenly tapping on its periphery with a wooden
mallet.

CAUTION
 Be careful not to damage oil seal and outer race.

Inspection

7
 Stepped wear or cracks on axle shaft splines Replace

Seized, scratched, noisy or rusted bearing or improper rotation of rollers Replace

Cracked or damage wheel hub Replace

Damaged oil seal felt ring. Replace

Installation

Install reverse order of removal.

Bearing adjusting
– Lubricate on taper roller bearing.
– Tighten roller bearing lock nut in wheel hub until wheel hub can no longer be rotated with one
hand.
– From that position, turn back lock nut approx. 600.
– Turn back wheel hub two or three rotations so that bearing settles down.
– Again tighten lock nut until it can no longer be rotated with one hand; then turn back
approx.600.
– Install snap ring and settles down felt ring, install lock washer so as to set its hole in the pin of
snap ring. Screw lock nut.
– Turn wheel hub back and forth two or three rotations to see if rotation starting torque is within
specifications. Rotation starting force:10～29N（refer to Fig.1-11）.
– Measure axial play of wheel hub to see if it is within specification. Axial play is less than
0.08mm （refer to Fig.1-12）.

Fig.1-11 Fig.1-12

8
2 Steering system
Structure of Steering System
The steering system consists of steering device and steering axle assembly. See figure 2-1.
The steering device is composed of steering wheel assembly, steering tube device, locking handle
and the hydraulic diverter. See figure 2-2. Both the steering column and steering wheel can be put
forward and backward by an angle of 6°which can meet the requirements of different operators.
When the truck is disconnected, turn the steeling wheel by a force of 1kg and release. The
steering wheel can return by an angle of 10°automatically.
The steering axle assembly is composed of the steering axle, steering knuckle, steering hub,
steering wheels and steering cylinders. See figure 2-3.

Steering device

Steering axle assy

Figure 2-1 Steering System

9
2.2Structure of Steering Device

1 steering wheel assy

2 steeringwheel nut
3washer16
4 steering column
5 clamp lever
6 Circlip
7 Locking shaft
8 Locking sleeveⅠ
9 Locking sleeveⅡ
10 bolt
11 washer
12 nut
13 washer
14.bolt
15.bushing
16 steering gear

Figure 2-2 Structure of Steering Device

No. Specification Tightening torque Note

2 M16×1.5 26.5 Nm～32.5Nm Steering wheel nut

10 M10×20 15.7 Nm～21.6Nm bolt

12 M12 58 Nm~78 Nm nut

10
2.3 Steering Axle

Figure 2-3 Steering Axle

1. bolt 2. washer 3.right stop plate 4.left stop plate 5.adjusting washer

6.master pin 7. right master pin 8. damper 9. screw 10.washer

11.cover plate 12.bolt 13.washer 14.steering axle 15.oil seal

16.bearing 17.fastening bolt 18.steering hub 19.bearing 20.lock nut

21.lock washer 22.sphere nut 23.paper pad 24.end cap 25.grease cup

26.pin roll 27.pin roll 28.snap ring 29.bearing 30.bottom connecting rod

31.upper connecting
32.snap ring 33.bearing 34.nut 35.pin
rod

36.grease cup 37.oil seal 38.bearing 39.bearing 40.dustproof cover

11
 41.master pin 42.fastening bolt 43.left knuckle 44.steel bushingⅠ 45.steel bushingⅡ

46.adjusting washer 47.cover 48.sensor 49.cover 50.cover

51.retainer plate 52.rigt knuckle 53. nut 54. bolt 55.steering cylinder

2.3.1 Key Data

Axle Type Centre bearing, rotational

Maximum steering angle of
80°
inside wheels
Steering angle
Maximum steering angle of
55.7°
outside wheels
Longitudinal clearance mm 0～1
Adjusting washers for N163-220020-000（δ =0.5mm、1.0mm、1.6mm、3.0mm four
longitudinal clearance kinds）
Kingpin

Axial clearance of kingpin ≤0.20mm

Adjusting washers for

N163-220012-000(δ=0.1mm、0.3mm、0.7mm) three kinds
kingpin(46)
Hub bearing
Screw down the nut of knuckle till the hub cannot be removed
Pretightening force with hand. Or stop when the torque of hub bolt reaches 10 to
29 Nr. Turn the nut slightly to 1/8 to 1/6 of one circle.
Axial clearance No clearance in the axial direction

Tightening torque for key fasteners

Note: Tightening torque is measured on basis of the key fasteners are not lubricated. No
grease on the bearing surface of bolts and nuts.

No. Specification Tightening torque Note

1 M10×1.25×30 40.9 Nm～49 Nm Bolt (figure 2-3)
9 M6×12 8.5 Nm～10.2 Nm Bolt (figure 2-3)）
12 M14×1.5×40 176 Nm～212 Nm Stop bolt (figure 2-3)
22 M16×1.5 176 Nm～212 Nm Sphere nut (figure 2-3)
42 M10×1.25 40.9 Nm～49 Nm Fixing bolt (figure 2-3)

Truck Model 2t～2.5t 3.0 t～3.5 t

Weight of Steering Axle

96～99 98～100
(kg)

12
2.4 Steering System Installation Attention
Precautions – Loosen lock bolts；
– Make sure the hydraulic connectors, bolts
and hoses are clean before installing.
– Check if the pipeline work is correct and
make sure the left and right steering
direction is not fitted reversely.
– Turn the steering wheel to the left and
right fully and check if the force is even on
both sides and check for the stability of
the truck.
– Remove grease nipples onmaster pin;
– Jack up the rear wheels. Turn the steering
（ Right knuckle: Remove the steering
wheel to left and right slowly for several
times. Bleed the air in hydraulic pipes and angle sensor, No. 48 sensitive angle
in the cylinders. sensor, cover 47, 49, 50, etc., be careful
– When the engine shuts down, turning the not to misplace, the left and right knuckles,
the steering kingpin are different）
steering wheel with 1kg force. Releasing
– Remove the master pin（Left and right
the hand and the steering wheel should
；
main sales are different）
turns back with 10°automatically.

2.5 Dismounting and Adjustment of

steering axle
Dismounting

Wheel hub
– Jack up and support forklift truck body with
wooden blocks.
– Remove tire.
– Remove hubcap.
– Remove steering spindle nut.
– Pull off hub assembles. CAUTION
– Remove bearing inner race.  Hold master pin to prevent it from

CAUTION dropping
Not to drop bearing inner race. – Take off spindle, thrust bearing and shim.
 Be careful not to damage oil seal.
Inspection：
Master pin and steering spindle – Replace spindle if cracked.
– Dismount the knuckle and the nut which is – Replace bearing if its rollers or roller
connected to the pull rod device. Surfaces are rusted or nicked.
Disassemble the pull rod device. – Replace needle bearing if it is damaged
13
– Replace thrust bearing and dust cap if from the left side, and the sensitivity
them damaged. sensor, cover, etc. are mounted on the
Installation
right side.
Installation procedures are in reverse Wheel bearing installation and adjustment
sequences of dismounting. Pay attention to
– Apply anti-rust oil to the contact surface of
the following notes.
– Always insert master pin from the bottom. the lock nut (20) and the bearing (19)
– Install thrust bearing, set the tighten-ring – Turn the steering hub(18) with one hand,
Below the support and loosen-ring. Create the tighten the lock nut (20) with the other
axial clearance by adding or decreasing some hand until it is difficult to turn the steering
washers. Keep the axial clearance less than
0.2mm. hub (18), rotate the lock nut (20) in the
opposite direction by about 60°~ 90 °(or
CAUTION
1/6-1/4 turn).;
 Thrust ball bearing is installed on the
– Turn hub 2-3 turns and rotate the bearing
upper side of the steering knuckle.
roller in place;
Adjusting washer is mounted on the
– Turn the steering hub(18) with one hand,
bottom of the knuckle.
tighten the lock nut (20) with the other
– Apply lubrication grease to inner hand, and the initial rotational torque is
dustproof shell, loose ring and straining 0.88 Nm ~ 2.65 Nm.
ring; – Place the protruding part of the lock
– Do not apply lubricating grease to faying washer (21) into the groove of the
face of needle bearing outer ring and steering knuckle, adjust the lock nut (20)
knuckle; so that the threaded hole is aligned with
– Apply lubricating grease to roller needle of the hole in the lock washer (21) and
needle bearing and ball of thrust ball tighten with screws.
bearing; Turn the hub two turns and measure whether

– The straining ring of the bearing (39) is the initial rotation force at the hub bolt position
below and the loose ring is on top. is 10 N to 29 N and ensure that there is no gap
– The dust cover (40) is installed with the in the axial direction.
large opening facing down.
– The right knuckle, the kingpin is different

14
2.6 Troubleshooting and corrections on the steering system

Condition Cause and Analysis Correction

Oil pump damaged or breakdown Replace

Steering wheel Priority valve (Control valve) plugged or
Clean or replace
fails to turn damaged
Hose (or joint) damaged or pipeline plugged Clean or replace
Low pressure on steering overflow valve(located Adjust the pressure
on control valve
Air in pipelines Bleed air
Controlling pipelines plugged Clean or replace
Hard to steer
Priority valve (Control valve) malfunction Check or replace
Steering reset failed or retaining flat spring
Replace the flat spring
broken(or lack of elasticity)
Severe inner leakage in steering cylinder Check the piston seal
oil level is lower than the standard level Refill oil
Suction tube or strainer plugged Clean or replace
Smear or fill calcium
insufficient lubrication
base grease
Abnormal noise
bolts or nuts loosen fasten
Adjusting washer of the shaft installed incorrect Adjust
Knuckle bearing on both ends of connecting rod
Replace
damaged
Wheel nuts loosen fasten
Running unstably Wheel bearing is belonged the adjusting range Adjust
Adjusting washer of the shaft installed incorrect Adjust
Seal of guide sleeve on steering cylinder
Oil leakage Replace
damaged or pipelines / connectors damaged.

15
3 Brake System
Brake system is composed of service brake and parking brake. Service brake refers to the
hydraulic brake depressed on the hydraulic system by foot while parking brake refers to the
mechanical brake applied by hand. Both service brake and parking brake function together with
the wet disc brake located in the transmission of wheel edges of driving axle.

3.1Foot brake piping system and brake master cylinder

3.1.1 Foot brake piping system
The foot brake piping system is composed of oil pot 9, pipeline 7, brake master cylinder, pipelines
12, 14, 15 and tee components, hoops and so on. See Figure 3-1.

Fig.3-1
The oil pot is located on the left side of the instrument rack, and the oil pot can be seen by opening
the cover. DOT3 brake fluid should be added to the oil pot. Check the pipeline for oil leakage every
week. If it is insufficient, it should be added in time.

16
3.1.2 Brake master pump
The master pump contains a valve seat, check valve, return spring, primary cup, piston and
secondary cup, which are kept in place with stop washer and stop wire. The exterior of the cylinder
is protected against dust by means of a rubber dust cover. The piston is actuated through the push
rod by operation of the brake pedal. Once the brake pedal is depressed, the push rod pushes the
piston forwards. And the brake fluid in the front cavity of cylinder flows back to the reserve tank
through the return port until the primary cup blocks up the return port. After the primary cup passes
the return port, the brake fluid in the cylinder is pressurized and opens the check valve, flowing
through the brake pipelines to the wheel cylinder. Thus, each wheel cylinder piston is forced
outwards. It connects the brake shoes with the wheel drum which slows or stops the lift truck.
Meanwhile, the back cavity of the piston is filled with brake fluid led through the return port and
inlet port to lubricate the piston. When the brake pedal is released, the piston is forced backward
by the return spring. At the same time, the brake fluid in each wheel cylinder is pressurized by the
force of the brake shoe return spring, which makes the fluid returning into the master pump (front
cavity of the piston) through the check valve. With the piston in original position, the fluid in the
cylinder flows into the reserve tank through the return port. Reset the pressure of the check valve
to keep it in proportion to the a residual pressure of The brake fluid in the brake lines and wheel
cylinders in order to make sure each wheel cylinder piston cup is securely seated to prevent oil
leakage and eliminates of vapor lock when the lift truck comes to an emergency stop.

17
 1. push-rod fork
2. nut
3. push rod
4. cover
5. circlip for hole
6. 1st auxiliary aprons
7. piston
8. piston washer
9. pressure aprons
10.2nd spring seat
11.spring
12.spring seat
13.outlet valve
14.O-ring
15.inlet connector
16.spring clamp

17.vent screw

Figure 3-2Brake Master Pump

18
3.2 Hand brake device
The hand brake device adopts a hand-pulling soft brake wire cable device. It makes use of
auto-assist pressure linings type brake together with foot brake. Only when parking truck, use the
hand brake. Figure 3-3。

Condition Cause and Analysis Correction

Oil leakage in brake lines. Correct and refill oil

Air in brake lines. Bleed air

Insufficient
brake force Malfunction of master cylinder or wheel Correct or replace
cylinder.
Oil lines plugged Clean

No free Stroke of brake pedal. Adjust

Piston cup damage Replace

Brake
Weak or broken return springs. Replace
dragging
Returning port of master cylinder plugged Clean

Oil lines plugged Clean

The hand brake device uses a hand-held flexible shaft mechanism that uses an automatic
power-assisted shoe brake that acts on the front wheel in conjunction with the foot brake. Use the
hand brake only when the forklift is parked.
Before adjusting the hand brake, make sure the axle brake system is functioning properly.
1）Adjust nut B so that the length is equal to 68mm, then tighten lock nut B.
2）Tighten the adjusting nut A to adjust the hand brake tension. The pulling force is: when the
handle is locked, the tension in the Q direction is 147N-196N.
3）After the handbrake lever is properly adjusted, release the handbrake lever to ensure that
the brake is fully released.
4）Through the above adjustments, ensure that the hand brake device works normally.

Note: Apply a proper amount of lithium grease to the guide rail C and keep it applied

frequently.

19
Fig.3-3Hand brake

20
3.3Foot brake
3.3.1 Foot brake structure
2t-3.5tForklift right brake structure3-4。

Fig.3-4 forklift truck right brake assy

1. Brake mountbracket 2. Wheel cylinderbody 3. Cylinder return spring
4. Rubber cap 5.Piston 6.Cylinder dustcover
7. Push rod 8.Air bleeder cap 9.Air bleeder screw
10. Brake shoeassy (front) 11. Brake shoe assy (rear) 12. Guider
13. Adjuster cable 14.Adjusting bolt 15. Pawl
16.Spring 17. Brake shoe return spring 18.Return spring
19.Parking brake rod 20.Strut level 21.Spring
22.Bolt 23.Washer 24.Snap ring
25.Guider 26.Spring support rod 27.Spring bracket
28.Spring 29.Plug 30.Oil connector
31.Bush 32.Brake steel cable

21
Replace brake shoe:
– Place the forklift truck on level concrete.
– Start the forklift and raise carriage about 100mm.
– Place chocks behind rear wheels to prevent movement of forklift truck.
– Loosen wheel nuts two or three turns each.
– Tilt mast fully backward, and place a wooden block under each side of outer mast.

WARNING
 Do not allow wooden blocks to touch front tires.
– Tilt mast forward until front tires are raised from surface.
– Support forklift truck by putting additional wooden blocks under each side of front-end frame.
– Stop the forklift.
– Remove wheel tire nuts and brake drum.
– Replace brake shoes with new ones.
– Install brake drum.
– Adjust shoe to drum clearance:
a. Remove adjusting hole plug on the bottom of the brake assemble.
b. Insert a flat-blade screwdriver to adjusting hole, turn adjusting ratchet wheel downward to
expand the brake shoes until wheel hub can not be turned by hand.
c. Move the ratchet wheel 2～3 notches to allow the wheel hub to be turned freely, slight
friction is allowed between the brake and shoe lining.
d. Replace the plug.
e. Install wheels.
f. Properly adjusting pedal stroke.
g. Remove blocks.
h. make sure no person or obstacle is around forklift, then operate forklift in reverse at 2 to 3
km/h, set foot on brake pedal 2～3 times.

22
3.4Brake system schematic

Fig 3-5 Schematic diagram of drum brake principle

23
4 Hydraulic system
4.1 Structure of hydraulic
Hydraulic system mainly consists hydraulic fuel tank and its accessaries, gear pump, priority
valve, hydraulic steering gear, control valve, steering cylinder, tilting cylinder, check valve, lift
cylinders and hydraulic pipelines. See figure 4-1 as follow.

1. hydraulic fuel tank 2. gear pump 3. priority valve 4. hydraulic steering

and accessarie
5. control valve 6.steering cylinder 7. left tilting cylinder 8. right tilting cylinder
9. check valve 10. left lift cylinder 11. right lift cylinder

Figure 4-1 Structure of Hydraulic System

24
4.2 Working Principle of Hydraulic System
The high pressure oil from main oil pump to the multi-way valve is sent to the lift cylinder or the tilt
cylinder by the multi-way valve. When pulling the lift valve, the high pressure oil flows to the
downside of the piston which push the piston rod upward. When pushing the lift valve, the
downside of piston of lift cylinder is in connection with the low pressure and piston rod falls down
by dead weight and the load weight. The oil flowing out from the lift cylinder passes through the
check valve where slows down the falling speed. When operating the tilting valves, the high
pressure oil flows to a cavity of tilt cylinder and the other cavity is in connection with the low
pressure which realise the tilting back and forward of the mast. The other oil line flows to the
steering gear which makes sure the steering operation always in priority.

Fig.4-2-1 CPD20~35-XD4-SI25 Schematic diagram of hydraulic oil

25
Fig.4-2-2 CPD20~35-XD4-SI26 Schematic diagram of hydraulic oil

26
4.3Fault and elimination
Main pump
Trouble Probable cause Corrective action

Low oil level in tank. Add oil to specified level.

No oil from oil
pump Clean oil line and tank. If oil is dirty,
Clogged suction pipe or strainer.
change.
Worn bearing damaged backup
Replace faulty parts.
ring and O-ring.
Readjust to specified pressure using
Maladjusted relief valve.
pressure gauge.
Low discharge
Retighten suction side pipe.
pressure on oil
pump. Add oil in oil tank.
Air in oil pump.
Check pump oil seal.

Do not operate pump until bubbles in

tank disappear.
Cavitation due to crushed suction Adjust or replace crushed hose and clean
hose or clogged strainer. strainer.
Air being sucked from loose
Retighten each joint.
suction side joint.
Noisy oil pump Replace with new oil having proper
viscosity for temperature at which pump
Cavitation due to too high oil is to be operate.
viscosity.
To operate when oil temperature is
normal.

Bubbles in hydraulic oil. Determine cause of bubbles and remedy.

Faulty oil seal on pump, faulty
Oil leaking from
O-ring or worn sliding surfaces Replace faulty parts.
oil pump
on pump.

27
Control valve
Trouble Probable cause Corrective action

Loose of pressure-adjust screw. Readjusted and retighten.

Pressure of relief Distorted or damaged pressure-adjust Replace.
valve is not steady spring.
or too low. Worn or blocked relief valve core. Replace or clean.

Pump abated. Examine and repair pump.

Fork tilt forward Replace valve core and tilt lock
Worn or damaged tilt lock valve.
when control lever valve as an assembly.

is used while Broken tilting lock spring. Replace spring.

engine is off. Damaged tilt valve plunger O-ring. Replace O-ring.
Mast is unstable Replace tilt relief valve
Malfunctioning tilt relief valve.
when tilting forward. assembly.
Valve body and spool valve is worn Replace spool valve with
Lowering distance and clearance between them is too specified clearance.
of mast is big when great.
Spool valve is not in centre. Keep being in the centre.
spool valve is in the
Cylinder seal abated. Examine and repair cylinder.
centre.
Taper valve is worn or blocked by dirt. Replace or clean taper valve.
Damaged or distorted Replace spring.
Spool valve is not reposition-spring.
Dirt exist between valve body and Clean.
return neutral spool valve.
position. Blocked control device. Adjusted.

Not coaxial parts at reposition Reinstall.，be coaxial

Damaged O-ring. Replace.

Faulty seal of joint. Check and retighten.

Leakage Clean seal plate and retighten
Loose seal plate.
blots.
Loosed lock-nut of relief valve and
Tighten.
connect-nut between plate and plate.
Multi-way valve Multi-way valve moves back and forth
Adjustment
cannot move back to adjust handle interference
and forth

28
4.4Oil pump device
Oil pump device overview: It consists of motor, oil pump, pipe joint, bracket, cushion and so
on.See Fig 4-3

1、Gear Pump 2、washers 3、washers 4、bolts 5、Pump motor 6、Pipe joint assembly
7、Straight connector 8、O ring 9、washers 10 washers 11、Double bolt cushion
12、bolts 13、washers 14、Outer bracket 15、Inner bracket
Fig4-3 Oil pump device

Installation Precautions：
1、Install the left and right brackets to ensure that the motor axis is horizontal；
2、If the motor is unstable, you need to check the installation of the double-bolt cushion.
29
3、Fastening torque between oil pump and motor：40 Nm--50Nm。
4.4.1 Gear Pump
It is a kind of low noise gear pump and it contains the external gear pump which can
self-compensate the axial clearance and keep balance of radial hydraulic. It adoptes a
three-opening structure of character "8" location check. DU bushing is appllied in both front and
back covers within the casting aluminum alloy , central part is equipped with special casting iron
pieces. Therefore, it is impact resistance and in spread use of oil temperature, rotational speed
condition even in the case of high temperature and low speed, it can still keep high performanc
Main Parameter
Type: TMG1A30A4H1-R460D
Rated displacement: 30 ml/r
Rated pressure: 20.6 MPa
Max. pressure: 24.5 MPa
Rated speed: 2500 r/min
Min. speed: 400 r/min

Max. speed: 3000 r/min

Installation Instructions
– Before installation, make sure the rotation direction of gear pump can meet the system
requirement
– The coaxially between the gear pump axle and the motor axle must be less than 0.05mm,
– Connect the inlet and outlet connector, do not misconnect.
– Install the flanges and connectors. No bump ,scratch or burr, in case of oil or gas leakage and
noise-producing
– Avoid that there is no axial force or radial force on the gear pump axle. Install it smoothly
during the installation, no mounting or dismounting by force.

Operationand Maintenance
– Always follow the Instruction, never overload.
– Hydraulic oil requirement: summer, L-HM32 or similar viscosity hydraulic oil; winter, L-HV32
low temperature hydraulic oil;
– Starting for the first time, run without load to bleed the air in hydraulic system,until there is no
bubble.
– Keep the oil clean. Clean the oil tank and oil lines fully before refilling.

Inspect the oil cleanliness and strainers periodically, replace as necessary.

30
4.4.2 oil pump motor
AC motors rated at 25.4 kW.

Rated Rated Rated frequency Rated Insulation Protection Duty Weight Rated
Type power voltage current Hz speed class class kg Type power
kW V A r/min kW

TSA200-200-214 25.5 53 381 2280 5000 AC F IC00 IP20 52

HPB25.4-4 25.4 51 387 1620 3200 AC H IC00 IP20 5 115

Caution
 AC motor does not have commutator and brush. No maintenance. But it needs regular
inspection and dusty clearing.

4.5Multi-way valve

Fig 4-4Multi-way valve handle

31
 12
13
14
15
16
17
12
13
14
15
17 16
15
18
19

11
10
20 7
9
21 6
22 1,2,3 8
25
23
26 5
27 24 4
28

Fig 4-5Multi-way valve

Multi-way valve connector

Hinged bolt tightening torque：

Thread size G1/4 M16×1.5 G3/8 M18×1.5 G1/2 M20×1.5 M22×1.5

Tightening
30-45 50-65 60-100 60-100
torqueNm

Adjusting the pressure of the main relieve valve

The main relieve valve has been adjusted before leaving the factory, , it is not allowed to adjust at
will in general condition. Adjusting way is as follows:
(1) Park the truck on solid and smooth road, place in neutral, pull up the hand brake handle, tilt the
mast backwards to the end, and drop the fork to the ground. The engine stops.
(2) Open front soleplate, release the pressure mouth bolt of oil inlet pipeline in the multi-way valve,
and put in clean place. If hydraulic oil outflows, please protect the environment.

32
 -

(3) Connect the pressure gauge. Notice: a. Specification of gauge should be larger than 20Mpa. b.
taper thread at pressure mouth matches: Rc1/8R1/8; c. tightening torque is 20-22N•m.
(4) Start the engine, place the mast in vertical, and the fork is 300mm from the ground.
(5) Read out the indication in the pressure gauge, and judge is the main safety valve of multi-way
valve is in normal scope.
2.0t~3.5t：18.5MPa±0.25 MPa
(6) If the pressure is not in the normal scope, please release the main safety valve locknut, and
adjust adjusting bolt.
If the indication is smaller than the normal scope, inner hexagon spanner the adjusting bolt in
clockwise (+) to increase main safety valve pressure.
If the indication is larger than normal scope, inner hexagon spanner the adjusting bolt in
counterclockwise (-) to decrease main safety valve pressure.
(7) Stable the pressure in normal scope for 30’s.
(8) Release pressure gauge, install the bolt, and the tightening torque is 20-22N•m. Drop the mast
to the ground and tilt backward to end.
(9) Retighten the tightening nut, and fix it on the front soleplate.

Caution

① Specification is greater than 20MPa.

②Pressure measuring taper thread fit：Rc1/8R1/8；c.Tightening torque 20 N·m -22N·m.

33
4.6 Hydraulic Steering Gear
It is the load sensing hydraulic steering gear, containing integrated valves, which can be used
after connecting to priority valve by pipes. LS port of steering gear is connected to LS port of
priority valve, by which, the steering load pressure signals from the gear can be sent to the priority
valve and it control the oil supply to the steering gear from the system.
For the load sensing steering system, it can always meet the requirement of steering hydraulic
circuit and relevant flow can be distributed to assure the smooth, smart and easy operation of
steering regardless of load pressure, turning speed of the steering wheel.
The oil flow output from the pump, apart from the necessary supply to steering system, the
spare can be used for operation system, which eliminates the power lose caused by oil oversupply
to steering system and increase the system efficiency. Meanwhile the oil will be pressed to the left
and right cavities of steering cylinders and the piston rod of oil cylinder drives the steering wheel to
work.
There is no oil output from the pump when the truck is disconnected. The steering wheel drives
the rotor through spool, sleeve and coupling. The stator and rotor works as a pump which can
push the oil to flows to the steering cylinders and realize the manual steering.
Steering control unit
Main Parameter
Displacement: 80ml/r
Maximum output pressure: 17.5MPa
Set pressure of relief valve:12MPa
Set pressure of trimmer valve:18MPa
Function symbols

T A

P B LS

Fig4-7 Steeing gear

34
Attention on the steering gear installation and maintenance
– Keep the steering gear and the steering column in the same axle. Make sure there is axial
clearance. Check for the flexibility of the steering wheel.
– Avoid any axial force applied on input terminal of the steering gear during the installation.
– Assure all the parts clean and prevent dust or dirt going to the inner side of steering gear and
hydraulic system.
– Do clean the connectors of outlet pipes. Do not seal by tapes instead of seal rings.
– Make sure all the hydraulic fluid ports are installed correctly. Follow the sequences below on
pipelines installation. Connect P port (Pressure oil inlet) with the CF port of priority valve.
Connect the T port (low pressure oil return port) with T port of the control valve. Connect LS
port (load sensing) with the LS port of priority valve. Connect A port with the right fluid port of
steering cylinder and B port with the left fluid port of steering cylinder.
– A, B, P, T ports thread size M20×1.5，T=60～100N·m. LSports thread size M12×1.5，T=30～
36N·m.
– Do not dismantle the steering gear frequently unless malfunction of the steering gear is
confirmed.
– Make sure all the parts are clean and protect the parts against crash when dismantling the
steering.
– Put or take out the spool and sleeve vertically to prevent the pull pin dislocated during the
installation or dismantlement.
– Pay attention to the match of markers when installing the universal driving shaft and the rotor.
– Do not forget to fix the steel ball of the check valve and pull pin. Make sure the bolts are
installed correctly.
– Fasten the bolts evenly during the installation and guarantee the torque is between 40～
50N.m. Or else, it’s easy to cause dead center or steering difficulty.
– Make sure the fluid clean. Avoid the dirt block the spare parts of the steering gear and cause
the malfunction of steering. Therefore, it’s important to check the condition of the filter element
and the fluid. Replace it as necessary.
– If it is difficult to steer or the steering gear failed to turn, check for the cause carefully. In order
to protect the spare parts, do not turn the steering wheel blindly. Neither casually dismantles
the steering gear. It’s prohibited to turn steering wheel by two operators simultaneously.
The maximum manual steering torque of the gear is 130N.m.

Hydraulic Steering Gear common failures and troubleshooting measures

35
 Fault Probable reason Phenomenon Corrective action

Combined part bolts

Retighten these bolts
loosen
Oil
Combined face or journal
leakage Replace sealing ring
sealing ring damage

Gasket damage Replace gasket

Insufficient oil supply Turn steering wheel slowly is light

Check for oil pump work condition
from oil pump and turn fast is heavy.
If there are bubbles in oil that give
out irregular noise when rotating Bleed the air in the system and
Air in the steering system
the steering wheel but the cylinder check for oil suction pipe leakage
stops-and-goes.
Oil level is lower than
Hard Refill oil to specified position
specified position
steering
oils are too viscous Use specified oil

Steering wheel is heavy when If the ball losses, install another

Ball check valve
turning fast or slowly, and no one. If the ball is blocked by dirt,
disorder.
pressure in steering system clean it.
The pressure of steering No load or light load steering is Check out the reason, recover or
system is lower than work light, but much load steering is improve system pressure
pressure heavy.
Steering wheel cannot return to the
Spring leaf broken Replace spring leaf
middle automatically
Steering Dial pin or universal Pressure fluctuations increased Replace dial pin or universal
failure driving shaft opening significantly, even worse ,cannot driving shaft
broken
Rotor ororuniversal
deformeddriving steer Teeth space engagement
Steering wheel rotates or moves
shaft opening broken or from side to side freely between compact point teeth on
deformed universal driving shaft and on the
No
Overlarge stator radial or Steer after misfire, steering wheel rotor.
human Replace stator
axial clearance turns but the cylinder keep still.
steering

Fault Probable reason Corrective action

steering pump efficiency is too low,
cannot reach the required pressure
The pressure of system relief valve is
low or spring intensity of relief valve
The pressure of relief valve of steering
decreased
Turning steering wheel slowly is gear is low or the valve core get stuck
light and turning fast is heavy or no
The oil of steering system returns
power to steer
unsmooth
The load of steering is too heavy
The pipelines of load sensor have
leakage, work unsmooth or kink,
Steering gear has inner leakage or the

36
 Fault Probable reason Corrective action
shut-down steering non-return valve
cannot reset or has leakage
The damaged inlet non-return valve
plugged the oil to the steering gear
The resistance of steering column itself
is very strong. The steering lever
bends or it interferes with valve
Steering wheel is heavy when element of the steering gear.
turning fast or slowly, The mechanical resistance of steering
gear itself is big
Low steering pump efficiency
Low relief valve pressure
Air in the steering system
The connecting rod of steering wheel
has large clearance or bend
Steering wheel swings and the Seal in steering cuylinder damaged and
vehicle can not run straightly generate inner leakage
Trimmer valve or oil supply valve has
large leakage
The load hold facility of A and B port of
steering gear itself reduces
The connecting rod of steering wheel
has large clearanc
Trimmer valve or oil supply valve has
large leakage
The vehicle can not run straightly
The reset characteristics of steering
gear is not well
The tire pressure difference of steering
wheels is too big
Steering gear has large inner leakage
The relief valve or double-way overload
valve set the same presure
Steering cylinder has large inner
Hard to feel the terminal point of
leakage
the steering wheel
The double-way overload valve or oil
supply valve has large inner leakage or
gets stuck
The returning pipe plugged
Air in the steering system
Steer inaccurate or crawl
Steering cylinder has inner leakage
Steering mechanism connection drops
out
Trimmer valve or oil supply valve gets
Steering wheel can trun easily,but stuck
the rear wheels keep still or turn Cavities mixed of the steering cylinder.
slowly,just like no power to steer Piston falling off the cylinder lever.
The inner parts of steering gear
Replace the steering gear
damaged
Lack of oil Refill hydraulic oil
The clearance of the contacts between
steering gear and steering column is big
Large empty stroke of steer wheel The steer connecting mechanism has
large clearance
Air in the hydraulic system, and Bleed the air in the hydraulic
37
 Fault Probable reason Corrective action
cavitation erosion of oil is serious systerm
The reset characteristics of trimmer
Replace the steering gear
valve or oil supply valve is not well
The steering gear and steering column
have interference which makes steering
stiffly.
There are burrs between valve core and
valve sleev
reset incorrect or Heel Turn High oil return backpressure may make
reset incorrect.
Spring leaf broke or lacks of elasticity
The frictional resistance between axle
head of valve core and front cover of
steering gear is big
Faulty connection when steering gear
Steering wheel turn itself or shake assembling
repeatedly Connect the inlet port to A or B port

The sleeve of valve core gets stuck.

Stator and rotor are stuck

Pumping source or steering safety valve
lacks of pressure.
Plugged oil pipeline or faulty pipeline check for the connection of oil
connection pipeline
The steering wheel gets stall Steering column gets stuck. adjust the steering column
The inner parts of steering gear Maintain or replace the
damaged steering gear
The damaged inlet non-return valve
plugged the oil to the steering gear or
non-return valve plugged when shut
down.
The rear wheels make reverse Connect the steering pipeline
A and B port connect reversely
turning when turning the steer correctly
Steering
wheel wheel is blocked The inlet non-return valve of steering Maintain or replace the
gear damaged, the oil flow back steering gear
Air in the pipeline Bleed the air in the hydraulic
Pipeline shakes and there is system
hydraulic noise in the load
Orifice of load port is small
sensing steering system. The
truck vibrates when running, Set the pressure of relief valve to an
incorrect value

38
4.7 Steering Cylinder
Steering cylinder is di-functional. The piston rod can be connected with knuckle through the
connecting rod. The fluid from hydraulic steering gear flows to the steering cylinder and drives the
movement of piston rod to the left and right side, which drives the truck steer to left and right.
Structure of steering cylinder can be found in figure 4-8.

2
3
4

6
9
5

7
1

5
9
6
4
3
2

1.piston rod 2.LBH scraper seal 3.ISI seal ring 4.combination seal 5.O-ring
6.guide sleeve 7.glyd ring 8.steel cylinder 9. composite bush
Figure 4-8 Structure of steering cylinder
Attention on the installation and disassembly of the steering cylinder
– Lubricate every part with clean hydraulic fluid.
– Keep the cylinder away from any dust and dirt.
– Prevent the cylinder barrel and inlet, outlet from scratching.
– Keep the opening of ISI seal ring inward and the opening of LBH scraper seal outward.
– Protect the O-ring from being damaged during the installation.
– Push the guide sleeve carefully into the cylinder barrel. Protect the O-ring and inner seal ring
from being damaged. Lubricate the clearance of the seal rings with the same brand hydraulic
fluid as the operating oil.
39
 4.8 Tilting Cylinder

1
3
6 2
1

21
20 4
19 5
24 10
23
7
17 9
13
11
12
8

15
14

16

18
22
19
20

1. circlip for hole 2. bearing 3. earring 4. washer 5. nut

6. bolt 7.scraper seal 8. guide sleeve 9. U-ring 10.circlip for shaft
12.steel cable baffle
11.cover 13.step seal 14.O-ring 15.composite bush
ring
16.piston rod 17.cylinder 18.O-ring 19.OSI seal ring 20.retainer ring
21.support ring 22.piston 23.nut 24.pin 25.spacer bush

Figure 4-9 Structure of tilting cylinder

40
Disassembly of tilting cylinder Decomposition of tilting cylinder

Operating Procedures as follow.

– Retain the tilting cylinder with a jaw vice.
– Drain out the remaining fluid in the
Caution cylinder by way of pulling the piston rod

Pay attention to the following notes when back and forth when both inlets and

disassembling the tilting cylinder. outlets are open.

– Remove the circlip for hole (1) with a plier
 Fix the outer mast with steel wire of
and take down the bearing (2).
crane. Prevent the mast falling after
– Remove the circlip for shaft (10) with a
disassembling the cylinders.
plier.
 Keep away from the truck. Never stand
– Pull out the guide sleeve (8), piston rod
on the fork carriage when it’s fitted (16) and piston (22) etc. out of the cylinder
with forks. (17) by way of earring (3).
Operating Procedures as follow.
– Remove the pin (24) and screw down the
– Lower down the fork carriage thoroughly.
nut (23).
– Screw out the bolts from left side of the
– Take out the piston (22) of the piston rod
outer mast and pull out the pin.
(8) and remove the OSI seal ring (19),
– Dismantle the pipeline which is near the
retainer ring (20), support ring (21), piston
inlet of the tilting cylinder.
(22) and O-ring (18).
– Screw out the bolts on the frame support.
– Dismantle the guide sleeve (8) off the
Pull out the pin and disassemble the tilting
piston rod. Remove the cover (11), steel
cylinder.
cable baffle ring (12), O-ring (14), scraper
Follow the reverse sequences of disassembly
seal (7), U seal ring (9), step seal (13),
to install the cylinder.
composite bush (15) from the inner and
outer side of the sleeve.
41
 The maximum clearance should not
exceed 0.2mm. Otherwise replace the
piston.
– If any seal ring is found overworn, aged or
scratched or flaw lip, replace them timely.
Installation and adjustment of tilting
cylinder
– Clean up every part with gasoline and dry
up with compressed air before installation.
Caution Smear some hydraulic fluid on the
 Once scraper seal (7), U seal ring (9),
cylinder inwall, piston and piston rod
O-ring (14),O-ring (18),OSI seal ring
surfaces and the surfaces of seals.
(19) are removed, replace them for
(Hydraulic fluid should be some type as
these are no use.
the working oil.)
Inspections on Key Components – Follow the reverse sequences of the
– Check for deformation and the scratch decomposition to assemble the cylinder.
and corrosion of the inwall. If the cylinder Keep an eye on the installing direction of
is badly damaged or severely deformed, the seals. When the lip of seal ring passes
replace a new one. If the scratch or through the inlet an outlet, press it gently
corrosion is not that serious, polish it with a smooth pole, in case the chamfer
with”00”abrasive paper and lubrication oil. edge of the inlet and outlet lip damages
– Check for the deformation of the piston the lip.
rod and see if it is dent or with pocking – After the piston is put in the cylinder, the
marks and corrosion. movement in a whole stroke should be
– Light scars on the internal surface of the smooth and no obstruction and not
guide sleeve donot impact its jammed.
performance. But if the unilateral abrasion Inspection and adjustment of the mast
loss reaches 0.2mm ～ 0.3mm, the seal tilting angles.

rings fails to function. Replace timely. – Keep the truck fully loaded and the mast

– Check for the scars, cracks on the piston in a vertical direction.。

and check if the seal groove is damaged – Lift the forks 300～500mm off the ground.
or not. Keep the fit clearance of cylinder Leave the range quadrant on the
and pistion between 0.10mm～0.15mm. tangent plane of the inner mast and read

42
 the angle.
– Tilt the mast forward to the end. Value of
the quadrant angle is the forward tilting
angle. Tilt the mast backward to the end.
Value of the quadrant angle is the
backward tilting angle.
– If the angle is big or small, turn the earring
on the top of the piston to reset and fasten
with bolts and nuts.

43
 4.9 Lifting Cylinder
The lifting cylinder is piston type applied with shock absorber. For the structure of lifting cylinder,
see figure 5-5.

1. piston rod 2. DKI dustproof ring 3. ISI seal ring 4. O-ring 5. guide sleeve
6. cylinder body 7. steel cable bafflering 8. piston 9. support ring 10.guard ring
13. steel cable 14.nipple
11.OSI seal ring 12.valve pocket 15.O-ring
baffle ring component
16.sleeve
Figure 4-10 Structure of lifting cylinder

44
Disassembly of lifting cylinder the guide sleeve.
– Pull the piston rod (1) out of cylinder (6).
– Take the spacer bush (16) out of piston
rod.
– Remove the steel cable baffle ring (13),
valve pocket (12), OSI seal ring
(11), .guard ring (10), and support ring (9)
off the piston.
– Dismount the piston (8) from the piston
rod and remove steel cable baffle ring (7).
Caution – Remove nipple component （ 14 ） and
 Keep away from the truck.
O-ring（15）from cylinder body（6）
Operating Procedures as follow.
– Lower the lifting cylinder to the end to Caution
compress the oil back to the tank. Close  Replace the scraper seal and seal
the electric switch. rings once they are removed.
– Unscrew the cylinder support bolts on the
Inspections on Key Components
piston rod and on the mast.
– Check for deformation and the scratch
– Disconnect the oil return pipe of lifting
and corrosion of the inwall. If the cylinder
cylinder and disassemble inlet pressure
is badly damaged or severely deformed,
hose of the bottom regulator valve and the
replace a new one. If the scratch or
pressure hose connected to the cylinders.
corrosion is not that serious, polish it
– Screw up the U bolts on the dead plate of
with”00”abrasive paper and lubrication oil.
outer mast beam and the fastening bolts
– Check for the deformation of the piston
on the opposite side.
rod and see if it is dent or with pocking
– Dismount the chain on the mast.
marks and corrosion.
– Lift the inner mast with steel wire and take
– Light scars on the internal surface of the
away the left and right lifting cylinders.
guide sleeve do not impact its
Decomposition of tilting cylinder
performance. But if the unilateral abrasion
Operating Procedures as follow.
loss reaches 0.2mm ～ 0.3mm, the seal
– Retain the tilting cylinder with a jaw vice.
rings fails to function. Replace timely.
– Screw out the guide sleeve (5) with a
– Check for the scars, cracks on the piston
hookwrench and take O-ring (4) and DKI
and check if the seal groove is damaged
scraper seal (2) and ISI seal ring (3) out of
or not. Keep the fit clearance of cylinder
45
 and piston between 0.10mm～0.15mm.
The maximum clearance should not
exceed 0.2mm. Otherwise replace the
piston.
– If any seal ring is found over worn, aged
or scratched or flaw lip, replace them
timely.

46
5 LIFTING SYSTEM
5.1 General Description
The lifting system is composed of mast, fork carriage, forks, load backrest, lifting chain, rollers,
lifting cylinder and tilting cylinder. It combines pipelines and hydraulic system to constitute the
working device of a forklift, which is the executing unit to load and unload cargos for a forklift.
Usually, it is classified by mast types which include single stage mast, duplex mast and triplex
mast. The forklift trucks produced by Hangcha can be installed with wide view duplex mast; full
free lift duplex mast (container mast included) and full free lifting triplex mast. The mast type
brings in the CL coordinated rolling type.
The wide view duplex mast is composed by one outer mast which cannot be lifted or lowered and
one inner mast with flexibility to stretching up and down. The cylinder bottom of liftling cylinders is
fixed by bolts on the beam of outer mast. Ends of piston rod are connected to the beam assembly
of the inner mast. Fix the oil cylinder to the dead plate with U bolts. Generally, the free lifting height
is within 160mm. Installing the two lifting cylinders on the back of the mast contributes to the wide
view for the operator. For some small ton trucks, the cylinders are mounted on the outside of the
mast.
Forks are hooked on the fork carriage. Rollers and side rollers are applied on the fork carriage.
Meanwhile main roller and side rollers are installed on the bottom of the inner mast.
Hydraulic fluid from the control valve passes through the governor valve and comes into the
lifting cylinder. It drives the piston and piston rod up which coordinately pushes the inner mast
upward. In the meantime one end of chain from the chain wheel of the inner mast is remained still
on the outer mast, while the other end is connected with the fork carriage. Fork carriage and forks
can be lifted along with the lifting of the inner mast, which contributes to the loading lifting.
3 meters duplex mast is the standard mast type on HC forklift. Optional mast configurations are
listed as follow.
wide view duplex mast: 2.5 m to 6m
full free lifting duplex mast: 2.5 m to 3.7m
full free lifting triplex mast: 4 m to 7m

47
 1.outer mast 2.inner mast 3.load backrest 4.carriage 5.fork
6.chain 7.left lifting cylinder 8.right lifting cylinder 9.tilting cylinder 10.roller
Figure 5-1 Vision of duplex mast

48
5.2 Data of assembly and debugging
Inspection and adjustment

position Assy clearance Repair clearance

Mast to lift roller mm 0.1～0.8 0.2～1.0

gasket mm 0.5 / 1.0 / 2.0

Mast to support guide plate mm 0.1～0.8 0.2～1.0

gasket mm 0.5 / 1.0 / 2.0

Inner mast to carriage side
mm 0.1～0.6 0.2～1.0
roller
gasket mm 0.5 / 1.0 / 1.5

Lift chain deflection mm 25～30

Tightening torque of main components

position Nm（N·m）

Lock nuts of lifting chain 176～216(M18)，245～314（M20）

Bearing covers of mast to drive axle 176～216（M18）

Lock nuts of Tilting cylinder 89～118（M8）

Lifting cylinder bolt(head) 76～107（M12）

Lifting cylinder bolt（bottom） 44～58（M10）

Fixxing bolt of lifting cylinder（U type） 29～39（M10）

Weight of the basic mast

Truck type 2.5t 3.0 t 3.5 t

Mast weight 1000 kg 1100 kg 1200 kg

49
5.3 Trouble shooting and corrective action

Fault Probable cause Corrective action

Tilting cylinder and seal ring abraded Replace piston seal ring or tilting
Fork carriage or
excessively cylinder.
mast tilts
automaticly The valve control rod spring of multi-way valve
Replace
disorder
Fork carriage
piston jamming or piston rodbends Replace the damage parts.
raises up
and down
sluggishly. Too much dirt is accumulated in the cylinder. Clear

Adjust clearance between channel steel

Carriage assembly adjustimproperly
rail and side roller.
Insufficient clearance between rollers
Adjust clearance of rollers.
and inner and outer mast
Fork carriage is
lifted or lowered Biting foreign materials between moving part. Remove foreign materials.
unsmoothly.
Apply grease on contact surfaces of
Insufficient lubrication.
sliding parts.（butter）

Inner mast deflection or carriage bends Repair or replace.

Forks are lifted Adjust lifting chains of both sides to the
Improper adjustment of lifting chains
unevenly same tightness
Grease stiffened or rollers get stuck by
Clean and lubricate the rollers.
Lifting roller accumulated dirt
cannot rotate
Improperly adjustment of lifting roller. Adjust.

Insufficient lubrication. Lubricate.

Too much noise Side rollers on fork carriage adjust improperly. It Adjust the rollers and side rolling
on the mast strikes the mast channel steel, when the adjusting gaskets
extended
Rubber pad mast
onlowering.
lower of outer mast is out of By adjusting shims and rubber pad,
work for container forklift truck. piston rod will touch the bottom of
cylinder body after inner mast is in
Excessive wear occurs between the oil pump Replace the worn parts or the oil
touch with rubber pad.
body and gears, causing too much clearance. pump.
The piston Yx-ring of lifting cylinder has been
Replace Yx-ring.
worn, resulting in inner leakage.
Springs of the multi-way valve and relief valve
Replace with a new spring
disorder
Excessive wearing of the hydraulic control valve
Insufficient lifting Replace
occurs, resulting in excessive oil leakage.
power or unable
Oil leaks occur between the hydraulic control After regrinding, reassemble and
to lift
valve sections. rescrew the bolts in order
Tighten the joint nuts and check for
hydraulic pipeline leakage
damage of seal and connecting nuts
High hydraulic oil temperature, low oil Change the faulty hydraulic oil or stop to
Viscosity and insufficient oil flow reduce the oil flow, and check for the
reason of high oil temperature trouble.
Overloaded Observe the lifting capacity limit.

50
5.4 Mast Disassembly and Installation

Caution
 Be careful during the disassembly
as the fork, fork carriage and mast
are such heavy parts.
5.4.1 Dismantle the fork and mast
assy – Dismount the carriage assembly from the
– Screw out the fastening bolts from the inner mast.
central part of the fork carriage which – Remove the lifting pressure tube and the
prevents the forks from falling off the low pressure oil return tube.
carriage. Pull out the fork pin and move
the forks to the central breaches of the
carriage.
– Remove the forks shank by dragging out
the fork shanks.

Warning
 Keep the hands and feet off the forks.
Watch out when dismantling the forks.
– Lift the inner and outer masts with steel
Do not put hands for feet under the
wire.
forks or between the fork and carriage.
 Do not dismantle the fork from the
upper face of fork blade. Prevent any
damage caused by fork falling.

– Remove the set bolt and shaft pin from

the front of tilting cylinder.

– Tie up the carriage assy with steel wire

and crane it with lifting equipment.
– Screw out the nuts on ends of the chain
and dismantle the chain from the carriage
assy.
– Screw out the bolts on the bearing cover
of the outer mast.

51
– Disassemble the mast assy.
Following the revers sequences of
disassembly to install the mast.

52
5.4.2 Spare Parts Disassembly Disassemble the inner mast.
Tie up the inner mast with steel
Warning
 Be careful when disassembling the wire. Slide out the inner mast with a
mast as it is quite heavy. lifting equipment.
Disassemble the lifting cylinder.
– Place the mast flat on the ground. Screw
out the bolts on the piston rod of lifting
cylinder and U bolts on the outer mast and
the fastening screws.

Inspection
– Check for damage of the roller and roller
holder and other involved parts
Replace the damaged parts as necessary.

– Slide the inner mast and disassemble the

lifting cylinder.
Take out the rollers.
– Stretch out the inner mast from the bottom.
Remove the retainer rings from the
composite rollers and take away the side
rollers. Prepare twoplectanes with about
10mm thickness and diameter at Φ53 and
Φ58 respectively. Cover the roller holder
with the two plectanes. Dismount the
composite rollers and main rollers with a
bearing puller.
– If there is no bearing puller, unclench the
rollers carefully. (even unclenching power for
all directions). Otherwise, the rollers would
be damaged.

53
5.4.3 Assembly and adjustment

warning
 Be careful when assembling as the
inner and outer masts are quite
heavy.
Mount the roller
Install the inner mast into the outer mast
and mount the roller securely. – Adjust the clearance A of left and right
side evenly with a thin washer and make it

Adjust the clearance between the roller and

mast channel. Name the distance between
the rollers on inner mast and outer mast
as L. And adjust as follow.

“L” dimension Unit：mm

Truck model
Class Ⅲ Class Ⅱ
Max lifting
3 Ton 2～2.5 Ton
height mm
2500～3300 368 328
3600 388 348
4000 418 378
4500 443 403

54
 guide plate and assemble the mast and lifting
cylinder on the forklift truck. Connect the oil
return tube and the high pressure tube.

5.4.4Assemble the left and right

cylinders and adjust the cylinder
position.
– Install the left and right cylinders into the
mast. Insert the locating pin to the location
hole which is on the bottom beam of the
outer mast.
– Keep the clearance of rolling channel flange – Set the upper end of the piston rod into
within 0.8mm ～ 1mm. Do not adjust the the cylinder holder of the inner mast.
clearance. If it is over worn, replace the Make all directions evenly positioned. If
rollers. there is height difference on left and right
– Smear some lubricating grease on the sides, apply a washer between the
connecting surfaces of inner and outer cylinder holder hole and the upper end of
mast and also on the rollers and channel the piston rod and adjust.
rail. But in some areas with strong wind – Fix the cylinder to the left and right
and sand, carefully decide whether to channels (blocks) of the outer mast with a
smear grease or not. Avoid the sand cylinder clamp. Mount the rubber plug and
sticking on the surfaces. seamless tube. Finally, screw up the bolts.
– Clearance between the guide plate and
mast channel.
– Adjust the clearance B between guide
plate and inner mast column with a thin
washer and make it within 0.5mm～1mm.
Thin washer might not be wanted as
necessary. The thickness of the washer
should be around 0.2m.

5.4.5 Adjust the lifting chain

Install the fork carriage into the inner mast
and mount the chain. Screw two bolts on
each side of the chain. Make the mast in a
vertical direction and lower down to the end.
Adjust the nuts on the bottom of the chain
Smear a layer of lubricating grease on the and make the lower end of the fork carriage
55
 is about 74mm off the ground. side roller of the composite roller
respectively.
– Calculate the difference values between A
and B, A and Bˊ, A and B" respectively.
Each difference value is the clearance
between the roller and inner mast
channel.
Evenly adjust the washers of each side roller
on left and right. Adjust the clearance to the
following range.
In order to adjust the tension of the chain, A-B = 0.2 mm～1mm
lower the lifting cylinder until the forks is on A-B' = 0.1mm～0.8mm
the ground. Adjust the chain nut (three nuts A-B" = 0.1mm～0.8mm
at each end) till length of C reaches to the
rated value when the finger presses the
central part of chain.
The length of “C” is around 25mm~30mm.

Thin adjusting washer：0.5mm、1mm。

– Use equal quantity of washers on left and
right sides.
– After the clearance is set. Slide the fork
carriage on the inner mast upward and
downward. Check if it is smoothly
operated.

5.4.6 Adjust the clearance of rollers

on the fork carriage assy.
– Measure the distance A between the two
channels of the inner mast. Collect the
value on the top, central part, central
beam of the inner mast and the bottom
respectively.
– Measure the space from left and right side
B、Bˊ、B" of rollers on fork carriage and

56
6 Electrical system

Warning
 Before inspecting any electric components, put away conductive items such as jewelry
and bracelet in case of shorten circuit, and turn off the start switch and disconnect the
earth wire.
 Make sure that the battery was disconnected before applying any electric maintenance

Inspection
Inspect all electric circuits according to the circuit diagram. Conduct the continuity or shorten
circuit tests by using the regular testing lights or multimeter. Before testing, check following
conditions
Every electric part or wire should be fixed on its terminal connector securely;
– Every connector is kept in position securely. No corrosion or stains.
– The surfaces of every wire is not cranked, aged or damaged;
– Every connectors should be kept a safety distance with its metal parts nearby,
– Every wire should be fixed on its terminal connector correctly
– Wires should be kept away from parts with sharp edges
– Wires should be kept away from rotating or moving parts
The wire should be long enough between static parts and athletic parts, to withstand vibration and
shock sufficiently
6.1 Motor

Maintenance of motor
– Keep clear and dry around the motor. Do not put other goods on or in the motor.
– Check regularly for securely installation of the motor, and check for loosen, smoke and
insulation aging of the motor terminal bolt
– Check for overheat of motor regularly during the working time. If there is any abnormal smell,
stop and inspect immediately.
– Never overloaded. Never leave the motor near the strong magnetic objects.
– If there is any malfunction during the operating time, power off , stop and inspect immediately,
such as electric leakage, speed dropping suddenly, shanking sharply, big noise, overheat and
smoking or smoking motor terminal bolt.
– Monitor the running condition of the motor regularly during operating. If there is any abnormal
phenomenon, stop immediately, such as overheat abnormal noise. Operate until malfunction
is corrected.
– Clean the surface of motor regularly, replace the grease of the motor bearing

57
 annually(working temperature of grease is -40℃~+200℃)

Caution
 AC motor does not have commutator and brush. No maintenance. But it needs
regular inspection and dusty clearing.

Caution of motor disassembling

– Do not disassemble the motor arbitrarily, follow the rules of CAUTION OF MOTOR
DISASSEMBLING;
– To protect the motor shift, do not remove the motor by putting ropes on motor shift, during the
disassembling and assembling process
– Be careful of the outer coder, No strike and protect the connector of both signal wire. Do not
knock against coder gear when disassembling and inspecting the coder. Clear the gear
before assembling
– Clear rust and other stain fully before assembling.
– No any part damages during the assembling
– Wire connection should be correct and secure. No cutting-edge protrusion, no stain on
insulation, and keep dry
– The motor rotor can rotate easily by hands.
– The wire between motor and controller should be as short as possible

58
6.2meter
Instrument installation position, located in the upper right corner of the instrument
rack.

6.2.1 Instrument interface

59
Key Function
basic skills
Icon name function

Upper shift key Movethecursoruporadd1tochosenfigure;switch

fromhomescreentoSmode;
Left shift key move the cursor to the left;
switch from home screen to P mode;
Right shift key move the cursor to the right;
switch from home screen to E mode;
move the cursor down, or minus 1 from chosen figur
Down shift key
e;switch from home screen to SPE mode (low speed
mode);switch from home screen to SPE mode;

Cancel shift key cancel current operation and return to previous men
u;
Confirm shift key confirm current operation and switch from home
screen to menu mode;

Vehicle Control Shortcut Keypad (Optional)

icon name Function

60
 F1 function key 1
F2 function key 2
drive external relay, and
F3 function key 3 specific function is subject
F4 function key 4 to field usage.

F5 function key 5

Combinatorial key
icon name Function
In the main interface, press "up key" and "down key"
Upper shift key
at the same time, you can see the instrument

Left shift key information, including the instrument number, SIM

card number and software version number

6.2.2 Meter andcontrollerFault code

The meter is used with the controller, so the “fault code” displayed by the meter is the controller
fault code. The "hexadecimal" fault in the fault code table is the computer interface connected to
the controller for the computer with the fault diagnosis, and the fault code displayed on the
computer.
Fault code
Serial Fault hex Analytical description solution
number code
ERROR Incorrect start Accelerator pedal
1 20 0x14 Release pedal switch
switch active before key on
ERROR Incorrect start Forward switch or Turn off the direction
2 21 0x15
reverse switch active before key on switch
ERROR Forward switch and reverse
3 22 0x16 Direction switch fault
switch active at the same time
ERROR Throttle analog value out of Throttle fault or
4 23 0x17
range analog need to be
5 24 0x18 ERROR Throttle analog fault calibrated
ERROR Traction controller CAN Check CAN wire of
6 31 0x1F
communication fault controller and display
7 32 0x20 ERRORBattery voltage low Need charge
8 34 0x22 ERROR CPU fault Reset key
ERRORIncorrect start Tilt switch active
9 36 0x24 Reset tilt switch
before key on
Reset side switch
ERROR Incorrect start Side switch active
10 37 0x25
before key on
61
 Serial Fault hex Analytical description solution
number code
ERROR Incorrect start Attachment switch Reset attachment
11 38 0x26
active before key on switch
ERROR Incorrect start Lift switch active
12 39 0x27 Reset lift switch
before key on
Lift analog fault or
13 40 0x28 ERROR Lift analog value out of range
need to be calibrated
Steer analog fault or
14 43 0x2B ERROR Steer analog value out of range
need to be calibrated

WARNING Traction controller speed Vehicle speed is too

15 44 0x2C
protection high alarm

1.Traction controller
encoder fault
WARNING Traction controller encoder 2.Traction motor
16 45 0x2D
fault speed sensor
connection wire is
open
Traction controller
WARNING Traction controller
17 81 0x51 temperature is low
temperature is low
alarm
Traction controller
WARNING Traction controller
18 82 0x52 temperature is high
temperature is high
alarm
Traction controller
ERROR Traction controller temperature
19 83 0x53 temperature sensor
sensor fault
fault

1.Traction motor
temperature is low
WARNING Traction motor temperature is
20 84 0x54 2.Traction motor
low
temperature sensor is
fault

1.Traction motor
temperature is high
WARNING Traction motor temperature is
21 85 0x55 2.Traction motor
high
temperature sensor is
fault

62
 Serial Fault hex Analytical description solution
number code

1.Traction motor
temperature sensor is
fault
ERROR
22 86 0x56 2.Traction motor
Traction motor tenperature sensor fault
temperature sensor
connection wire is
open

1.Traction motor
encoder fault
2.Traction motor
23 87 0x57 ERROR Traction motor encoder fault
speed sensor
connection wire is
open

WARNING 1.DC bus voltage high

24 88 0x58 DC bus voltage of traction controller is 2.The ramp is too
high steep

WARNING DC bus voltage of traction Need to charge or

25 89 0x59
controller is low check power wiring

WARNING The default value of the

26 90 0x5A Reset key
traction controller is updated

Battery low vehicle

27 91 0x5B WARNING Traction drive limit
speed limit

Check the wire of

ERROR Open drain of traction output
28 97 0x61 open drain of traction
open or short
output open or short

63
 Serial Fault hex Analytical description solution
number code
WARNING
29 98 0x62 Check power wiring
Traction controller over current or short

1.Check power wiring

ERROR
30 101 0x65 2.Controller enable
Traction controller short
before contactor

ERROR
Traction controller temper
31 102 0x66 Traction controller temperature is high cut
ature is high need cool
back

1.Traction motor
ERROR temperature is high
32 103 0x67 Traction motor temperature is high cut need cool
back 2.Traction motor temper
ature sensor fault
1.Vehicle overload or
ERROR Mechanical clamping
33 104 0x68
Traction controller over current 2.Traction motor
speed sensor fault
ERROR Replace the
34 105 0x69
Traction controller precharge failed precharge resistance
ERROR DC bus voltage of traction
35 110 0x6E Battery need charge
controller is low cut back
DC bus voltage of
ERROR DC bus voltage of traction
36 111 0x6F traction controller is
controller is high cut back
high cut back
DC bus voltage of
ERROR
traction controller is high
37 112 0x70 DC bus voltage of traction controller is
cut back (Hardware
high cut back(Hardware monitoring)
monitoring)
Traction motor
ERROR temperature sensor or
38 114 0x72
Internal power supply error speed sensor connection
wire is open
Pump controller
Traction motor temperature sensor or
39 121 0x79 temperature is low
speed sensor connection wire is open
alarm
Pump controller
WARNING
40 122 0x7A temperature is high
Pump controller temperature is high
alarm
Pump controller
ERROR Pump controller temperature
41 123 0x7B temperature sensor
sensor fault
fault
1.Pump motor
WARNING
42 124 0x7C temperature is low
Pump motor temperature is low
2、Pump motor
64
 Serial Fault hex Analytical description solution
number code
temperature sensor
fault
1.Pump motor
WARNING temperature is high
43 125 0x7D
Pump motor temperature is high 2、Pump motor
temperature sensor fault
1.Pump motor tem
perature sensor fault
ERROR Pump motor temperature
44 126 0x7E 2、Pump motor
sensor fault
temperature sensor
connection wire is open

1.Pump motor speed

1、Pump motor temperature sensor fault sensor fault
45 127 0x7F 2、Pump motor temperature sensor 2、Pump motor speed
connection wire is open sensor connection
wire is open

DC bus voltage of
WARNING
46 128 0x80 pump controller is
DC bus voltage of pump controller is high
high
WARNING
47 129 0x81 Check power wiring
DC bus voltage of pump controller is low
WARNINGThe default value of the pump
48 130 0x82 Reset key
controller is updated
WARNING Battery voltage low
49 132 0x84
Pump drive limit need charge
Check the wire of
ERROR
50 137 0x89 open drain of pump
Open drain of pump output open or short
output open or short
WARNING Pump controller over current
51 138 0x8A
or short
ERROR
52 141 0x8D Check power wiring
Pump controller short
ERROR
53 142 0x8E
Pump controller temperature is high cut back
Pump motor
ERROR
54 143 0x8F temperature is high
Pump motor temperature is high cut back
alarm
ERROR Pump controller current
55 144 0x90 Reset key
calibration error
ERROR Replace the pre
56 145 0x91
Pump controller precharge failed charge resistance
ERROR DC bus voltage of pump DC bus voltage of
57 150 0x96
controller is low cut back pump controller is low
65
 Serial Fault hex Analytical description solution
number code
cut back
DC bus voltage of
ERROR DC bus voltage of pump
58 151 0x97 pump controller is
controller is high cut back
high cut back
DC bus voltage of
ERROR
pump controller is high
59 152 0x98 DC bus voltage of pump controller is high
cut back (Hardware
cut back(Hardware monitoring)
monitoring)
ERROR
60 153 0x99 Reset key
Pump controller CPU fault
ERROR Pump controller speed control Pump controller
61 154 0x9A
fault speed control fault
62 147 0x93 BMS cell voltage too high
63 148 0x94 BMS first fault
64 149 0x95 BMS secondary fault
65 156 0x9C BMS temperature protection
BMS over temperature
66 157 0x9D BMS over temperature protection
protection need cool
BMS single body over
67 158 0x9E BMS single body over discharge discharge need
charge
BMS over voltage
68 159 0x9F BMS over voltage protection
protection
69 163 0xA3 BMS over current BMS over current
70 164 0xA4 Charge protection Charge protection
Temperature
71 156 0x9C Temperature protection
protection
72 155 0x9B BMS CAN bus off BMS CAN bus off
Seat switch off after a period of time, the
73 165 0xA5 Reset direction switch
direction of the request to reset

BMS BMS indicates Limit

74 168 0xA8
BMS indicates Limit Current alarm Current alarm

BMS BMS indicates cutoff

75 169 0xA9
BMS indicates cutoff Current alarm Current alarm

BMS BMS indicates brake

76 170 0xAA
BMS indicates brake Current alarm Current alarm

BMS CAN
77 171 0xA8 BMS CAN Error
BMS CAN Error
Proportional valve
78 200 0xC8 Proportional valve error
error
EEPROM KO
79 13 0x0D Reset key
HPG CONTROLLER EEPROM KO
66
 Serial Fault hex Analytical description solution
number code
VMN LOW HPG CONTROLLER
80 30 0x1E HPG CONTROLLER BATTERY BATTERY VOLTAGE
VOLTAGE LOW LOW NEED CHARGE
NO FULL COND. DC MOTOR VOLTAGE
81 33 0x21 RESET KEY
HIGH
I=0 EVER
HPG CONRTOLLER
82 49 0x31 DC MOTOR OPERATING CURRENT IS
SENSOR FAULT
ZERO
STBY I HIGH HPG CONRTOLLER
83 53 0x35
HPG CONRTOLLER OVER CURRENT OVER CURRENT
TH. PROTECTION HPG CONTROLLER
84 62 0x3E HPG CONTROLLER TEMPERATURE TEMPERATURE
HIGH HIGH NEED COOL

HPG CONTROLLER
BATTERY LOW
85 66 0x42 BATTERY LOW
HPG CONTROLLER BATTERY LOW
NEED CHARGE

DRIVER SHORTED HPG CONTROLLER

86 74 0x4A
HPG CONTROLLER DRIVER SHORTED DRIVER SHORTED

COIL SHORTED HPG CONTROLLER HPG CONTROLLER

87 76 0x4C
COIL SHORTED COIL SHORTED

VACC NOT OK HPGCONTROLLER

88 78 0x4E
HPG CONTROLLER VACC NOT OK VACC NOT OK

INCORRECT START
HPG CONTROLLER
89 79 0x4F HPG CONTROLLER INCORRECT
INCORRECT START
START

CHECK CAN WIRE

CAN BUS KO CAN
90 241 0xF1 OPEN AND CAN
HPG CONTROLLER CAN BUS KO
SPEED RATE
BATTERY OVERVOL. HPG CONTROLLER
91 242 0xF2 HPG CONTROLLER BATTERY OVER BATTERY OVER
VOLTAGE VOLTAGE

KEYOFF SHORTED HPG CONTROLLER

92 243 0xF3
HPG CONTROLLER KEY SHORTED KEY SHORTED

67
 Serial Fault hex Analytical description solution
number code
TURN OFF THE
WATCHDOG
PUMP
93 244 0xF4 HPG CONTROLLER WATCHDOG
CONCTACTOR
ERROR
PARAMETER
WAITING FOR MC TURN OFF THE
HPG CONTROLLER WAITING FOR PUMP
94 246 0xF6
MAIN CONCTACTOR
CONTACTOR PARAMETER
CHECK DISPLAY
95 161 0xA1 DISPLAY CAN FAULT AND CONTROLLER
CAN CONNECTION

6.3 Controller
6.3.1 Overview
Safety and protection features and monitoring features
SAFETY & PROTECTION FEATURES
– Polarity protection of the battery
– Connection errors
– All inputs are protected against connections errors.
– Current overload protection
it have detecting element，limit peak current.
– Thermal protection
① If the controller temperature exceeds 85°C, thermal protection will work; the
maximum current reduces in proportion to the thermal increase. Once the
temperature exceeds 95°C, it will shut down automatically and give a warning.
② If the motor temperature exceeds 145°C, thermal protection will work; the maximum
current reduces in proportion to the thermal increase. Once the temperature exceeds
160°C, it will shut down automatically and give a warning.
– Low Battery protection When the capacity of flattery is low, the maximum speed and current
reduce greatly
– External guard Protection；
Electric control is hermetical which can protect against dust and liquid into the body.

– Starting order protection

Starting should follow right operating orders. If the operating orders are incorrect, truck cannot
start. Drive demand should be sent after turning the key on, thus the truck starts.

68
– Whenelectrical elements are damaged, the control can protect itself to avoid more damage.

6.3.1.2 Monitoring features

①Temperature monitoring
②Motor current monitoring
③Voltage monitoring
④Charging timeout monitoring
⑤CANOPEN PDO timeout monitoring

NOTE：
– Before maintaining the controller, cut off the power. Connect a 10-100 ohm resistance to the
positive and negative poles of controller to release residual voltage in the capacitor, or else
there might be an electric shock.

– Magnetic field and radiation of surroundings will effect onthe inverter，controller may be
damaged due to the long time effect. So keep away from magnetic field and radiation.

69
6.4 Lithium battery
6.4.1 Lithium battery charging port
structure and truck side door
The charging port of the lithium battery and
the side door of the lithium battery are
separately introduced here.As the side door Note: The flat side of the plug is equipped
and charging port are often used during with a locking hook that snaps into the slot
when it is inserted into the battery socket.
charging. Therefore, after the charging is completed,
a. Truck side door the lock must be loosened. To release the
lock, you must press the button on the
charging gun.

2 3 4
5
3
1. Lock assembly 2. Side door 3. 6.4.2 Lithium battery fastening:
Fastening bolt（clamping device） The lithium on the right side of the lithium
4. Battery clamping device 5. battery clamp the truck frame for fastening
Lithium battery charging port purpose through the battery clamping device.
1. Press the lock to open the side door. There are 2 bolts on the clamping device.
2.The lithium battery charging port can
The heads of the bolts are welded with
be seen, and the charging port is covered
gaskets. When the bolts are tightened
with a cover. Open the cover and see the
clockwise, the lithium batteries are installed
charging port
horizontally.
b. Lithium battery charging port
structure
6.4.3 Lithium battery disassembly and
installation
The lithium batter drops to the bottom of the
body, and the side is secured by a protective
rod. It lies on the frame by weight. For the
70
removal and installation of lithium battery.
a. Remove the plug (1) between the
lithium battery and the truck body, open the
side door (2), tighten the bolt (3) on the
fastening device, and lift it up a small section
(4), then remove the lithium battery from the
truck body.

c. Lift the forklift or pallet truck 1cm, pay

2
attention to adjust the fork spacing, and

gently pull out the lithium battery.

Installment
Installation is opposite to disassembly.
4 3
Warning
3 Lift carefully. The lithium battery weighs
about 320 kg. It's very heavy.
Prevent crushing or pinching your hands
during installation.

b. Center the forks in the middle of the two

rows of rollers, remove the battery, and
transfer it to the forks.
Lift the lithium battery to the ground with a
lifting device. See the illustration above for
the fixing point.

71
6.4.4 lithium battery

safety warning
1.1 Do not short-circuit the battery. Do not heat the battery or place the battery in water.
1.2 Fully charge the new battery before use.
1.3 Do not mix different brands, different types, different capacities, and old and new batteries;
1.4 The battery combination should not be used in the case of inconsistent capacity saturation
of each single cell to avoid overcharge and over discharge of the cell;
1.5 To recharge the battery, use the battery charger specifically designed for the purpose, do
not use other chargers to prevent battery damage.
1.6 If the battery occurs odour, heating, discoloration, deformation or any abnormal
phenomenon during use, storage or recharging, immediately remove it from the equipment or
charger and stop using it. Please immediately contact the manufacturer technician department
or after-sales department.

72
structure size

Battery pack introduction

Battery pack specification Numerical value

size L1064*W761*H412

Series and parallel 2P25S

Q 80.5V

Nominal capacity 404 Ah

Rated energy 32.52 kWh

Battery pack quality 322 kg

Operating voltage range 62.5-91.25V

Continuous charging current 200A（SOC≤80%，25℃）

Operating temperature Charging：0℃-55℃

Discharge：-20℃-55℃

73
 Interface definition

Harness Corresponding
Alphabet colour
specification function
A 1.0 Key switch out Blue and white
B 1.0 Key switch in Blue
C / / /
D FL0.85 Vehicle CAN1H gray
E FL0.85 Vehicle CAN1H brown
F FL0.85 Debugging CAN1L brown
Charging
G FL0.85 gray
debuggingCAN2L
Charging
H FL0.85 brown
debuggingCAN2H
K FL0.85 Debugging CANL brown

L FL0.85 Debugging CAN1L gray

M FL0.85 Debugging CANH gray

Low-voltage communication interface definition

GB charging port interface definition

74
 Serial number Corresponding function

1 DC+

2 DC-

3 PE

4 S+

5 S-

6 CC1

7 CC2

8 A+

9 A-

The following operations are strictly prohibited

1) Do not put the battery near heat source, dangerous goods and hazardous material, such
75
 as fire, heater, corrosive chemical or hazardous machinery; store the batteries in cool, dry
and well ventilated places if not used;
2) Do not immerse the battery in water or other conductive liquid. This may result in personal
injury or property damage;
3) Electrodes short circuit is prohibited. Avoid any metal or other conductive objects touching
the positive and negative terminals of the battery. This operation may result in personal
injury or property damage;
4) It is forbidden to transport or store batteries together with metals such as tools, cables,
etc.;
5) Do not hammer, throw or step on the battery;
6) Do not connect the battery with the battery of other type in series or in parallel; This
operation may result in personal injury or property damage;
7) Do not operate the whole power system with lithium ion battery protection circuit board or
battery management system in series or in parallel; this operation may result in personal
injury or property damage. If needed, contact our technical department for correct
technical support;
8) Do not let children or other person lacking of safety knowledge have access to the
equipment. This operation may result in personal injury or property damage;
9) Do not disassemble, squeeze, puncture, storage at elevated temperature or bake the
batteries. Violent vibration, impact and falls from heights should also be avoided. This
operation may lead to security risks;
10) Do not operate the equipment in a location where static electricity and magnetic field is
strong. Or it may damage safety protection device, and lead to potential safety hazard;
11) Do not recharge without proper protection device(lithium ion battery circuit board
protection, BMS etc.) or with improper charging device (charger or DC power). This
operation may result in personal injury or property damage.

Basic terms and environmental conditions for lithium ion batteries

Basic terms and definitions

Nominal voltage: a suitable approximate value used to indicate the battery voltage;

Rated capacity: The capacity value specified by the manufacturer when the battery is fully

charged under specified conditions;

Actual capacity: The capacity actually discharged when a fully charged single cell is

discharged at a specified current under specified conditions;

76
Overdischarge: The state when the battery voltage is lower than the discharge cutoff voltage is

generally regarded as the state in which the battery enters the overdischarge state, which

generally refers to the state when the battery voltage reaches 0 V or even the voltage is

negative;

Maximum charging voltage: The charging voltage recommended by the manufacturer that

should not be exceeded during charging;

Overcharge: The state when the battery voltage is higher than the maximum charging voltage

is usually regarded as the battery entering the overcharge state;

Overcurrent: The battery's operation and charging current are higher than the maximum

allowable operation of the manufacturer, and the state of charging current is usually

considered as the battery entering the overcurrent state.

Normal temperature charge retention and capacity recovery capability: The battery is

discharged at 0.3C after 28 days storage at 20℃±5℃. The ratio of discharge capacity to rated

capacity is called normal temperature charge retention capability;

Then charged at 0.3C at 20℃±5℃,and then discharged to the termination voltage. The ratio of
discharge capacity to rated capacity is called capacity recovery capability;

Charge termination current: The current at which the battery terminates charging during a

specified constant voltage charge;

State of charge: The amount of electricity stored in the battery is generally expressed as a

percentage. For example, 30% SOC means that the battery currently stores 30% of the

nominal capacity. SOC is the abbreviation of State Of Charge, and the battery (group) is

charged state;

Explosion: the battery casing is broken, and solid matter inside is flushed out of the battery and

makes a sound;

Fire: Open fire appears in the battery case;

Leakage: The internal components of the battery (electrolyte or other substances) leak out of

the reservoir;

77
Battery Management System (BMS): An Electronic and electrical system monitors battery

voltage, current, and temperature and communicates with other systems such as chargers,

loads, thermal management systems, etc. through a series of control actions to optimize

battery performance.BMS is the abbreviation of Battery Manager System;

CAN communication: Control Area Network;
Charging mode CC/CV: CC mode is constant current charging mode, and CV mode is
constant voltage charging mode.

Basic environment in use

Charging temperature: 0 °C ~ 55 °C; Discharge temperature: -20 °C ~ 55 °C; the best use
temperature is 15 °C ~ 35 °C;
When the ambient humidity HR is less than 85%, the battery should be kept as dry as
possible;
When charging the battery, try to shallow charge or discharge, thus increase the battery life.

Cautions for use and maintenance of lithium ion battery

Basic requirements for battery use

1) Under any circumstances, when testing or using the battery, the terminal voltage of the
single battery must be tested in real time. It is strictly forbidden to test the battery pack in
series without a management system or a protection board to avoid overcharging or
overdischarging of the battery;
2) The new battery is generally only 50% charged. Please do not use it for a long time before
the BMS and charger are commissioned, so as to avoid the truck being stopped due to
insufficient battery power during use;
3) Battery management system: In order to ensure the safe and effective use of the battery
and maximize the service life of the battery, the lithium battery product should be
equipped with a dedicated power lithium battery management system (BMS) and a
dedicated lithium battery charger, when a small number of small capacity batteries are
used in series and in groups, you can also use a reliable lithium battery protection board.
The Battery Management System (BMS) is as follows:
Overcharge Undervoltage
Parameter
protection 3.75V protection 2.7V
configuration
voltage voltage
78
 Maximum Over-discharge
charging 200A protection 2.2V
current voltage
Over
Overcharge temperature
3.67V 60℃
release voltage protection
temperature
Undervoltage Over discharge
2.8V 2.6V
release voltage release voltage

4) In the process of using the battery, it is strongly recommended to adhere to the principle of
shallow charge and discharge. The best performance is between 30% and 100% of the
power.When the open-circuit voltage of single batteries drops to 3.0V, the actual charge is
less than 10%. At this time, the battery pack should be charged in time;
5) When testing or using the vehicle, always pay attention to the remaining battery capacity
of the battery pack, and avoid using the trailer to transport the vehicle for charging when
the power is exhausted. In the process of trailer, auxiliary systems such as DC/DC (power
supply for lighting, wipers, etc.), steering power, brake power, etc. are still consuming
power. Trailer for a long distance will also lead to battery overdischarge;
6) The high-voltage safety protection work of the battery pack must be well done.The drive
main circuit and the low-voltage electrical circuit (including the vehicle body) must be
properly isolated, and the reliable DC air circuit breaker and fast DC fuse should be
selected;
7) It is strictly forbidden to separately draw power from the individual batteries in the battery
pack to supply power to the low-voltage electrical equipment of the vehicle, so as to avoid
the destruction of the consistency of the entire battery.

Basic requirements for lithium ion battery installation

The battery pack should be installed in the correct orientation. Do not reverse or reverse the
installation;
Do not violently disassemble, and avoid personal and property losses;

Basic requirements for lithium ion battery connection

During the battery connection operation, be sure to pay attention to the correct port insertion;
Be careful during battery connection, avoid that the whole battery is reversed and shorted.

Basic requirements for storage and maintenance of lithium ion battery

The battery pack is stored in an incompletely charged state, typically around 40%. Product
79
storage environment requirements are as follows:
Storage temperature: storage time <3 months, then stored at -40 ° C ~ 60 ° C, 40% SOC;
storage time > 3 months, then stored at 0 °C ~ 25 °C, 40% SOC;
Storage humidity: 2% RH ~ 90% RH. Storage within 85% RH is recommended;
Storage environment: The product should be stored in a clean, ventilated and cool
environment, and avoid direct sunlight, high temperature, corrosive gas, severe vibration,
mechanical shock and heavy pressure; away from heat source; altitude is less than 1500
meters, atmospheric pressure is 86kPa~ 106kPa.

Basic requirements for lithium ion battery transportation

During the transportation of the battery, it is necessary to avoid exposure to sunlight for a long
time and rain;
During the loading and unloading process, the battery should be handled gently to prevent
falling, rolling, and heavy pressure;
During the process of transportation and use, the battery should be protected from strong
impact and excessive extrusion, so as to avoid battery case or internal structural damage;
During the process of transportation and use, the battery should take necessary protection
against the positive and negative electrodes of the battery to avoid short circuit and fire.
Preparation for lithium ion battery installation operation
Please read the instructions such as the battery instruction manual, battery installation
operation and maintenance manual provided by our company;
Strict insulation treatment must be performed on tools such as socket wrenches, fixed
wrenches, and screwdrivers used for installation operations;
Wear anti-smashing shoes and insulated gloves when installing. Do not wear watches, metal
bracelets, necklaces, etc.

Daily maintenance
1） There should be professionals when charging, make sure the plug and socket is well
contacted, charging facility work normally. If abnormal, only charge after being repaired.
2） Check the vehicle dashboard before charging and discharging to ensure that all values
are within the normal range;
3） When charging and discharging, avoid water or other conductive objects splash to the
battery connector, for example, use when exposed to heavy rain. Before using the product,
please read the product specification, instruction manual and use attentions to understand the
use method and application range of the product. In the event of incorrect product use,
incorrect connection of the circuit or the input power, load function and other parameters that
80
do not conform to the performance parameters marked in the product specification are
improper use. The company does not assume any responsibility for damage to products, loads
and peripheral connections caused by improper use.

Cautions:
1. Charge the lithium battery immediately after per discharge to avoid battery loss;
2. Never place the battery near high temperature heat source, such as fire and heater etc.;
3. Do not use the battery in a location where static electricity and magnetic field is great,
otherwise, the safety devices may be damaged, causing hidden trouble of safety.
4. Avoid using the battery under high temperature for a long time, otherwise, it may cause
overheat of the battery or function invalid or service life being shortened;
5. Do not operate an electric vehicle equipped with a lithium battery in an environment where
the temperature exceeds 55 °C; if the power battery system is below -25 °C, the power battery
system needs to be self-heated above -10 °C to operate the vehicle;
6. Do not dismantle the battery box under any circumstance;
7. Never drop or knock the battery box etc.;
8. Short circuit of the battery is prohibited, never put any other object or tool to avoid battery
short circuit;
9. Never wash battery box directly, prevent water getting into the battery and ensure the safety;
it's forbidden to mix batteries of different brands, volumes and types;
10. Battery should be kept in a cool and dry place and avoid direct sunlight;

Maintenance instruction:
1. Do not change the battery setting parameter at will without the permission of the
manufacturer;
2. If the lithium battery needs to interrupt or suspend charging, do not hot plug, avoid current
arc to damage charging base;
3. Charging time below 0 °C will be longer than normal temperature charging time;
4. If the lithium battery is not used for a long time, it is necessary to charge and discharge the
battery once a month. The best SOC interval for battery storage: 50%-80%.

81
6.5 Fuse box assembly
Fuse
Disassemble
1、 Turn key switch to "OFF";
2、 Press lock buckle on control box, and open the cover;
3、 Remove fuse from box;
Explanation
If fuse or relay is broken, replace with new one, the schematic is as follows (see the inside of
the forklift control box for details):
①If fuse is damaged, be sure to eliminate cause of problem before installing new fuses;
②Never use fuse higher than specified rating.

Fuse position
Fuse list

Position Capacity Application component

F1 10A DC converter
F2 5A 80V power output end
F3 5A 24V power output end 1
F4 10A Flasher, 24V power output end 2
F5 5A Horn, 24V power output end 3
F6 10A 24V output end 4
F7 10A Headlamp, 24V output end 5
82
 F8 24V Power reserve
F9 10A Emergency stop button

Fusible links
A melting fusible link can be watched or touched easily, if it is uncertain of melting, use
multimeter or lamp to test.

Caution
1. If fusible links is melted, maybe because of short circuit(power or current is too high).
No matter which reason, please check and eliminate fault.
2. Fusible links can cause heat, do not enlace with adhesive tape. Do not put fusible links
near other rubber or wiring assembly.
6.6Lighting System

Bulb Specifications
Lamp W
Front combination lamp
Headlamp 10.08W-10.26W
Steering lamp 2W
Width lamp 2W
Rear combination lamp
Brake and width lamp
12V-24V
Steering lamp
1.6w
Reverse lamp
Rear headlamp 36V-1.5W
9V-80V
Caution light (At 12V <1A, the current decreases as the
voltage increases)

Location of light

83
 后组合灯
Rear combination lamp

前组合灯
Front combination lamp

Front combination lamp

Disassembly and assembly
1. Remove fixing bolt of bracket 2. Disconnect the wiring connector.
3. Replace faulty bulb with new one. 4. Assembly is the opposite procedures.

Wire Wire Spec. Function

Color
导线颜色
Red 导线规格
0.75mm2 Headlamp
功 能
红色
Yellow Turn 大灯
0.75mm2
0.5mm2
黄色 0.5mm2signal 转向灯
黑色 lamp 地线
0.75mm2
绿色
Black 0.5mm2Width 示宽灯
0.75mm2
lamp
Green 0.5mm2

Rear combination lamp

Disassembly and assembly

1. Remove fixing bolt of bracket. 2.Disconnect the wiring connector.
3. Replace faulty bulb with new one. 4. Assembly is the opposite procedures.

84
 Black wire ground Blue wire turn left
Grey wire reverse

Red wire brake White wire turn right Green wire width

85
6.7 Switch
Combination switch
Turn left
左
Forward前
进 N
F 转
R
OFF

中 F 中
Neutral
N
Neutral位 R OFF
位
F Turn right
Reverse后 右
N OFF
R

退 转
Direction switch Turn signal lamp switch
Headlamp switch
Direction switch

Removal
1. Remove combination meter;
2. Screw off bolt, disconnect connector of wiring;
3. To install, reverse removal procedures.

Inspect direction switch

Disconnect switch connector, and check whether each connection point is on
Use multimeter(with ohm) to inspect whether it is on when lighting switch is on these
positions:forward , N, reverse.

86
 Forward F
N
R

Hole site 1 2 3 4 5 6
Wire color Pink Brown Blue
F
Neutral N
Power
R 60W 60W 60W 60W 60W 60W
Function

F
N
Reverse R

Turn signal lamp switch

Removal
1、 Remove assembled instrument.
2、 Remove bolt, and disconnect wiring terminal
3、 Fixing sequence is opposite to removing sequence.
After installing turn signal lamp switch, insure the distance between turn signal lamp switch
and top of steering column is 61mm.
Check
Use multimeter(with ohm) to inspect whether it is on when lighting switch is on these positions

Turn left

OFF

Neutral
Hole site 1 2 3
OFF
Wire color Grey Blue White
Power
60W 60W 60W
Function
Turn left
OFF
Neutral
Turn right
Turn right

87
 Headlamp switch
Removal
4、 Remove assembled instrument.
5、 Remove bolt, disconnect wiring terminal
6、 Fixing sequence is opposite to removing sequence.
After installing turn signal lamp switch, insure the distance between turn signal lamp switch
and top of steering column is 61mm.
Check

Use multimeter(with ohm) to inspect whether it is on when lighting switch is on these positions

Hole site 4 5 6
Wire color
OFF
Power
60W 60W 60W
Function
Light off
Low beam
High beam

Key (start) switch

（1）Remove combination meter.
（2）Disconnect connector of wiring.
（3）Remove nut, washer, spacer and instrument
plate.
（4）To install, reverse removal procedures.
Adjust ledge of switch to proper length when
installing.
Inspect
Use multimeter (with ohm) to check key switch whether it is on at each position

88
 Explanation

Off Run

Start
Off
Run
Start

Note The above table“ 〇” means being connected. .

89
 Hand brake switch
(1)Remove hand brake.
(2) Disconnect connector of
wiring.
(3) Remove screws and washers.
(4) To install, reverse removal
procedures.
Adjust ledge of switch to proper
length when installing. 2,3,4

1.Hand brake harness

2.Screw
3.Washer
4.Washer
5.Inching switch

1 5

Hand brake wiring harness

6.8 DC fan and others

（1）Remove nuts and washers.
（2）Remove DC fan.
（ 3 ） Disconnect connector of
wiring.
（4）To install, reverse removal
Red Black
procedures.
Adjust ledge of switch to proper
length when installing.

90
Transition harness

91
 Back-up buzzer

Disassembly and assembly

1. Disconnect connector of wiring and
remove bolts.
2. To install, reverse removal
procedures.

Horn

Disassembly and assembly

1. Remove the connector of the horn
cable
2. Remove bolt and horn.
3. To install, reverse removal
procedures.

Radiator fan
Disassembly and assembly
1. Remove the connector of the fan
cable.
2. Remove bolt and fan
3. To install, reverse removal
procedures.

92
6.9 Electrical system principle diagram

CPD20~25-XD4-SI25
93
CPD20~25-XD4-SI26
94
CPD30~35-XD4-SI25
95
CPD30~35-XD4-SI26
96
 Maintenance record

Date Maintain content Maintainer

■Address For: OVERSEAS USERS
■Address: 666 Xiangfu Road, Lin'an, Hangzhou,Zhejiang, China
■Fax: 0086-571-889267890086-571-88132890■ ZIP:311305
■Web: http://www.hcforklift.com■E-mail: [email protected]