HANGCHA CPD10 / CPD40 (1~5t J Series Counterbalanced Battery Forklift Truck). SERVICE MANUAL (2010)

FOREWORD

Thanks for your purchasing our forklift truck.

4 wheel counterbalanced battery forklift truck is our company’s new product. It has the character

of small turning radius, beautiful shape, small dimensions, low gravity.

This operation manual is the explanations that how to use 1-3tJ series forklift truck correctly. It

will instruct you how to operate safety and precautionary maintenance.

To ensure safety and exert the truck’s potential, all the personnel that in charge of operation,

maintenance and management must read this manual thoroughly before starting work with the forklift.

This manual is applicable to container trucks.

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.

The meanings of model

Tow electric

Rise electric

Rated capacity（t）/

Truck model

control

load centre distance（mm）

1244

1254

CPD10/15/18/20/25/30J

1.0/500,1.5/500,1.8/500,

(CURTIS)

2.0/500,2.5/500,3/500,

ACS

CPD10/15/18/20/25/30J D1

4/500,4.5/500,5/500

(INMOTION)

1238

EVC255

1.0/500,1.5/500,1.8/500,

CPD10/15/18/20/25/30/35J C1

(CURTIS)

2.0/500,2.5/500,3/500,3.5/300

1238

1236

1.0/500,1.5/500,1.8/500,

CPD10/15/18/20/25/30/35J C2

(CURTIS)

2.0/500,2.5/500,3/500,3.5/300

1238

CPD40/45/50J C2

4/500,4.5/500,5/500

(CURTIS)

CONTENT

FOREWORD

1. DRIVING SYSTEM

1.1 ENGINE FOR FORKLIFT

1.2 GEAR BOX

1.3 DRIVING AXLE

2. STEERING SYSTEM

2.1 STEERING DEVICE

2.2 STEERING AXLE

3. BRAKE SYSTEM

3.1 MASTER CYLINDER

3.2 FOOT BRAKE

3.3 HAND BRAKE DEVICE

4. HYDRAULIC SYSTEM

5. LIFTING SYSTEM

5.1 DATA

5.2 FAULT

5.3 MAST

5.4 LIFTING CYLINDER

5.5 TILTING CYLINDER

6. ELECTRICAL SYSTEM

6.1 CPD10/15/20/25/30J FORK

6.2 CPD10/15/20/25/30/35J C1、CPD10/15/18/20/25/30/35J C2、CPD40/45/50J C2 FORK

6.3 CPD10/15/20/25/30J D1 FORK

7. MAINTENANCE RECORD

1. Driving system

Drive system is composed most components such as electrical engineering, gear box, driving axle

detent tyre and wheel rim.

Gear box is two grades reduce speed gear, one grade straight gear and one grade planet gear. So the

gear box is very small.

Detent is a hoof detent, if you need know the particular content, you can see relevant portion of the

trig system.

1.1 Engine for Forklift

1.1.1Data

CPD10/15J/18J

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

separate

XQ - 5-3A

5.3

139

1700

3200

IC01

IP20

tow

excitation

series

XQD -8.2-3D

8.2

172.8

1600

3200

IC01

IP20

work

excitation

CPD20/25J

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

separate

XQ-7A

180

1200

2400

IC01

IP20

112

tow

excitation

series

XQD-8.6-3D

8.6

248

1600

3200

IC00

IP44

work

excitation

CPD30J

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

separate

XQ - 10.2 A

10.2

162.5

1500

IC01

IP20

120

tow

excitation

series

XQD - 10 -3D

161.6

2000

IC01

IP20

work

excitation

CPD10/15/18J C1

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

YDQ6.8-4HC

6.8

222

1200

2000

IC01

IP20

tow

series

XQD -8.2-3D

8.2

172.8

1600

3200

IC01

IP20

work

excitation

CPD20/25J C1

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

YDQ9.1-4HC

9.1

280

1200

2000

IC01

IP20

110

tow

series

XQD-8.6-3D

8.6

248

1600

3200

IC00

IP44

work

excitation

CPD30/35J C1

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

YDQ11.75-4HC

10.6

180

1200

IC01

IP20

110

tow

series

XQD - 10 -3D

161.6

2000

IC01

IP20

work

excitation

CPD10/15/18J C2

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

YDQ6.8-4HC

6.8

222

1200

2000

IC01

IP20

tow

YDQ-8.6

8.6

248

1600

3200

IC01

IP44

work

CPD20/25J C2

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

YDQ9.1-4HC

9.1

280

1200

2000

IC01

IP20

110

tow

YDQ-8.6HC

8.6

248

1600

3200

IC00

IP44

work

CPD30/35J C2

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

YDQ11.75-4HC

10.6

180

1200

IC01

IP20

110

tow

YDQ - 10

161.6

2000

IC01

IP44

work

CPD40/45/50J C2

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

YDQ16.6-4HC

16.6

250

3100

5000

IC00

IP20

155

tow

YDB25.4-4

25.4

387

1620

3200

IC00

IP20

115

work

CPD10/15J D1

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

TSP180/4-180-48V

10.5

280

1200

2000

IC01

IP20

135

tow

TSW112/4-195-T-48V

285

2000

3200

IC01

IP20

work

CPD20/25J D1

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

TSP180/4-180-48V

10.5

280

1200

2000

IC01

IP20

135

tow

TSW112/4-195-T-48V

285

2000

3200

IC01

IP20

work

CPD30J D1

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

TSP180/4-180-80V

10.6

180

1200

2000

IC01

IP20

135

tow

TSW112/4-195-T-80V

12.8

216

2000

3200

IC01

IP20

work

CPD40/45/50J-D1

Rated

Max.

Excitations

Insulation

Cooling

Protecting

Ration

Weight

Model

Power

Voltage

Current

speed

Speed

Remark

Mode

Grade

Mode

Grade

(m)

(Kg)

( kw)

(V)

(A)

(r/m)

tow

TSP180/4-200

16.6

／

IC01

IP20

work

TSP160/4-250-T

387

1620

IC01

IP20

Height above sea level

No exceed 1200m

Remark

electromotor

Environment

temperature

40⁰C/-25⁰C

applied range

highest/lowest

Relative temperature

Until on the surface of motor dew 100%

Cooling air

Must not contain volatile gas

Three times of rated current ,admit

most work

Tractor motor

time is one minute

current of the

One point eight times of rated current

motor

Lifting motor、steering motor

,admit time is one minute

Admit temperature Rolling bearing（Environment

temperature not exceed

40⁰C）

95⁰C

From brush box catadrome side to surface of the

JD1

2～4mm

commutation

not

Cooling insulation resistance（When it approach work

< 45V

0.5MΩ

temperature, please measure by 250Vmegohmmeter）

45V～110V

1MΩ

JD1

Brush

Metal plumbagin brush trade J201 chart No 5CZ、578

not

1.1.2 Failure diagnosis

CPD10-30

Failure phenomenon

Possible cause

All of sheet copper nigrescence

Brush’s pressure is wrong

Parts of commutator according to

parts is short circuit

a certain order nigrescence

armature coil is short

parts of commutator is not fasten to armature coils open circuit

Parts of commutator are

commutator’s center line location change

nigrescent, but without definite

·commutator’ s surface is rough, out of round

rule

·motor vibration

clearance between brush and box is bigger.

·working surface distance between the box and commutator is

Brush wear and tear, change

bigger

colors and break

·mice between parts of commutator extrude

·material of the brush is bad

trademark of the brush is wrong

·motor overload

commutator is unholy

commutator is rough or out of round

·mica or parts of commutator extrude

brush seat grinding is bad

Sparkle strong

the pressure of brush is not enough big

trademark of the brush is wrong

the brush lock in the box

the brush frame is loose or vibrational

the polarity and tactic order of magnetic pole is wrong

the sparkle of brush is strong

The brush and wire heat

the brush is not contacted with the cable

the cable is thinner

The brush have noise

the surface of the commmutator is rough

1.1.4 Use and maintain

CPD10-30J

The commutator has four check windows, with which you can observe and maintain the

commutator and brush. There are four average distributing magnetic poles in seat. The magnetic pole

coil is made of F state copper thread, dipping with F state insulating varnish. Parts of stator and neutral

position of brush have been adjusted; users mustn’t unpack and adjust randomly.

·Check armature for rotation and void frictionize.

·Check outgoing line of electric machine for connection

·Brush should slide freely in the brush hold box.

·Check reverse chip for neatness, if need be，clear canaliculus between the reverse chip or the

commutator surface of powder, can used cleanly calico of soft and no thread downy , maybe surface

had oil ,calico can dip alcohol when wiping (stop process).

check all fasteners whether fastened.

·brush’s shelf must reliable fastened, can’t become flexible. If need running or disassembly brush’s

shelf， must make out marker，can become flexible bolt. When the brush’s shelf reposition, aim at

marker line, screw down bolt, in order to keep brush in the former neutral location.

·winding isolating resistance should check of fix a date, when near work’s temperature, under rule data,

otherwise should put up dry.

fix a date open window shutter, check inside part whether transmutation and reverse partial circs

whether up to snuff.

you should often clean bed load and other dirt on the motor’s shell, in order to giving out heat quantity

best.

Every half year check motor one time as follow:

a. Inspect exterior and clean the dust for the motor；

b. Clean or replace bearing, during running it is permitted to giving off abnormal noise for bearing；

c. Inspect the brush’s abrasion, if necessary replace it.

Burnishing for brush：

·When replaces the brush, using ―00‖ thin emery cloth to burnishing it. During burnishing you can haul

the emery cloth leftward or rightward.

·After burnish the brush and clean the commutator with emery cloth, the motor should lowered voltage

and limiting speed to running under load, in order to safety, till the brush’s working face is shined.

CPD10/15/18/20/25/30/35J C1

CPD10/15/18/20/25/30/35J C2、CPD40/45/50J C2

CPD10/15/18/20/25/30J D1、CPD40/45/50J D1

CPD10/15/18/20/25/30/35J C1 、 CPD10/15/18/20/25/30/35J C2 、 CPD40/45/50J C2 、

CPD10/15/18/20/25/30J D1、CPD40/45/50J D1 fork don’t have commutator and brush，not need

maintain. You must clear dust everyday.

1.2 Gear box

Gear box is two grades reduce speed gear, one grade straight gear and one grade planet gear. So the

gear box is very small.

Trouble

Probably cause

Method of troubleshooting

When traveling or change

Gear clearance is too big.

Adjust.

direction

Too much worn of gear.

Replace.

Oil level is low.

Add oil.

Too much noise when traveling

Gear clearance is too big.

Adjust.

Too much worn of gear.

Replace.

1. Box

2.Bearing pedestal

3. Bolt

4.Bearing pedestal

5.O joint ring

8.Dual

11. dual articulated

9. Axletree 6206

10.Axletree 6307

12.Axletree 6305

articulated gear

gear

15.Positioning

13.axes

14. O joint ring

16. Bolt

17. Pinion

board

18. Axletree 6208

19. Tank cap

20. Bolt

21. Bolt

23.Pin

27.right differential

28.left differential

24. Girth gear

25. bolt

26.nut

carrier

29. Gear shaft (I)

30. Face gear

31. Gasket

32. Planetary gear

33. Thrust washer

34. Axletree 6211

35. Straight pin

36.Gear shaft (II)

37. Paper gasket

38.pin

39. Lock plate

40. Lock washer

1.3 Driving axle

1.3.1 Data

Type

1-1.8t

2-2.5t

4-5t

Full floating, axle and truck body direct install, front

Driving axle type

Tire pressure

10.30MPa

Wheel hub rotation starting torque at hub blot N

10～29

Axial play of wheel bearing mm

less than 0.08

weight

125-130

195-198

202-208

350-380

1.3.2 Trouble diagnoses and corrections

condition

Probable cause

Corrective action

loose driving axle and body connecting blots.

Tighten.

loose wheel nut

Tighten.

·worn or damaged wheel hub bearing.

Replace.

Abnormal noises

·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.

Fig.3-1 Driving axle

1. Rim

2. Brake drum

3. wheel hub

4.Wheel nut

5. Wheel hub bolt

6. Bolt

7.Brake Assembly

8. Wash

9.Bolt

10. Half-axle nut

11. Half axle

12.Bolt

13. Oil seal

14. Taper roller

15. Adjusting nut

bearing

16. Lock nut

17.Pin

18. Paper shim

19. Oil seal

20.Axle case

21. Supporter

Tighten torque: N.m

1-1.8t

2-3t

4-5t

44-58

73.5-88.3

105-156

76-107

118-147

157-176

nut connecting brake

324-373

260-347

324-373

Bolt and nut connecting

324-373

support plate and truck

260-347

324-373

157-176

441-588

1.3.3Driving 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.5-1

。

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.

10) Remove bolts securing axle mounting bracket to frame.（see fig.5-2）.

11) Remove nuts securing axle case to differential gear carrier.（see fig.5-3）.

12) Remove driving axle assemble.

Fig.1-1

Fig.1-2

Fig.1-3

13）Remove brake drum，remove wheel hub.

14）Remove axle mounting bracket and brake component from axle tube.

15）Remove oil seal from axle tube.

16）To install driving axle assemble in the reverse order of removal. Observe the following:

① When installing axle mounting bracket and brake component, apply a coat of calcium grease to axle

tube.

② Apply 1/3～2/3 of volume of calcium grease to wheel hub，then install them on axle tube.

③ Install oil seal with its part number facing to the inside of forklift truck.

④ attach seal tape （PVC, white）to drain plug then installed after cleaned it.

⑤ Replenish axle case with gear oil. Tighten vent plug after clearing.

2.8

1-1.8t

GL-5

Gear oil (L）

3.2

2-3t

85W/90

4.5

4-5t

Vent plug should clear instantly to prevent pressure inside of wheel hub from rising.

1.3.4. Axle shaft and wheel hub

Remove

1）Raise the front end of forklift truck and support frame with wooden blocks.

2）Remove front wheel and axle shaft.

3）Remove lock nuts, lock washers, snap ring, felt ring, adjusting nut. Use special tools.

4）Remove brake drum（refer to Fig.5-4）；

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.5-5）. b. evenly tapping on brake drum with brass bar or wooden mallet.

Fig.1-4

Fig.1-5

5）Remove wheel hub, be careful not to drop bearing inner race.

6）Remove oil seal and inner bearing as an assembly by evenly tapping on periphery of seal with a

wooden mallet and brass bar.

7）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

Stepped wear or cracks on axle shaft splines

Replace

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

Replace

rollers

Cracked or damage wheel hub

Replace

Damaged oil seal felt ring.

Replace

Installation

Install reverse order of removal.

1.3.5 Bearing adjusting

1）Lubricate on taper roller bearing.

2）Tighten roller bearing lock nut in wheel hub until wheel hub can no longer be rotated with one

hand.

3）From that position, turn back lock nut approx. 60⁰.

4）Turn back wheel hub two or three rotations so that bearing settles down.

5）Again tighten lock nut until it can no longer be rotated with one hand; then turn back approx.60⁰.

6）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.

7）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.1-6

；

8）Measure axial play of wheel hub to see if it is within specification. Axial play is less than 0.08mm

（refer to Fig.1-7）.

Fig.1-6

Fig.1-7

2. Steering system

Steering system include rear steering axle and steering device.

2.1 Steering device

It consists of steering wheel, upside steering column, downside steering column, bearings, steering gear,

priority valve, clamp bolt and hydraulic switch etc. You can adjust the steering angle forward and

backward by yourself. Refer to fig. 2-1.

1. Steering wheel

3.Upside steering

8.Gimbal

10. Down side

12. Bearing

column

steering axle

13. Snap ring

14.Down side

17. Steering gear

18. Priority valve

19. Clamp bolt

steering column

22. Clamp lever

26.Hydraulic

switch

Fig. 2-1 Steering device

2.2 Steering axle

2.2.1 General specifications

Axle centre（none for 4-5t）

Axle body

Center support, swing type

type

Vertical play（mm）

0～1

Inner

1-1.5t

79.5º

wheel

2-3t

80º

Turning

Adjusting shim for end

1-1.8t

56º

angle

Outer

shaft of axle thickness

0.5, 1.0, 1.6

wheel

2-3t

55.7º

（mm）

Tyre

0.9MPa

Part No.

N163-220020-000

pressure

Kingpin

wheel hub bearing

Less than

Tighten steering spindle nut until

Kingpin axial play（mm）

0.20

drive wheel hub no longer

Pre-tighten

rotates with one hand. Then

Kingpin adjusting washer

loose 1/8～1/6 rotations.

Or wheel hub rotation starting

thickness（mm）

Part No.

torque at hub blot 10-29.8N

Axial

0.10, 0.30, 0.70

N163-220012-000

Less than 0.10

play(mm)

Truck type

1-1.8t

2-2.5t

3-3.5t

4-5 t

weight Kg

66-68

96-99

98-100

135-150

2.2.2 Trouble diagnoses corrections

condition

Probable cause

Corrective action

loose wheel nut

tighten

·wheel bearing out of adjustment.

adjust

Unstable driving

improperly adjusted shims.

adjust

faulty steering system.

refer to turning system section

insufficient lubrication.

Apply calcium grease

loose bolts and nut.

tighten

Noises

improperly adjusting shim for axle end Shaft.

adjust

damaged joint bearing at two ends of rod.

replace

2.2.3 Remove

Wheel hub

Jack up and support forklift truck body with

Wooden blocks.

Remove tire.

Remove hubcap.

Remove steering spindle nut.

Pull off hub assembles.

Remove bearing inner race.

Caution：a. Not to drop bearing inner race.

b. Be careful not to damage oil seal.

2.2.4 Kingpin and steering spindle

Remove rod.

Loose lock bolts.（See fig.2-2

；

Remove grease nipples on kingpin.

Remove kingpin.

Caution：Hold kingpin to prevent it from dropping. (See fig.2-3).

Take off spindle, thrust bearing and shim.

Fig. 2-2

Fig. 2-3

INSPECTION：

1）．Replace spindle if cracked.

2）．Replace bearing if its rollers or roller surfaces are rusted or nicked.

3）．Replace steel sleeve if it distortion, out of round, cracked.

4）．Replace thrust bearing and dust cap if them damaged.

Installation

To install, reverse the order of removal. Careful observes the following.

1）always insert kingpin from lower side.

2）install thrust bearing, set the tighten-ring below the support and loosen-ring. Pack all grease between

dust proof inside, loosen-ring, and tighten-ring.

3）adjust axial play to specification with shims. Axial plays less than 0.15mm.

4）the character of seal tape faces outside. Apple grease to roller of roller bearing, also apply grease

between lip and groove of seal tape.

5）pack all grease nipple with a sufficient.

2.2.5 Wheel bearing adjustment

1）Slowly rotate hub. Tighten steering spindle nut until it can no longer be rotated with one hand.

2）From that position, turn back steering spindle nut 1/6～1/4 rotation. Measure hub bolt force is 10～30N.

3）Make sure that hub rotates smoothly and that its axial play is within specification. Axial play is less

than 0.10mm.

2.2.6 Steering cylinder

图 2-4 Steering cylinder

1. Piston rod

2.LBH wiper

3. O ring

4.ISI seal ring

5. O ring

6. Guide sleeve

7. Glay ring

8. Crock

3. Brake system

The brake system is the front two-wheel braking type consisting of a master cylinder, brakes and

brake pedal.

3.1 Master cylinder

The master cylinder 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 from dust by means of a rubber dust cover. The piston is actuated through the push rod by

operation of the brake pedal. First, as the brake pedal, the push rod pushes the piston forwards. The

brake fluid in the 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 lines to the wheel cylinder. Thus,

each wheel cylinder piston is forced outwards. This brings the brake shoes into contact with the wheel

drum and slows or stops the lift truck.. Meanwhile, the cavity caused behind 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 back 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, thus returning into the master

through the check valve. With the piston in its original position, the fluid in the cylinder flows into the

reserve tank through the return port. The brake fluid in the brake lines and wheel cylinders has a

residual pressure proportioned to the set pressure of the check valve, which makes each wheel cylinder

piston cup securely seated to prevent oil leakage and eliminates of vapor lock developing when the lift

truck is sharply broken.

图 3-1 Master cylinder

1. Lock nut

2. Rod

3. Duct cover

4. Stop wire

5. Stop washer

6.Secondary cup

7. Piston

8. Primary cup

9. Spring

10. Check valve

11. Valve seat

12. Cylinder body

3.2 Foot brake

3.2.1 Brake

The configuration of the 2-3t right detent can refer to fig 3-2. The configuration of 1-1.8t 、4-5t right

detent Configuration was similitude to 2-3t.

Fig.3-2 2-3t forklift truck right brake assembly

1. Brake mount

2. Wheel cylinder

3. Cylinder return

4. Rubber cap

5.Piston

bracket

body

spring

6.Cylinder dust

7. Push rod

8.Air bleeder cap

9.Air bleeder

10. Brake shoe

cover

screw

assemble (front)

11. Brake shoe

12. Guider

13. Adjuster cable

14.Adjusting bolt

15. Pawl

assemble (rear)

16.Spring

17. Brake shoe

18.Return spring

19.Parking brake

20.Strut level

return spring

rod

21.Spring

22.Bolt

23.Washer

24.Snap ring

25.Guider

26.Spring support

27.Spring bracket

28.Spring

29.Plug

30.Oil connector

rod

31.Bush

32.Brake steel cable

3.2.2 Replace brake shoe:

Place the forklift truck on level concrete.

Start engine 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 engine.

Remove wheel tire nuts and brake drum.

10) Replace brake shoes with new ones.

11) Install brake drum.

12) Adjust shoe to drum clearance:

① Remove adjusting hole plug on the bottom of the brake assemble.

② 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.

③ 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.

④ Replace the plug.

⑤ Install wheels.

⑥ Properly adjusting pedal stroke.

⑦ Remove blocks.

⑧ 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.

3.3 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. If it occurs for foot brake malfunction, use hand brake to stop the truck.

condition

Probable cause

Corrective action

·Oil leakage in brake lines.

Correct and replenish.

Insufficient brake

·Air in brake lines.

Bleed air.

force

Improper functioning of master cylinder or

Correct or replace.

wheel cylinder.

·Clogged oil lines.

Clean

·No free play of brake pedal.

Adjust.

Faulty piston cup.

Replace

·Weak or broken return springs.

Replace

Brake dragging

·Clogged master cylinder returns port.

Clean

·Clogged oil lines.

4. Hydraulic system

The high pressure oil from main pump goes to control valve and divide it to two parts by dividing

valve inside control valve: one of them goes to lifting cylinder or tilting cylinder, another part goes to

steering gear with invariable flow to control steering cylinder. When lifting and tilting spool is in

neutral, high pressure oil return oil tank directly from pass way. When pulling lifting spool, high

pressure oil goes by throttle valve and then push piston rod under lifting cylinder piston. When pushing

lifting spool, it is that bottom of lifting cylinder piston connects with low pressure line and then piston

rod drops by deadweight and weight of cargo. In this time, oil from lifting cylinder goes by

unidirectional speed limiting valve so as to control the falling speed. When operating tilting spool, high

pressure oil goes to front house of tilting cylinder and another connects with low pressure line so as to

make mast tilt forward or backward.

Main pump

Trouble

Probable cause

Corrective action

Low oil level in tank.

Add oil to specified level.

No oil from oil

Clean oil line and tank. If oil is dirty,

pump

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.

Low discharge

pressure gauge.

pressure on oil

Retighten suction side pipe.

Add oil in oil tank.

pump.

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.

replace with new oil having proper

Noisy oil pump

Cavitation due to too high oil

viscosity for temperature at which pump is

viscosity.

to be operate.

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 on

Replace faulty parts.

oil pump

pump.

Control valve

Trouble

Probable cause

Corrective action

Loose of pressure-adjust screw.

Readjusted and retighten.

Distorted or damaged pressure-adjust

Pressure of relief

Replace.

spring.

valve is not steady

Worn or blocked relief valve core.

Replace or clean.

or too low.

Pump abated.

Examine and repair pump.

Replace valve core and tilt lock valve

Fork tilt forward

Worn or damaged tilt lock valve.

as an assembly.

when control lever

Broken tilting lock spring.

Replace spring.

used

while

engine is off.

Damaged tilt valve plunger O-ring.

Replace O-ring.

Mast is unstable

Malfunctioning tilt relief valve.

Replace tilt relief valve assembly.

when tilting forward.

Valve body and spool valve is worn and

Replace spool valve with specified

Lowering distance

clearance between them is too great.

clearance.

of mast is big when

Spool valve is not in centre.

Keep being in the centre.

spool valve is in

Cylinder seal abated.

Examine and repair cylinder.

the centre.

Taper valve is worn or blocked by dirt.

Replace or clean taper valve.

Damaged or distorted reposition-spring.

Replace spring.

Dirt exist between valve body and spool

Spool valve is not

Clean.

valve.

return neutral

Blocked control device.

Adjusted.

position.

Not coaxial parts at reposition

Reinstall.，be coaxial

Damaged O-ring.

Replace.

Faulty seal of joint.

Check and retighten.

LOOSE SEAL PLATE.

Clean seal plate and retighten blots.

Leakage

Loosed lock-nut of relief valve and

Tighten.

connect-nut between plate and plate.

Adjusting the pressure of the main relieve valve

The pressure of the main relieve valve is all ready adjusted in the factory, and it can’t be adjusted

generally. The following is an example of 3t truck to specify how to adjust the pressure.

(1). Put 125 percent of the rated load (2000kg) on the forklift stable.

(2).Step the accelerated pedal to the end, control the lift pole, if the forklift can get the height of

300mm,the main relieve valve is all right. Otherwise, adjust it as step (3).

(3).If the forklift can’t work, enhance the pressure main relieve valve, remove the front soleplate,

loosen the tightening nut of the main relieve valve, screw the adjusting nut clockwise to enhance

the pressure of the main relieve valve. If the height of lift is higher than 300mm, screw the adjust

nut anti-clockwise to reduce the pressure.

(4).Step the accelerated pedal to the end to make the forklift in the height range of 0-300mm. Otherwise,

adjust it as step (3).

Warning:

The load should be put stably.

·Don’t adjust if the pressure is already adjusted correctly.

5. Lifting system

5.1 Data

Inspection and adjustment

Place

Assembly clearance （mm）

Repair clearance（mm）

Mast to lift roller

0.1～0.8

0.2～1

Shims

0.5～1

Mast to back up metal

0.1～0.8

0.2～1

Shims

0.5～1

Inner mast to carriage side roller

0.1～0.6

0.2～1

Lift chain deflection

25～30 mm

Tightening torque

Place

Model or Lifting

N·m

1～1.5t

127-157（M16），245-314（M20 single chain）

Lift chain lock nut

2～3t

176-216(M18)

245-314（M20）

1～1.5t

89-118（M14）

Mast support cap blot

2～3t

176-216（M18）

1～1.5t

Tilt cylinder lock nut

89-118（M14）

2～3t

Lift cylinder bolt(head)

1～3t

76-107（M12）

1～1.5t

22-29（M8）

Lift cylinder bolt（toe）

2～3.5t

44-58（M10）

Lift cylinder fixing bolt

1～1.5t

14-18（M8）

（U type）

2～3t

29-39（M10）

Weight of basal mast

Model of truck

1.5 t

1.8 t

2.5t

4-4.5t

Weight of mast Kg

531

930

1000

1100

1450

1550

5.2 Fault

Fault

Probable cause

Corrective action

1.Tilt cylinder and ring abraded

Replace piston ring tilt cylinder.

Fork arm carrier or

excessively

mast tilt by itself.

2. The hydraulic control valve spring is

Replace it.

inoperative.

The fork arms

1. Caused by piston jamming or bent

Replace the faulty parts.

carrier moves up

piston rod.

and down

2. Too much dirt is accumulated in the

Strip it down and clean.

sluggishly.

cylinder.

1. Carriage bracket assembly out of

Adjust clearance with thrust metal

adjustment.

and carriage side roller.

2. Insufficient clearance between inner

Adjust clearance with rollers.

and outer masts or rollers and mast.

Forks are lifted or

3. Biting foreign materials between

lowered

Remove foreign materials.

moving part.

unsmoothly.

Apply grease on contact surfaces

4. Insufficient lubrication.

of sliding parts.（butter）

5. Bent carriage bracket assembly.

Repair or replace.

Forks are lifted

1. Lift chains out of adjustable.

Adjust lift chains.

unevenly

1. Grease stiffened or dirt accumulated

Clean and lubricate lift rollers.

Lift roller does not

on lift roller and mast sliding surfaces.

rotate

2. Improperly adjusted lift roller.

Adjust.

1. Insufficient lubrication.

Lubricate.

2. Improperly adjusted lift roller, side

Adjust.

roller and back-up metal.

Excessive mast

By adjusting shims and rubber

noise

pad, piston rod is in touch with

3. Rubber pad on lower of outer mast is

bottom of cylinder body after

useless for container fork lift truck.

inner mast is in touch with rubber

pad.

Fault

Probable cause

Corrective action

1. Excessive wear occurs between the oil

Replace the worn parts or the oil

pump body and gears, causing too much

pump.

clearance.

2. The lifting jack piston Yx-ring has worn,

Replace Yx-ring.

resulting in excessive inner leaks.

3. Springs of the multiple control valve

and its relief valve are inoperative oil

Replace.

leaks.

4.Excessive wear occurs of the hydraulic

control valve ,resulting in excessive oil

Replace.

Insufficient lift

leaks.

power or no lift

5. Oil leaks occur between the hydraulic

Dismantle for regrinding the joint

movement.

control valve sections.

surfaces and reassemble the valve.

Tighten the joint nuts and inspect

6. Leakage occurs in the hydraulic pipe.

the seal for damage.

Change the wrong hydraulic oil or

7. The hydraulic oil temperature is too

stop operation for reducing the oil

high. Oil viscosity is too low and the rate

temperature. Find out the reasons

is insufficient.

for high oil temperature and

eliminate the trouble.

8. The load carried is beyond the

Observe the lifting capacity limit.

designed capacity.

5.3 mast

Basic mast is 3m high, composed of inner and outer mast, fork arm carrier, fork arm, chain and idler

wheel, etc.

Fig5-1 Double lift mast with wide view

1.Outer mast

2.Inner mast

3.Back rest

4. Fork arm carrier

5.Fork

6.Chain

7.Left lifting

8.Right lifting cylinder

9.Tilting cylinder

10.Idler wheel

cylinder

Fig5-2

Double full free lift mast

1. Outer mast

2.Inner mast

3. Chain

4. Free lifting cylinder

5. Fork arm carrier

6. Fork

7.Left lifting

8.Right lifting

9. Fork arms

10.Tilt cylinder

cylinder

Fig 5-5 Lifting cylinder

1.LBH dust proof

2. ISI ring

3. Plug screw

4. O Ring

5.Piston

6.Bolt

7.Guide

8.bush

9. Cylinder body

10.Piston

11. Snap ring

12. Piston

13. Support ring

14. Back up rings

15. OSI ring

16. Valve guide

17.Snap ring

18. Steel axletree

19.Blowout patch

20.Adjusting washer

5.5 Tilting cylinder

Fig 5-6 Tilting cylinder

1. Retaining

2.Knuckle bearing

3. Support

4.Lubrication

5. Nut

ring

nipple

6. Bolt

7. dust proof

8. Cylinder

9. Guide

10. U ring

11. O ring

12. Piston rod

13. O ring

14. Thimble

15. U ring

16. Piston

17.Cylinder body

18. Washer

19. Nut

20. Pin

21.bolt

22.Nylon tray

23.Snap ring

24. Snap ring

25.Adjusting washer

6. Electrical system

6.1 CPD10/15/20/25/30J fork

6.1.1summarize

Curtis PMC 1244 MultiMode controllers are separately excited motor speed controllers designed

for use in a variety of material handling vehicles. These programmable controllers are simple to install,

efficient, and cost effective.

Typical applications include low lifts, stackers, fork lifts, reach trucks, personnel carriers,

counterbalance trucks, order pickers, boom trucks, and other industrial vehicles.

The 1244 MultiMode controller offers smooth, silent, cost effective control of motor speed and

torque. A four quadrant, full-bridge field

Winding control stage is combined with a two quadrants, half-bridge armature power stage to provide

solid state motor reversing and regenerative braking power without additional relays or contactors. The

1244 controller can also be specified to be compatible with CAN Bus communication systems.

These controllers are fully programmable by means of the optional handheld 1307 programmer.

Use of the programmer provides diagnostic and test capability as well as configuration flexibility.

Like all Curtis PMC motor controllers, the 1244 offers superior operator control of the vehicle’s motor

drive speed. Features include:

_ Full-bridge field and half-bridge armature power MOSFET design, providing

• Infinitely variable forward, reverse, drive, and brake control

• Silent high frequency operation

• High efficiency

_ Regenerative braking, providing longer operation on a single battery charge and reducing motor

brush wear and motor heating

_ Programmability through the 1307 handheld programmer

_ Complete diagnostics through the 1307 programmer and the internal Status

LED

_ Two fault outputs provide diagnostics to remotely mounted displays

_ Continuous armature current control, reducing arcing and brush wear

_ Automatic braking when throttle is reduced from either direction; this provides a compression

braking feel and enhances safety by automatically

initiating braking in an operator hands off condition

_ Deceleration Rate, Load Compensation, and Restraint features prevent downhill runaway conditions;

speed is controlled to within approximately

20% of level surface value

_ MultiMode allows four user-selectable vehicle operating personalities

_ Programmable to match individual separately excited motor characteristics

_ Meets or exceeds EEC fault detect requirements

_ Vehicle top speed is controlled and limited in each mode

_ Linear temperature and under voltage cutback on motor currents; no sudden loss of power under any

thermal conditions

_ High pedal disable (HPD) and static return to off (SRO) interlocks prevent vehicle runaway at startup

_ Creep speed adjustable from 0% to 25% in each mode

_ Continuous diagnostics during operation, with microprocessor power-on self-test

_ Internal and external watchdog circuits ensure proper software operation

_ Programmable coil drivers provide adjustable contactor pull-in and holding voltages

_ Hour-meter enable output is active whenever the controller is providing motor current

_ Optional Electromagnetic Brake Driver provides automatic control of an electromagnetic brake or

other similar function

6.1.2 Failure code

CPD10-30J

Fault table of tow controller

LED code

PROGRAMMER LCD

EXPLANATION

POSSIBLE CAUSE

DISPLAY

1,2

HW FAIL SAFE1-2-3

self-test or watchdog fault

Controller defective.

M-SHORTED

internal M- short to B-

1．Controller defective.

1. Motor field wiring loose.

FIELD OPEN

.Field winding fault

1, 2. Motor field winding open.

1，3

ARM SENSOR

armature current sensor fault

1．Controller defective.

FLD SENSOR

Field current sensor fault

1．Controller defective.

1．VSC input wire open.

2．VSC input wire shorted to B+

SPEED

CONTROL

2，1

VSC signal exceed range

or B-.

FAULT

3．Throttle pot defective.

4. Wrong throttle type selected.

1．.Improper seq. of direction and

throttle inputs.

2. Wrong START LOCKOUT

2，3

START LOCKOUT

starting sequence wrong

type selected.

3. Misadjusted throttle pot.

4. Sequencing delay too short.

cont. driver output over

1. Contactor coil shorted.

3，1

CONT DRVR OC

current

1. Main contactor stuck closed.

3，2

MAIN CONT WELDED

welded main contactor

2. Main contactor driver shorted.

internal voltage too low at

1. Controller defective.

3，3

PRECHARGE FAULT

startup

2. External short, or leakage path

to B- on external B+ connection.

MISSING

1 Any contactor coil open or not

missing contactor

CONTACTOR

connected.

3，4

1 Main contactor missing or wire

CONT DNC

main contactor did not close

to coil open.

1. Battery voltage >overvoltage

shutdown limit.

2. Vehicle operating with charger

4，2

OVERVOLTAGE

overvoltage

attached.

3. Battery disconnected during

regen braking.

1.Temperature >85℃ or <

-25℃.

2. Excessive load on vehicle.

Over-/under-temp. cutback

4，3

THERMAL CUTBACK

3. Improper mounting of

controller.

4. Operation in extreme

environments.

Fault table of lift (oil pump) controller

LED

PROGRAMMER

EXPLANATION

POSSIBLE CAUSE

code

LCD DISPLAY

NO voltage or controller

off

is not working, error (such

as MCII defective)

controller work normally,

0,1

■ ¤

no error

EEPROM miss data

EEPROM data check error，use

1,1

¤ ¤

EEPROM defective

programmer 1311 to change any

parameter can delete the error.

MOSFET short down.

1,2

¤ ¤¤

Hardware defective

Motor circuit is an open circuit.

2,1

¤¤ ¤

Low voltage

Battery voltage is too low.

The function of lifting lock of the

2,2

¤¤ ¤¤

Lifting lock.

controller is touch off.

Order fault （ Startup

Any switch of SS1-SS4 closes earlier

2,3

¤¤ ¤¤¤

lockout）

than KSI or INTERLOCK.

Main contact bonded。

3,2

¤¤¤ ¤¤

Contact err

The set of parameter ―CONTACT

CNTRL‖ is wrong.

Pre-charge circuit work with err.

3,3

¤¤¤ ¤¤¤

Pre-charge fault

Motor short down.

The connection of main contact

Contact has not been

3,4

¤¤¤ ¤¤¤¤

coil loose.

installed or is not close.

Main contact works abnormally.

The voltage of battery is lower than the

4,1

¤¤¤¤ ¤

Low -voltage protect.

set value of ―LOVOLT CUTBACK‖

4,2

¤¤¤¤ ¤¤

Over-voltage protect.

The battery voltage is too high.

The temperature of controller is

temperature

protect

too high or too low.

4,3

¤¤¤¤ ¤¤¤

（over-/under-temp）

Temperature

sensor

works

abnormal.

6.2 CPD10/15/20/25/30/35J C1、CPD10/15/18/20/25/30/35J C2、CPD40/45/50J C2

fork

6.2.1 Summarize

CURTIS company procreates controller ，adopt international advanced closed loop system and

advanced control technique。Designing large screen instrument，can clear display ―electric quantity‖、

―speed‖、―total time of run ‖ and so on information。Designation adopt code plus character manner，

increase maintain efficiency。Four work models can be set through meter so as to suitable for different

condition.

（1）Actuating motor

Actuating motor adopt three-phase alternating current frequency conversion electromotor，increase

conversion efficiency，not have commentator brush in order not to maintenance 。

（2）Lift motor

Lift motor JC1 is direct current motor, so is the motor of J series truck. Lift motor JC2 adopts

three-phase alternating electromotor，increase conversion efficiency，not have commentator brush in

order not to maintenance.

（3）SAFETY & PROTECTION FEATURES

① Reverse Polarity of the battery

②Connection errors

③All inputs are protected against connections errors.

④Current overload protection

⑤it have detecting element，control peak current.

⑥Thermal protection

If the controller temperature exceeds 85°C, the maximum current reduces in proportion to the

thermal increase. The temperature can never exceed 115

If the electric machinery temperature exceeds 145°C, the maximum current reduces in proportion to the

thermal increase. The temperature can never exceed 165

⑦Low Battery charge

When the battery charge is low, the maximum current is reduced proportionally to the battery

discharge.

⑧External Agents

Electric control is hermetical .The chopper is protected against dust and spray of liquid to

economy.

⑨Protection against accidental Start Up

A precise sequence of operations is necessary before the machine will start. Operation can not

commence if these operations are not carried out correctly. Requests for drive must be made after

closing the Key Switch.

（4）OPERATIONAL FEATURES

① Feedback control system make the vehicle speed follow accelerator ，whether low speed or not

high speed easy control .

② two archives speed and acceleration design ，can apply to most situation.

③ regeneration technology make change direction of fork even smooth。

④ three regenerative braking mode ：

A、acceleration pedal part release appear regenerative braking，

B、direction reverse regenerative braking，

C、ramp downslide appear regenerative braking，

Except increase security drive，reclaim part of electric energy，prolong work time of every time .

⑤ control speed during downgrade： speed lie on accelerator 。if speed exceed set point，controller

may automatic braking，this give optimal ramp.

Notice:

1 .Maintain electric control ，must first cut off electrical source，then hold 10-100ohmic resistance

join controller anode and cathode，release residual voltage in the capacitor, or else you may meet

tip-and-run danger.

2.Magnetic and radiation have some effect to inverter，long time effect may mangle controller, So

need apart form magnetic and radiation.

6.2.2 Error code

CPD10-35J C1 EC ERROR CODE TABLE

There are two LEDs including a yellow LED and a red LED. The two LEDs have four different display

modes, indicating the type of information they are providing.

DISPLAY

STATUS

Controller is not powered on, has a dead

Neither LED illuminated

battery, or is severely damaged.

Yellow LED flashing

Controller is operating normally.

Yellow and red LEDs both on solid

Controller is in Flash program mode.

Red LED and yellow LED flashing alternately

Controller has detected a fault.

TOWING CONTROLLER ERROR CODE TABLE

CODE

PROGRAMMER

POSSIBLE CAUSE

LCD DISPLAY

1，2

Controller Overcurrent

1. External short of phase U, V, or W motor connections.

2. Motor parameters are mis-tuned.

3. Controller defective.

1，3

Current Sensor Fault

1. Leakage to vehicle frame from phase U, V, or W (short in motor stator).

2. Controller defective.

1，4

Precharge Failed

1. External load on capacitor bank (B+ connection stud) that prevents the

capacitor bank from charging.

2. See 1311 menu Monitor » Battery: Capacitor Voltage.

1，5

Controller

Severe

1. Controller is operating in an extreme environment.

Undertemp

2. See 1311 menu Monitor » Controller: Temperature.

1，6

Controller

Severe

1. Controller is operating in an extreme environment.

Overtemp

2. Excessive load on vehicle.

3. Improper mounting of controller.

4. See 1311 menu Monitor » Controller: Temperature.

1，7

Severe Undervoltage

1. Battery Menu parameters are misadjusted.

2. Non-controller system drain on battery.

3. Battery resistance too high.

4. Battery disconnected while driving.

5. See 1311 menu Monitor » Battery: Capacitor Voltage.

6. Blown B+ fuse or main contactor did not close.

1，8

Severe Overvoltage

1. Battery Menu parameters are misadjusted.

2. Battery resistance too high for given regen current.

3. Battery disconnected while regen braking.

4. See 1311 menu Monitor » Battery: Capacitor Voltage.

2，1

Controller Undertemp

1. Controller is performance-limited at this temperature.

Cutback

2. Controller is operating in an extreme environment.

3. See 1311 menu Monitor » Controller: Temperature.

CODE

PROGRAMMER

POSSIBLE CAUSE

LCD DISPLAY

2，2

Controller Overtemp

1. Controller is performance-limited at this temperature.

Cutback

2. Controller is operating in an extreme environment.

3. Excessive load on vehicle.

4. Improper mounting of controller.

5. See 1311 menu Monitor » Controller: Temperature.

2，3

Undervoltage Cutback

1. Normal operation. Fault shows that the batteries need recharging.

Controller is performance limited at this voltage.

2. Battery parameters are misadjusted.

3. Non-controller system drain on battery

4. Battery resistance too high.

5. Battery disconnected while driving.

6. See 1311 menu Monitor » Battery: Capacitor Voltage.

7. Blown B+ fuse or main contactor did not close.

2，4

Overvoltage Cutback

1. Normal operation. Fault shows that regen braking currents elevated the

battery voltage during regen braking Controller is performance limited at

this voltage.

2. Battery parameters are misadjusted.

3. Battery resistance too high for given regen current.

4. Battery disconnected while regen braking

5. See 1311 menu Monitor » Battery: Capacitor Voltage.

2，5

+5V Supply Failure

1. External load impedance on the +5V supply (pin 26) is too low.

2. See 1311 menu Monitor » outputs: 5 Volts and Ext Supply Current.

2，6

Digital Out 6

1. External load impedance on Digital Output 6 driver (pin 19) is too low.

Overcurrent

2，7

Digital Out 7

1. External load impedance on Digital Output 7 driver (pin 20) is too low.

Overcurrent

2，8

Motor Temp Hot

1. Motor temperature is at or above the programmed Temperature Hot

Cutback

setting, and the requested current is

being cut back.

2. Motor Temperature Control Menu parameters are mis-tuned.

3. See 1311 menus Monitor » Motor: Temperature and Monitor » Inputs:

Analog2.

4. If the application doesn’t use a motor thermistor, Temp Compensation

and Temp Cutback should be programmed Off.

2，9

Motor Temp Sensor

1. Motor thermistor is not connected properly.

Fault

2. If the application doesn’t use a motor thermistor, Temp Compensation

and Temp Cutback should be programmed Off.

3. See 1311 menus Monitor » Motor: Temperature and Monitor » Inputs:

Analog2.

CODE

PROGRAMMER LCD

POSSIBLE CAUSE

DISPLAY

3，1

Coil 1 Driver

1. Open or short on driver load.

Open/Short

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，1

Main Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，2

Coil2 Driver

1. Open or short on driver load.

Open/Short

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，2

EM Brake Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，3

Coil3 Driver

1. Open or short on driver load.

Open/Short

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，4

Coil4 Driver

1. Open or short on driver load.

Open/Short

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，5

PD Open/Short

1. Open or short on driver load.

2. Dirty connector pins.

3. Bad crimps or faulty wiring.

3，6

Encoder Fault

1. Motor encoder failure.

2. Bad crimps or faulty wiring.

3. See 1311 menu Monitor » Motor: Motor RPM.

3，7

Motor Open

1. Motor phase is open.

2. Bad crimps or faulty wiring.

3，8

Main

Contactor

1. Main contactor tips are welded closed.

Welded

2. Motor phase U is disconnected or open.

3. An alternate voltage path (such as an external precharge resistor) is

providing a current to the capacitor bank (B+ connection stud).

3，9

Main Contactor Did

1. Main contactor did not close.

Not Close

2. Main contactor tips are oxidized, burned, or not making good contact.

3. External load on capacitor bank (B+ connection stud) that prevents

capacitor bank from charging.

4. Blown B+ fuse.

CODE

PROGRAMMER LCD

POSSIBLE CAUSE

DISPLAY

4，1

Throttle Wiper High

1. Throttle pot wiper voltage too high.

2. See 1311 menu Monitor » Inputs: Throttle Pot.

4，2

Throttle Wiper Low

1. Throttle pot wiper voltage too low.

2. See 1311 menu Monitor » Inputs: Throttle Pot.

4，3

Brake Wiper High

1. Brake pot wiper voltage too high.

2. See 1311 menu Monitor » Inputs: Brake Pot.

4，4

Brake Wiper Low

1. Brake pot wiper voltage too low.

2. See 1311 menu Monitor » Inputs: Brake Pot.

4，5

Pot Low Overcurrent

1. Combined pot resistance connected to pot low is too low.

2. See 1311 menu Monitor » Outputs: Pot Low.

4，6

EEPROM Failure

1. Failure to write to EEPROM memory. This can be caused by

EEPROM memory writes initiated by VCL, by the CAN bus, by

adjusting parameters with the 1311, or by loading new software into the

controller.

4，7

HPD/Sequencing Fault

1. KSI, interlock, direction, and throttle inputs applied in incorrect

sequence.

2. Faulty wiring, crimps, or switches at KSI, interlock, direction, or throttle

inputs.

3. See 1311 menu Monitor » Inputs.

4，7

Emer Rev HPD

1. Emergency Reverse operation has concluded, but the throttle, forward

and reverse inputs, and interlock have not been returned to neutral.

4，9

Parameter

Change

1. This is a safety fault caused by a change in certain 1311 parameter

Fault

settings so that the vehicle will not operate until KSI is cycled. For

example, if a user changes the Throttle Type this fault will appear and

require cycling KSI before the vehicle can operate.

6，8

VCL Runtime Error

1. VCL code encountered a runtime VCL error.

2. See 1311 menu Monitor » Controller: VCL Error Module and VCL

Error. This error can then be compared to the runtime VCL module ID and

error code definitions found in the specific OS system information file.

6，9

External Supply Out of

1. External load on the 5V and 12V supplies draws either too much or too

Range

little current.

2. Fault Checking Menu parameters Ext Supply Max and Ext Supply Min

are mis-tuned.

3. See 1311 menu Monitor » Outputs: Ext Supply Current.

CODE

PROGRAMMER

POSSIBLE CAUSE

LCD DISPLAY

7，1

OS General

1. Internal controller fault.

7，2

PDO Timeout

1. Time between CAN PDO messages received exceeded the PDO

Timeout Period.

7，3

Stall Detect

1. Stalled motor.

2. Motor encoder failure.

3. Bad crimps or faulty wiring.

4. Problems with power supply for the motor encoder.

5. See 1311 menu Monitor » Motor: Motor RPM.

8，7

Motor

1. Motor characterization failed during the motor characterization process.

Characterization Fault

8，8

Encoder

1. Encoder characterization failed during the motor characterization

Characterization Fault

process.

2. Motor encoder pulse rate is not a standard value (32, 48, 64, 80 ppr).

8，9

Motor Type Fault

1. The Motor type parameter value is out of range.

9，2

EM Brake Failed to

1. Vehicle movement sensed after the EM Brake has been commanded to

Set

set.

2. EM Brake will not hold the motor from rotating.

9，3

Limited

Operating

1. Limited Operating Strategy (LOS) control mode has been activated, as

Strategy（LOS）

a result of either an Encoder Fault (Code 36) or a Stall Detect Fault (Code

73).

2. Motor encoder failure.

3. Bad crimps or faulty wiring.

4. Vehicle is stalled.

9，4

Emer Rev Timeout

1. Emergency Reverse was activated and concluded because the EMR

Timeout timer has expired.

2. The emergency reverse input is stuck On.

Lifting (pump) controller error code table is the same as that of CPD10-30J.

CPD10/15/18/20/25/30/35J C2、CPD40/45/50J C2 EC ERROR CODE TABLE

Lifting (pump) controller error code table is the same as that of CPD10-30J C1

Towing controller error code table is the same as that of CPD10-30J C1

6.3 CPD10/15/20/25/30J D1 fork

6.3.1 Summarize

INMOTION company procreates controller ，adopt international advanced closed loop system and

advanced control technique。Designing large screen instrument，can clear display ―electric quantity‖、

―speed‖、―total time of run ‖，―work time of drive ‖，―work time of lift ‖and so on information。

Designation adopt code plus character manner，increase maintain efficiency。It also through meter

check periphery component to come true function of handset

(1) Actuating motor

Actuating motor adopt three-phase alternating current frequency conversion electromotor，increase

conversion efficiency，not have commentator brush in order not to maintenance 。

(2) Lift motor

Lift motor adopt three-phase alternating electromotor ，increase conversion efficiency，not have

commentator brush in order not to maintenance.

(3) Safety & protection features

① Reverse Polarity of the battery

② Connection errors

③ All inputs are protected against connections errors.

④ Current overload protection

⑤ It have detecting element，control peak current.

⑥ Thermal protection

If the controller temperature exceeds 85°C, the maximum current reduces in proportion to the thermal

increase. The temperature can never exceed 115

If the electric machinery temperature exceeds 145°C, the maximum current reduces in proportion to the

thermal increase. The temperature can never exceed 165

⑦ Low Battery charge

When the battery charge is low, the maximum current is reduced proportionally to the battery

discharge.

⑧ External Agents

Electric control is hermetical .The chopper is protected against dust and spray of liquid to economy.

⑨ Protection against accidental Start Up

A precise sequence of operations is necessary before the machine will start. Operation cannot

commence if these operations are not carried out correctly. Requests for drive must be made after

closing the Key Switch.

(4) Operational features

① Feedback control system make the vehicle speed follow accelerator ，whether low speed or not

high speed easy control .

② Two archives speed and acceleration design ，can apply to most situation.

③ Regeneration technology make change direction of fork even smooth。

④ Three regenerative braking mode ：

A、acceleration pedal part release appear regenerative braking，

B direction reverse regenerative braking，

C、 ramp downslide appear regenerative braking，

Except increase security drive，reclaim part of electric energy，prolong work time of every

time .

⑤ Control speed during downgrade： speed lie on accelerator 。if speed exceed set point，controller

may automatic braking，this give optimal ramp

Notice:

1 .Maintain electric control ，must first cut off electrical source，then hold 10-100ohmic resistance

join controller anode and cathode，release residual voltage in the capacitor, or else you may meet

tip-and-run danger.

2.Magnetic and radiation have some effect to inverter，long time effect may mangle controller, So

need apart form magnetic and radiation.

6.3.2 Error code

(1) Errors detected by VMC20

Code.

Source

Condition

When

Tract

Main

Reset

Remark

101

Switch startup error

ACCEL switch active at startup

KEY→ON

OFF

ACC SWITCH=OFF

Traction setspeed=0

102

Switch startup error

FW|REV switch active at startup

KEY→ON

OFF

FW=REV= OFF

Traction setspeed=0

103

Direction

switch

FW and REV ON at the same time

KEY=ON

OFF

KEY=OFF

Traction setspeed=0

error

104

Accel pot error

Pot voltage > 95% or Pot voltage <

KEY=ON

KEY=OFF

Traction setspeed=0

5% of VX_out

105

Accel switch error

Voltage > 30% when ACC switch

KEY=ON

KEY=OFF

Traction setspeed=0

is not active

107

Battery

under

48V:Less than 28.2V/.8s

KEY=ON

OFF

KEY=OFF

Detected by VMC20, not by ACS.

voltage

36V: Less than 24.8V/.8s

108

ACS under voltage

Voltage < limit (Parameter) for

KEY=ON

OFF

KEY=OFF

Detected by VMC20, not by ACS

more than 0.8sec

109

Battery over voltage

More than 65V/0.8s

KEY=ON

OFF

KEY=OFF

Detected by VMC20, not by ACS.

110

ACS over voltage

Voltage > limit (Parameter) for

KEY=ON

OFF

KEY=OFF

Detected by VMC20, not by ACS

more than 0.8sec

111

Communication

See 5.2.1.

KEY=ON

OFF

KEY=OFF

Traction setspeed=0

error

KEY=OFF

Only happens at the place where the

112

PM brush wear

wear and tearsensor = ON

KEY=ON

option sensor install.

KEY=OFF

Only happens at the place where the

113

PM thermal

PMheat sensor = ON

KEY=ON

option sensor install.

OFF

Charge a battery.

114

Battery low voltage

batteryLED = ON

KEY=ON

OFF

KEY=OFF

Connect with the engineer of Danaher

115

Startup error

Startup interior error

KEY=ON

(2) Errors detected by drive ACS (EMCY)

Code

Source

Condition

When

Tract

Main

Reset

Remark

Short circuit

ACS is shorted or motor terminals

KEY=ON

ACS may be damaged if short

251

OFF

KEY=OFF

are shorted

circuit is internal.

252

ACS over temperature

ACS hs temp > 115 degC

KEY=ON

OFF

KEY=OFF

Motor

over

Motor temp > 185 degC

KEY=ON

253

OFF

KEY=OFF

temperature

ACS current sensor

ACS current sensor error

KEY→ON

ACS must be repaired

254

OFF

KEY=OFF

error

Charging timeout

ACS capacitors are not charged

KEY→ON

Check charging circuit

255

OFF

KEY=OFF

within 10sec from power on

ACS no response

ACS does not respond at startup

KEY=ON

Check CAN bus wiring.

256

OFF

KEY=OFF

ACS PDO timeout

ACS CAN open timeout (detected

KEY=ON

Check CAN bus wiring.

257

OFF

KEY=OFF

by VMC20)

ACS SDO error

ACS SDO error (wrong SW

KEY=ON

Check SW version

258

OFF

KEY=OFF

version)

CANopen timeout

ACS CAN open timeout (detected

KEY=ON

Check CAN bus wiring

259

OFF

KEY=OFF

by VMC20)

ACS low voltage trip

ACS voltage <15V

KEY=ON

Instantaneous voltage

260

OFF

KEY=OFF

ACS high voltage trip

ACS voltage > 68V (software)

KEY=ON

Instantaneous voltage

261

OFF

KEY=OFF

ACS high voltage trip

ACS voltage >68V (hardware)

KEY=ON

Instantaneous voltage

262

OFF

KEY=OFF

ACS PCB temp > 115 ℃

263

ACS PCB temp trip

KEY=ON

OFF

KEY=OFF

(only GEN4，GEN5not )

Other urgency instance from

264

Other error

KEY=ON

OFF

KEY=OFF

ACS

(3)Errors detected by drive ACS (Warning)

Code

Source

Condition

When

Tract

Main

Reset

Remark

ACS low temp warning

ACS heat sink temp < -20 ℃

KEY=ON

KEY=OFF or Heat

Lowest Accel will be used.

201

sink temp normal

ACS high temp warning

ACS heat sink temp > 85 ℃

KEY=ON

KEY=OFF or Heat

Lowest Accel will be used.

202

sink temp normal

203

Motor high temp warning

Motor temp > 145 ℃

KEY=ON

KEY=OFF

Lowest Accel will be used.

Heat sink temp sensor error

ACS heat sink temp

KEY=ON

KEY=OFF

Lowest Accel will be used.

204

sensor error

205

Motor low temp warning

Motor temp < -50 ℃

KEY=ON

KEY=OFF

Lowest Accel will be used.

Motor temp sensor error

Motor temp sensor

KEY=ON

KEY=OFF or sensor

Lowest Accel will be used.

206

not connected or short circuit

connected

Speed feedback sensor error

Speed feedback sensor

KEY=ON

KEY=OFF or sensor

ACS can not control speed

207

not connected / short circuit

connected

correctly. No driving allowed.

ACS high voltage warning

ACS voltage > 68V

KEY=ON

KEY=OFF or voltage

Lowest Accel will be used.

208

back to normal

ACS low voltage warning

ACS voltage < 22.5V

KEY=ON

KEY=OFF or voltage

Lowest Accel will be used.

209

back to normal

ACS default values loaded

Default parameters are used

KEY=ON

KEY=OFF

Turn the key s witch off and on again.

210

in ACS

Power reduce

Power is reduced (by

KEY=ON

KEY=OFF

211

some warning condition)

Checksum error

Calibration parameter

KEY=ON

KEY=OFF

212

checksum error

213

PCB temp <-20 ℃

KEY=ON

KEY=OFF

PCB low temp warning

(onlyGEN4，GEN5 not )

PCB temp > 100 ℃

214

PCB high temp warning

KEY=ON

KEY=OFF

(only GEN4，GEN5 not )

PCB temperature sensor error

215

PCB sensor error

KEY=ON

KEY=OFF

(only GEN4，GEN5 not )

216

Current sensor default error

Current check default error

KEY=ON

KEY=OFF

(4)Errors detected by pump ACS (EMCY)

Code

Source

Condition

When

Tract

Main

Reset

Remark

351

Short circuit

ACS is shorted or motor terminals

KEY=ON

OFF

KEY=OFF

ACS may be damaged if short

are shorted

circuit is internal.

352

ACS

over

ACS hs temp > 115 ℃

KEY=ON

OFF

KEY=OFF

See 1.2.2.1

temjperature

353

Motor

over

Motor temp > 185 ℃

KEY=ON

OFF

KEY=OFF

See 1.2.2.2

temperature

354

ACS current sensor

ACS current sensor error

KEY→ON

OFF

KEY=OFF

ACS must be repaired

error

355

Charging timeout

ACS capacitors are not charged

KEY→ON

OFF

KEY=OFF

Check charging circuit

within 10sec from power on

356

ACS no response

ACS does not respond at startup

KEY=ON

OFF

KEY=OFF

Check CAN bus wiring.

357

ACS PDO timeout

ACS CAN open timeout (detected

KEY=ON

OFF

KEY=OFF

Check CAN bus wiring.

by VMC20)

358

ACS SDO error

ACS SDO error (wrong SW

KEY=ON

OFF

KEY=OFF

Check SW version

version)

359

CANopen timeout

ACS CAN open timeout (detected

KEY=ON

OFF

KEY=OFF

Check CAN bus wiring

by VMC20)

360

ACS low voltage trip

ACS voltage <15V

KEY=ON

OFF

KEY=OFF

Instantaneous voltage

361

ACS high voltage

ACS voltage > 68V (software)

KEY=ON

OFF

KEY=OFF

Instantaneous voltage

trip

362

ACS high voltage

ACS voltage >68V (hardware)

KEY=ON

OFF

KEY=OFF

Instantaneous voltage

trip

363

ACS PCB temp trip

ACS PCB temperature > 115 ℃

KEY=ON

OFF

KEY=OFF

(none for GEN4，GEN5 only)

364

Other error

KEY=ON

OFF

KEY=OFF

Any other EMCY form ACS.

ACS low temp

ACS heat sink temp < -20 ℃

KEY=ON

KEY=OFF or Heat

Lowest Accel will be used.

301

warning

sink temp normal

ACS high temp

ACS heat sink temp > 85 ℃

KEY=ON

.KEY=OFF or Heat

Lowest Accel will be used

302

warning

sink temp normal

(5)Errors detected by pump ACS (Warning)

Code

Source

Condition

When

Tract

Main

Reset

Remark

Motor

high

temp

Motor temp > 145 ℃

KEY=ON

KEY=OFF

See 1.2.2.2 Lowest Accel will

303

warning

be used.

Heat sink temp sensor

ACS heat sink temp sensor

KEY=ON

KEY=OFF

304

error

Motor low temp warning

Motor temp < -50 ℃

KEY=ON

KEY=OFF

See 1.2.2.2 Lowest Accel will

305

be used.

Motor temp sensor error

Motor temp sensor not

KEY=ON

KEY=OFF or sensor

306

connected or short circuit

connected

Speed feedback sensor

Speed feedback sensor not

KEY=ON

KEY=OFF or sensor

ACS can not control speed

307

error

connected / short circuit

connected

correctly. No driving allowed.

ACS

high

voltage

ACS voltage > 68V

KEY=ON

KEY=OFF

Lowest Accel will be used.

308

warning

voltage back

normal

ACS

low

voltage

ACS voltage < 22.5V

KEY=ON

KEY=OFF

Lowest Accel will be used.

309

warning

voltage back

normal

ACS default values

Default parameters are used in

KEY=ON

KEY=OFF

Turn the key switch off and on

310

loaded

ACS

again.

Power reduce

Power is reduced (by some

KEY=ON

KEY=OFF

311

warning condition)

Checksum error

Calibration

parameter

KEY=ON

KEY=OFF

312

checksum error

PCB temperature <-20 ℃

KEY=OFF

313

PCB low temp warning

KEY=ON

(only GEN4，GEN5not )

PCB temperature

100

℃

KEY=OFF

314

PCB high temp warning

KEY=ON

(only GEN4，GEN5 not )

PCB temperature sensor error

KEY=OFF

315

PCB sensor error

KEY=ON

(only GEN4，GEN5 not )

Current sensor default

316

Current check default error

KEY=ON

KEY=OFF

error

FOREWORD

Thanks for you purchasing our J series battery forklift truck.

Four wheel counterbalanced battery forklift truck is our company‟s new product. It has the character of

small turning radius, beautiful shape, small dimensions, low gravity, good stability, superior performance.

This operation manual is the explanations that how to use 1-5tJ series forklift truck correctly. It will instruct

you how to operate safety and precautionary maintenance. To ensure safety and exert the truck‟s potential,

all the personnel that in charge of operation, maintenance and management must read this manual

thoroughly before starting work with the forklift.

As the improvements of products of our company, maybe there are some differs between this operation

manual with your forklift truck.

If you have any questions please keep touches with HANGCHA GROUP CO., LTD. sales department or

let the agents know.

Tow electric

Rise electric

Rated capacity（t）/

Truck model

control

load centre distance（mm）

CPD10/15/18/20/25/30J

1244(CURTIS)

EVC255(CURTIS)

1.0/500,1.5/500,1.8/500,2.0/500,

2.5/500,3/500

CPD10/15/18/20/25/30J D1

ACS(Danaher)

ACS((Danaher)

1.0/500,1.5/500,1.8/500,2.0/500,

CPD10/15/18/20/25/30/35J C1

1238(CURTIS)

EVC255(CURTIS)

2.5/500,3/500,3.5/300

1.0/500,1.5/500,1.8/500,2.0/500,

CPD10/15/18/20/25/30/35J C2

1238(CURTIS)

1236(CURTIS)

2.5/500,3/500,3.5/300

CPD40/45/50J D1

ACS(Danaher)

4.0/500,4.5/500,5.0/500

CPD40/45/50J C2

1238(CURTIS)

4.0/500,4.5/500,5.0/500

©Dec. 2010 5^th edition HANGCHA GROUP CO., LTD.

CONTENT

Foreword

1. Name of main parts or component

2.Instrument and Controls

Meter Panel

Controls

3.Body and Others

4.Safety instructions

5.The structure and stability of truck

6.Running-in of the new truck

7.Daily maintenance

8.Driving and operation

Driving

Traveling

Turning

Stopping or parking

Stacking load

Un-stacking load

Check after operation

9.Deposit

10.Storage battery

The Automatic Watering System of the Forklift Battery

11.Maintenance summarization

Preventive maintenance schedule

Replace the key safe parts termly

Table for bolt‟s tight torque

Table for oil used in the truck

12.Truck‟s convey, lifting, towing

13.Parameters

14.Scutcheon

15.The use, assembly and safe rules of attachment

16.Related safety instruction and standard

17.Maintenance record

gradient and so on is much higher. It is

Meter Panel

applied for transporting mass of good in

CPD10/15/18/20/25/30/35JC1

short time and climbing big gradient slop，

CPD10/15/18/20/25/30/35JC2

but it costs more energy，so the mode will not be

used in normal state except emergency.

CPD10/15/18/20/25/30J

Mode P is power mode. All kinds of

CPD40/45/50J C2

index are lower than that of super mode. It is

applied for the case of long distance

transporting and needing higher power or

speed.

Mode E is economical mode. All the

parameters are optimized. Working in this

mode can save power so it is applied for a

long time work after charging, and it is

suggested to work in this mode in normal

work-time.

Mode SPE is safe mode. Thus the max

vehicle speed is limited to about 7km/h. It is

applied for working in busy storage and

cabined room.

A、Battery warning

Notice: the default mode is mode E. after

As the following diagram shows, from

power cutting every time, the work mode

the left to the right, the battery decreases

resets to mode E no matter which mode it is

from full state to the only one case, which

before power cutting, but the switch key is

represents that the battery leaves only 20%.

still in the mode before turn off.

Thus the whole battery indicator bar will

twinkle, and the state indicator lamp will be

bright, now please stop working and charge

immediately.

The mode can be switched through the

mode switch button (G) among the mode of

S, P, E, SPE, as the above diagram shows.

C、Parking brake indicator lamp

Notice：Charging in time is very important,

otherwise it will affect the lift-span of

battery！

B、Mode indication

When using the parking brake, the lamp will

As the diagram shows, the pictures

be bright.

from the left to the right represent the mode

of S, P, E, SPE respectively；

Mode S is super mode, thus the truck‟s

D、State indicator lamp

acceleration, deceleration rate, max climbing

When there is something wrong with

the electrical controller, or operate

improperly, the battery is in lower power,

the lamp will be bright and twinkles.

E、Error code display area

Display the error code of electrical

controller.

Notice：“TRAVEL” is the error code of tow

electrical controller, “HYD” is the error

code of pump controller. “TRAVEL OK”

means it works without error。

Notice： the error code of tow electrical

controller refers to the appendix.

F、Work-time accumulate timer

When the truck key switch turns on, the

left hour timer will start to time. The

minimal resolution is 10% of an hour, the

other two hour timers are not used.

CPD10/15/20/25/30/35J D1

SPEED

km/h

BAT%

Low battery warning (C)

When battery quantity is lower than 20%

of maximum capacity, the indicator lights

are on, at the same time, buzzer beep.

When LED shows no power, please

k as possible.

Communicate indicator (A)

Speed limited indicator

(D)

When this lamp lights, it meanings the

truck working at low speed mode. The

maximum speed of truck decreased.

Error indicator (B)

Press button 1, you can switch the high

When operation is wrong or the truck is

will display on the

ndicator lights on.

Accelerate indicator (E)

)

When this lamp lights

o use for operator.

truck working at low ac

The maximum acceler

ou can

low acc

operator

Parking brake indicator (F)

When pulling on the parking brake le

T IME

28H

B A

CT TIM

Speed limited button (H)

tch the high speed

Push the button once again, it switch to

speed display mode.

Dashboard display LED (M)

When turn on the key switch, the system

will self-diagnose, the lamp will lights on

one by one. After self-diagnose, LED

will display truck speed and battery

capacity. You can know your truck‟s

working condition through the LED

dashboard.

Key switch

The key switch has two “on/ off”

position, you should push the Direction

switch lever to neutral and loose the

accelerator pedal, then turning the key

switch to “on” position clockwise.

Caution!

Rear big lamp switch (optional)

1. Turning the key switch “on” does not

Rear big lamp switch (push\pull) has

make the forklift truck move, if the

only one shift.

Direction switch lever is not in the neutral

Connector

battery

Far light

position or the accelerator pedal is pushing.

Position

2. Error code maybe appear, don‟t worry

about it.

3. The Direction switch lever should be

× Means connected

returned to neutral and move you foot from

Caution!

the accelerator pedal. Then the truck can be

This light does not relate to key switch

operated.

position, so please don‟t forget to turn off

Then the error code should be

the rear big lamp when you leave the

disappeared.

truck.

Horn button [13]

Fuse box

Press the rubber cover at the center of

J\JC1\JC2 Series

steering wheel to sound horn. The horn

sounds even when the key switch is in

the “off” position.

Combined light switch [9]

This combined light switch is composed

of turning light switch and big/small

lamp switch. Turning light indicates the

traveling direction. When turn on the

switch, the lamp flashes.

Forward

Left turning lamp flashes

Neutral

Lamp goes off

1st is a diode preventing from connecting

Backward

Right turning lamp flashes

in reverse.

2nd is a control circuit fuse (10A).

Caution!

3rd and 4th are fuses for light and horn

The turn signal lever does not

circuit. (10A respectively)

automatically return to the neutral

5th is light fuse 10A.

position. Reset it by your hand.

6th is spare fuse 10A.

Big/small lamp switch has two shifts.

JD1 系列

First shift small lamp lights on; second

1st is control circuit10A.

shift big and small lamp both light up.

2nd is main contact circuit fuse 10A.

Emergency disconnect switch [4]

3rd is instrument fuse 10A.

4th and 5th is light fuse 10A.

When happen emergency, presses down

6th is spare fuse 10A.

the emergency disconnect switch, and

then the main power of the truck will be

Caution!

When replace a new fuse, please choose the

cut off, the truck stops working.

same capacity fuse of the old one.

Caution!

Please don‟t use the emergency

disconnect switch to substitute the

function of key switch.

pressed, the forklift trucks moved

Controls

forward. When the lever is pushed

Steering wheel [1]

backward, the forklift trucks moved

The steering hand-wheel is operated

backward.

in the conventional manner, that is, when

Caution!

the wheel is turn right, the truck will turn

While traveling, if change the

to the right; when the wheel is turn left,

Forward- Reverse lever, electric braking

the truck will turn to the left. The steer

will operate，speed will lower until stop，

wheels are located at the rear of the truck.

then travel to the opposite direction.

These cause the rear of the truck to swing

out when a turn is made.

Warning!

Turning the key switch “on” does not

This truck is provided with the

make the forklift truck move, if the

power steering, so heavy hand-wheel

Forward-Reverse lever is not in the

operation is caused when the steering

neutral position or the accelerator pedal

motor comes to a stall. To put the power

is being pressed. In this case, the

steering in operation again, restart the

Forward-Reverse lever should be

steering motor without delay.

returned to neutral and move you foot

from the accelerator pedal. Then the

Parking brake lever [3]

truck can be operated.

Use this parking brake lever to park

the lift truck. And the parking brakes are

applied on the front two wheels by

Lifting lever [10]

pulling up on this lever. To release the

parking brakes, move the lever forwards.

There is a micro switch at the left

side of the parking brake lever, tense the

lever makes running invalid.

For the truck of CE: if you leave the seat

without tensing the lever, it will warn and

remind you to tense the lever.

Warning!

If parking on a grade is unavoidable, be sure to

block the wheel.

The forks can be raised or fell by

Forward-reverse lever [2]

pulling backwards or pushing the lever.

Lifting speed can be controlled by tilt

The forward-reverse lever is used for

backwards angle of lever and the

switching

between forward

and

lowering speed can be controlled by tilt

backward moves. When the lever is

forwards angle of the lever.

pushed forward and accelerator pedal

Tilting lever [11]

Caution!

Loosen the accelerator pedal when truck

is working, truck can make soft brake

The mast can be tilted by operation

of this tilt lever. Pulling on this lever

backwards will tilt the mast backwards,

and pushing it forwards will tilt the mast

forwards. The tilt speed can be controlled

by tilt angle of the lever.

Caution!

The tilt lock mechanism built in the

hydraulic control valve does not allow

the mast to tilt forwards while the

electricity is being shut down even if the

tilt lever is pushed forwards.

Pedals

Brake pedal [6]

Press this pedal to slow or stop the

truck. At the same time, the brake light

comes on.

Caution!

No permitted to press the brake pedal and

the accelerator pedal at same time,

otherwise, it is harmful to the traveling

motor.

Accelerator pedal [7]

As the accelerator pedal is slowly

pressed, the drive motor start turning and

the forklift truck will start to move.

According to the force applied to the

pedal, the speed is adjusted with not

steps.

Warning!

Before open the key switch to press

the accelerator pedal, the more function

digital indicator shall show alarm

information. Then you must release the

accelerator pedal.

the storage batteries.

3.Body and Others

You can lift up the hood with little

Seat

effort with an aid of hood damper. To

Adjust operator‟ seat to the position

lock the hood, push down on the front of

hood until it covered.

where is comfortable for you and

provides

easy

controls.

Before

Caution!

Be careful do not to catch you fingers in

proceeding with work, adjust operator‟s

the hood when closing it.

seat and make sure that it is securely

Depress the spring insurance before you close

locked. Adjust the operator‟ weight

the hood, then press the head of the hood.

through rock- suspends system level. The

rear of the seat is adjustable.

Left & Right battery cover hood

Seat switch (only for trucks exporting

The battery is covered hood, one left

to Europe or option)

and one right. When you want to take off

For the safe of truck, when you leave

the hood, you should take off the knob at

the seat longer than 5 seconds, the truck

first.

will stop traveling.

Fork stopper

Safety belt

Please keep back and waist close to

seat as far as possible, and fix safety belt

at the same time.

Inspect whether bolts fixed belt are

loose or not. Do not use belt with a knot.

Do not make belt press on stiff or fragile

things, and do not make belt attrite with

sharp things to avoid wearing. Do not

make seat backrest too be tilted;

otherwise safety belt may not extend

correctly.

Do not remove any part of belt at

will. Please often inspect the belt used

Fork stoppers are locked the forks in

frequently, if found any abnormal,

position. To adjust fork spacing, pull up

replace it at once. And the life for use is

fork stoppers, turn 90°and shift the forks

3-5 years, scrap it ahead of schedule if

to the desired position. The fork spacing

found any abnormal.

should be adjusting according to loads to

There is a safety belt on the seat,

be handled.

before you operate the forklift truck,

please fasten the seat belt to protect

Warning!

yourself.

The forks should

set

Overhead safe guard

symmetrically to machine centerline and

The overhead guard used is strong

fork stoppers should always be locked

enough to meet safety standard, and

again.

protects the operator from falling

There are one gap on the below

materials. The top gap is used to lift the

beam. It is used to attach goods.

batteries. It is forbidden for use a truck

It is forbidden to lock the fork on the gap

that does not with safeguard.

position, to prevent the fork fall off from

the gap.

In the middle of the above beam, a

Hood

bolt used to prevent fork works here.

The hood can be swung up fully to

Please change the bolt as soon as it is

provide easy examining and maintenance of

damaged.

Change fork

Steering column tilting angle adjuster

Take down the old fork: Firstly,

locate the fork to the middle, decline it to

the ground and make the mast forward,

then operate the truck traveling backward,

the fork will be taken down.

Change new fork: Firstly, make the

fork dead against the truck and forklift‟s

mast to the bottom, then operate the truck

traveling forward, aim at the two gaps

and beams, and raise the mast. Adjust the

position of the fork.

Safety step and safety grip

The tilting angle of the steering

The safely steps are provided on

column is adjustable to suit individual

both side of the truck body. The safely

operators. Turn the hand lever upward to

grip is provided on the front left pillar of

release the steering column and locked

the overhead guard. Use the safely step

by turning it downward.

and safely grip when mounting and

Hydraulic oil reservoir cap

dismounting the truck.

The hydraulic oil reservoir cap is

Brake fluid reservoir cup

located at the right rear end, below the

The brake fluid reservoir cup is

battery hood; open the right side battery

located at the meter board.

hood when adding oil. After fill in clean

hydraulic fluid, tighten lock the cap.

Caution!

Air leakage plug

The brake fluid is poisonous, be

careful do not drop down. When add

There is an air leakage plug on the

brake fluid, be careful do not let dirt and

oil tank to let air in the tank goes out.

other thing drop into reservoir cup.

You‟d better often check the plug and see

whether been jammed.

Chair disconnecting switch

Head lights and combination lights

When the operator leaves seat, this

Two headlights and combination

switch cut off, and the power of truck is

lights (turn signal, show width lamp) are

cut off.

installed at the front side of the truck.

Take care of the lights, and wipe dirt, if

Safety seat belt (for the trucks

any, and replace any damaged light

exporting to Europe or option)

immediately.

There is a safety belt on the seat,

Rear combination lights

before you operate the forklift truck,

please fasten the seat belt to protect

The combination lights at the rear

yourself.

side serve as turn signal, show width

lamp, brake lamp, and back-up lamp. Pay

Rear big lamp (for the trucks

attention to keep them from being

exporting to Europe or option)

damaged or covered with dust, if any,

The rear big lamp is set on the

clean or replace immediately.

safeguard. If it is broken, please replace a

new one at once.

4.Safety instructions

1. Only trained and authorized

operator shall be permitted to operate the

truck.

4. Operator must wear helmet, safety

shoes and work clothes.

Because there will bring

exploding gas in the bosom of the battery,

2. Inspect the truck at periodic

prohibit any flame nearby it absolutely.

intervals for oil or water leak,

·Do not let any tools close the two

deformation, lousiness, etc. If neglected,

terminal of the battery to avoid spark or

short life of components will be caused

short circuit.

and in the worst case a fatal accident

6. The movement road of forklift

would occur.

should be solid and smooth coagulation

·make sure having replaced good

road or similar to the road suitable for

parts during periodic check.

vehicle. Recheck the state of working

·Wipe off oil, grease or water from the

ground.

floor board and foot and hand controls, if

The considered climatic conditions

any.

when the forklift designs are:

Strictly prohibit smoking and spark

Temperature

20℃-50℃; the wind

nearby the storage battery when checking

speed does not surpass 5m/s; the air

it.

relative humidity is not bigger than 90%

·If maintenance on high position,

(temperature 20℃). The forklift is not

such as mast, front and rear lamp, please

suitable in the flammable explosive

be careful to prevent fall down or be

working conditions.

clamped.

7. Never mount or dismount the

·Be careful do not be scalded when

moving truck. Use the safety step(s) and

inspect the motor, controller and etc.

safety grip facing the truck when

whatsoever in trouble, you must

mounting or dismounting the truck.

stop the forklift, hang a mark of “danger”

or “trouble” and take off the key, at the

same time inform the manager. Only

after the trouble is removed, you may use

the forklift.

If trouble occurs when lifting cargo,

to Climb or descend, or the storage

battery electrolyte, the hydraulic fluid,

the brake fluid has the revelation, please

organizes the personnel to repair

immediately.

8. Never attempt to work the

controls unless properly seated.

Before starting, adjust the seat so

you can get easy access to all hand and

foot control.

9. Before starting up, make sure that:

Please fasten seat bolts.

The parking brake lever is applied

securely.

15. Keep your mind on your work.

The forward-reverse lever is in

16. Keep your head, hands, arms,

neutral.

feet and legs within the confines of the

·Before staring, make sure no one is

operator‟s compartment. Never stretch

under, on and close to the truck.

out for any reason.

·Don‟t step the accelerate pedal or

control the lifting lever or tilting lever

before turning on power.

10. Operate the controls smoothly.

Avoid sudden stops or turns.

·It is dangerous to make a sharp

brake. Otherwise the truck has the

possibility of overturn.

11. Pay attention to the route of the

truck; be sure to make a wide sight.

12. Never allow other person(s) to

ride on the forks, pallets or on the truck.

17. The pallet and skid used should

13. Taking account of the shape and

be strong enough to endure the load.

material of loads to be handled, use a

Never use damaged or deformed ones.

proper attachment and tools.

18. We afford all type of attachment,

·Avoid hoisting the load, with wire

such as rotating roll clamp, bale clamp,

rope hung on the forks or attachment,

side shifter, and crane jib etc. You should

since the wire rope may slide off. If

refit the truck under ours license if you

needed, a qualified personnel for slinging

want. It is forbidden to refit it by

operation should perform, making use of

yourself.

a hook or crane arm attachment.

19. Safeguard protect you do not be

Take care not to protrude the forks

hurt by the goods fallen. Load bracket

out of the load. The protruded fork tips

protect you load goods smoothly. It is

may damage or turn over the adjacent

forbidden to use truck without safeguard

load.

or load bracket.

14. Know the rated capacity of your

20. It is forbidden to walk down the

lift truck and its attachment, if any, and

fork or the attachment.

never exceed it.

It is forbidden to walk up the fork or

·Do not use a man as an additional

stand on the fork.

counterweight. It‟s quite dangerous.

reverse tilt

when stacking and

un-stacking loads. Never tilt forward

unless load is over stack or at low lift

height.

·When stacking loads on a high

place, once make the mast vertical at a

height of 15 to 20 cm above the ground

and then lift the load farther. Never

attempt to tilt the mast beyond vertical

when the load is raised high.

To un-stack loads from a high place,

insert forks into the pallet and drive

backwards, then lower the load. Tilt the

mast backwards after lowering. Never

attempt to tilt the mast with the load

raised high.

21. It is forbidden to put your hands,

arms or head stretch between the mast

25. It is dangerous to travel with

and safeguard. Once clamped, the life

forks higher than appropriate position

has danger.

regardless of whether loaded or not.

It is forbidden to put your hands in

Keep the good traveling posture. (When

inner and outer mast.

traveling, the forks should be 15 to 30 cm

above the ground or floor and the mast

tilted backward)

·Do not operate the side shift

mechanism, if equipped, when the forks

are raised and loaded, since this will

cause the truck to be unbalanced.

22. The goods is liable to drop

26. Watch for branches, cables,

turning or passing rough road when it

doorways, or overhangs. Pay caution

departures the center. And the forklift

when working in congested areas.

may turn over more probably.

Slow down and sound horn at cross

aisles and other locations where vision is

23. Don‟t stack loads on forks in

restricted.

such a way that the top of loads exceeds

·When make a turn, be sure the

the load backrest height. If unavoidable,

speed of the truck is lower than the 1/3

make sure the load is fastened. When

max. of allowable speed.

handling bulky loads that restrict your

vision operate the truck in reverse or

have a guide. When lead by a guide,

make sure you understand hand, flag,

whistle or other signals. When handling

long loads such as pipe, lumber etc or in

the case of the Large-sized model, or

operate with long attachment, be

extremely careful of load end swing at

corners or in narrow aisles. Be alert for

27. Affirm keeping some distance

others.

from roadside and flat roof.

24. Use minimum forward and

28. Before driving over a dock-board

31. Never lift loads with the truck

or bridge-plate, be sure that it is properly

inclined. Avoid loading work on a grade.

secured and strong enough to sustain the

weigh.

32. Never permit anyone to stand or

walk under upraised forks or other

29. When operating loaded truck,

attachments if machine is so equipped. If

have the rear end of your machine

unavoidable, use a safety stand or block

pointed downhill.

to prevent a possibility of fork

·When operating unloaded truck,

attachments falling down or moving

have the rear end of your machine

unexpectedly.

pointed upgrade.

Do not make a turn on the grade, in

33. Inspect the surface over which

order to avoid overturn.

you will run. Look for holes, drop-offs,

obstacles, and look for rough spots. Look

for anything that might cause you to lose

control, bog down or upset.

·Clear away trash and debris. Pick up

anything that might puncture a tire or let

the load lose balance.

Slow down for wet and slippery

roads. Stay away from the edge of the

road. If unavoidable, pay more attention.

·Do not operate the truck when the

weather is execrable, such as windy,

thunder storm, snow and etc. Especially

when wind speed is higher than 5m/s,

don‟t operate the truck outside.

34．An accumulator is required for

controller. Forbid to touch within B+ and

B- to prevent from wounding by

electricity. Before checking or cleaning,

please connect loads (contactor circuit or

horn for example) between B+ and B-

first to discharge for capacitor of

30.the goods is liable to drop turning or

controller.

passing rough road when it departures the

center. And the forklift may turn over more

35. Pulling the hand brake when

probably.

parking on flat. If necessarily parking on

ramp, you should place the wedges under

wheels.

·Descending the fork to the ground

and keeping a little forward tilting, shut

off key switch and take off key.

Pull out the battery plug.

The parking place must be far away

from fireworks.

36. You can tow the forklift to the

load cargo.

safe place with towing pin when the

forklift can‟t run.

43. There are enough light at truck

·Don‟t tow the truck which steering

work ground. At night, open the head

system or brake system has been

lamp to collocate enough lamp-house.

damaged.

44. Only in the event that the truck

37. There is operating method and

manufacturer is no longer in business and

warning label on the truck. Please

there is no successor in the interest to the

operate the truck obey the rules on the

business, the user may arrange for a

label and this manual. Often inspect the

modification or alteration to a powered

nameplate, when damaged or lost please

industrial truck provided, however, that

replace it.

the user shall:

a) Arrange for the modification or

38. Fire extinguisher must be

alteration to be designed, tested and

prepared at working place. Users can

implemented by an engineer(s) expert in

select fire extinguisher along with truck,

industrial trucks and their safety;

and it usually is fixed on rear supported

b) Maintain a permanent record of

leg of safety shelf, it is easy to pick.

the design, test(s) and implementation of the

Driver and manager should be

modification or alteration;

familiar with the position and operation

c) Approve and make appropriate

of fire extinguisher.

changes to the capacity plate(s), decals,

tags and instruction handbook;

39. Please use stock when conveying

d) Affix a permanent and readily

little goods, it is forbidden to use fork

visible label to the truck stating the

directly.

manner in which the truck has been

modified or altered together with the date

40．The work road surface for forklift

of the modification or alteration, and the

should be stability and unknit, cement,

name and address of theorganisation that

blacktop or beton. If there are snow, ice,

accomplished the tasks.

water or other eyewinker, bar. Eliminate

all, then work. Otherwise the truck will

be out of control and lead the safety

accident.

41. Move the truck to the place which

respects traffic when it anchors. If the

reason is brake or turn system, move it

by a suitable truck (Reference the part of

truck move); Other reasons, use a suitable

truck to traipse, tie the cord outside of

truck. Please abide by the traffic

regulations when traipse the truck on

calzada.

42. After take-down the hood, water

tank cover board, overhead, backrest of

mast, unallowed to operate the truck or

5.The structure and stability of truck（Prevent the forklift to turn

over!）

It is very important for operator to know the truck‟s structure and relationship between

load and stability.

Caution

the structure of the truck

The basic structure of the truck is mast (include mast and

forks) and body (include tire).

The lift truck keeps the balance of weight between

the truck body and the load on the forks with the center

of the front wheels as a fulcrum when the rated

capacity load is placed in position.

Due care should be paid to the gravity center of

loads and forklift to maintain the stability of the truck.

Caution

Load center

There is difference in gravity because of the loads‟

shape, such as box, board and large roller. It is very

important to distinguish the difference of the gravity

center of loads for evaluating the truck‟s stability.

Warning!

If the truck will turn over, do not attempt to get out of the truck because the speed of

overturn is much faster than your speed. You should hold the steering wheel handle, stretch

your feet, and this practice will let you in the seats. Operator fastens the safety belt please.

Caution Gravity center and stability

The combined gravity center that is

composed of the forklift center and the load

gravity center determine the stability of lift

trucks.

When unloaded, the barycenter does not

change; when loaded, the barycenter is

determined by the truck and the load‟s center.

The barycenter is also determined by the

tilting and lifting of the mast.

The combined center is determined by these

factors:

Load‟s size, weight and shape

The lifting height

The tilting angle

The acceleration

The radius of turning

The road and grade‟s angle

The attachments

Caution! The stability zone of the barycenter

In order to make the truck stable, the combined

center must be in the triangle which is made up of

two points that the two front wheels attach ground

and the midpoint of the back axle.

If the combined center is in the front driving

axle, the two front wheels become two fulcrums,

the truck will overturn. If the combined center

departures the triangle, the trucks shall overturn in

the corresponding direction.

Caution

The max. load（weight and load center distance）

The load center distance is defined that: the

distance between the load center and the fork

carriage or the front of the fork carriage. The max.

load means the maximum load the truck can charge

at the normal load center distance. The relation

between the max. load and load center distance

shows on the capacity chart. You should reduce the

weight of load if the load center distance inclines to

the fork carriage.

！ Caution

Capacity chart

The chart given shows the relation between the

load center and the weight of loads.

Before loading, make sure that the load and the

load center distance in the range of capacity chart.

If the load‟s shape is complex, put the most

weightily part on the middle of the forks, and

close to the fork carriage.

！ Caution

Velocity and acceleration

One object will keep quiescence until force works on it. Also, a moving object will

keep moving until force works on it .This is just inertia.

According to inertia, when truck starts moving, one force works backwards, and when

truck stops moving, one force works forwards. So, it‟s dangerous to brake suddenly,

because it causes one large force works forwards, and it‟s easy to cause truck overturn or

load slide off.

When the forklift makes a turn, will exert a centrifugal force outward from the curve

center. This strength pushes forklift outwards and causes it to turn over. About stability

region is very small, so decelerate when turning. If the cargo transported at the high

position, it‟s easier to turn over.

6.Running-in of the new truck

We recommended operating the machine under light load conditions for the first stage

of operation to get the most from it. Especially the requirements given below should be

observed while the machine is in a stage of 100 hours of operation.

1. Must prevent the new battery from over discharging when early used. Usually should

recharge when discharging down to 20%.

2. Perform specified preventive maintenance services carefully and completely.

3. Avoid sudden stop, starts or turns.

4. Oil changes and lubrication are recommended to do earlier than specified.

5. Limited load is 70～80% of the rated load.

7.Daily maintenance

Warning!

The earnest complete maintenance, can

When using an air compressor, at first,

keep the forklift to be at the good status. And

adjust the air pressure of the compressor.

the safety of the truck is related with your

Otherwise it will cause a serious accident,

job and your life.

since the maximum pressure of compressor

Warning

higher than the pressure tire can bear.

except checking lights and operating

capability, you should shut off the key

Tire Pressure (GB/T2982-2001)

switch and pull out the plug before checking

electric system.

Driving

Turning wheel

Truck

prohibit operate forklift with trouble.

wheel

(rear wheel)

type

little trouble brings big accident.

(front wheel)

1-1.5t

860KPa

1000KPa

1. Inspect oil leakage: include hydraulic

1.8t

1000KPa

oil, electrolyte and brake fluid

Inspect connector of the oil pipe and

2-2.5t

850KPa

900 KPa

storage battery to see whether there is any

3.0t

850KPa

900KPa

leakage. Use your hand or eyes to inspect,

Forbid to use a flame.

3.5t

850KPa

900KPa

4-5t

930 KPa

860KPa

2. Inspect tire

Caution!

Turn the tire valve cap counter

clock-wise and move it. Using a tire pressure

Above for the pneumatic tire pressure, is not

gauge, measure the inflation pressure, and

suitable the solid tire.

adjusting it to the specified pressure, if

needed. After making sure there is no air

leakage from the tire valve, reinstall the cap.

Check that each tire does not get damaged at

the tread surface or side face. Make sure the

wheel felloe is not bended.

Warning!

Since the tires of forklift truck need have a

high inflation pressure to carry heavy loads,

even a small bending of rims or a little

damage at the tread surface could cause an

accident.

Warning!

All bolts and nuts should be screw tight

to the stipulation torque after the tire and the

wheel felloe was assembled, then charge is

allowed. Types have expansion energy after

changing, so the tire pressure does not

surpass the rating.

Please put the tire in a protection frame

or tie it with a iron chain when charging to

Tighten torque refers to <<Bolt tighten

prevent accident happening.

torque force table>>

3. Replace tire

Truck type

Front nut

Rear nut

When the tire is damaged, you should

1-1.8t

157-176 N.m

76-107 N.m

replace it in time. Use a jack to make the tire

just beyond ground, then put a wood block

2-3.5t

441-588N.m

157-176 N.m

under the chassis. Loosen nut ① or ④,

4-5t

441-588N.m

157-176 N.m

replace a new tire. Tighten the nut crossly

and symmetrically.

5. Check brake pedal

Step the brake pedal, check it for

4. Inspect the torque of hub nut

slowness or block. The proper brake distance

Check the torque of hub nut whether meet

is 2.5m when free load. Adjust the height of

the requirement.

pedal to 115～125mm. Adjust brake booster

①Hub nut

push rod clearance to 1-3mm. The brake

②Divided rim bolt (some trucks do not

lamp should be lighted when the brake pedal

have )

steps on 10-20mm.

③Driving axle bolt

④Rear hub nut

⑤Divided rim bolt

6. Check the parking brake lever

Driving wheel (front wheel, expect 1-1.5t)

The force of hand brake lever is adjusted by

the bolt on the top of lever. The force

increases clock-wise screwing, and decreases

counter lock-wise screw.

Caution

To step the brake pedal is helpful to tighten

or loose the hand brake lever.

7. Check accelerate pedal

5) Loose the cap of hydraulic oil, pull

The acceleration changes as the stroke

out dipstick

changes.

6) Set a plate under the chassis, then

loose the fuel drain plug, and put the old oil;

8. Brake fluid level check

7) Dispose the old oil according to local

Open the brake lubricated cap cover. Check

environmental protection laws;

the fluid level in the range allowed. If lack,

8) Twist the fuel drain plug, join the new

please add, and check if there is air mix into

hydraulic fluid, and inspect whether have a

the pipe.

leakage;

9) Start the truck, lifting for 3-5 times,

Caution

and tilting for 3-5 times;

Please use brake fluid with one type, do not

10) Add hydraulic oil to required scale.

mix.

·Don‟t spatter the brake oil onto the surface

11. Drivers seat adjustment

of paint otherwise the paint will be damaged.

Make sure the driver‟s seat is properly

·When adding fluid, due should be taken to

located. If not properly, shift the adjusting

prevent dirt or water from entering the

lever to the right and move the driver‟s seat

reservoir.

to a position which provides easy access to

all foot and hand controls. After adjustment,

shake the driver‟s seat a little to be sure that

9. Check hydraulic oil

it is securely locked. Adjust the weight.

Loose the cap of hydraulic oil inside of right

frame, pull out dipstick and check it if the oil

12. Check battery

level is between the scales. Add oil when

Check the battery whether be installed

lack.

firmly.

Check proportion of electrolyte. Refer

to “battery” section.

Check the terminal for loose or damage.

Otherwise it will be adjust or replace.

10. Replace hydraulic oil

Replace hydraulic oil once half year on

schedule.

1) Stop the truck on smooth ground;

2) Turn steering wheel right to the

bottom, and enable the fuel drain plug to

have the enough space;

Pull in the plug and close the hood.

3) Tilt mast backwards to the bottom, and

Turn on the key switch

fall the forks to the ground

4) Pull on the hand brake

13. Instrument check (include battery

and left chains are equal.

capacity and error diagnose)

③ Adjust the chain tension: loosen the

Refer to instrument section.

lock nut (1) and adjust the chain by nut (2),

then locked nut (1).

14.

Lifting lever, tilting lever,

attachment lever

Check the lifting lever, tilting lever and

attachment lever for looseness. Return

position well.

15.Mast

Check the mast and the forks to insure

that:

1) The fork does not have crack and

distortion.

Forks were installed

firmly and correctly.

2) Check the oil cylinder, oil pipes for

leakage.

3) Check the rotation of idler wheel

4) Check the mast for crack or

distortion

Lifting

lever,

tilting

lever,

attachment lever

Check the mast whether works normally,

18. Check steering system

whether have unusual sounds.

Turn the wheel right and left separately

to check steering system.

16. Mast lubrication

You should grease lubrication to the

19. Turn signal, horn and other lamp

orbit of mast on schedule base on

check

requirement.

Make sure that the turn signal operates

Adjust the lubricate schedule according

properly by pull/push turn signal switch.

to your working condition. Add times when

Make sure that the sound of horn is

busy.

properly by press the horn button

To coordinate forklift's operation,

Check the other lamp and back-up

grease lubrication to the guide pulley and in

buzzer.

outer upright mounting.

20. Battery maintenance

Refer to battery section.

17. Lift chain tension check

① Raise the fork about 10-15 cm above

21. Other

the ground vertically.

For instance, pay attention to abnormal

② Push the middle of the chain with the

noise.

thumb. Make sure the tension for the right

8.Driving and operation

backward.

! Warning

（6） Loosen the hand brake lever

Before operating the truck, check all controls

Step the brake pedal and push the

and warning devices for proper operation. If

any damage or fault is found, don‟t operate

hand brake lever to the front position.

truck until corrected.

Hold the steering wheel with your left

Driving

hand and attach your right hand.

（1） Open the cap, and insert the storage

Traveling

battery plug, then close the cap.

Step the accelerate pedal slowly, the

truck will travel forward or backward.

Decrease speed

Loosen the accelerate pedal slowly, the

truck will decelerate.

Warning:

Don‟t step the accelerate pedal and brake

（2） Set the direction switch to neutral

pedal at the same time.

position

（3） Turn on key switch

Caution:

Decelerate the truck in the situations

Hold the steering wheel with left

following:

hand and turn on the key switch with right

turning;

close the goods or pallet;

hand.

close the deposit area;

（4） Tilt back the mast

enter a narrow passage

the condition of road surface is bad.

Control the lifting lever to set the

Turning

bottom of the fork 150-200mm above the

Unlike general passenger-cars, the

ground. Control the tilting lever to fully

turning wheels are located at the rear of

tilt back the mast.

the truck. This cause the counterbalance

swing out when turning.

（5） Control direction lever

Slow down the truck and turn the

Forward ： Push the direction lever

steering wheel toward the side which you

are turning. The steering wheel should be

forward.

turned a bit earlier than as with the front

Backward：Pull the direction lever

wheel steering car.

be handled.

! Caution

The pallet should be evenly positioned

Drive the truck slowly and control the

across both forks.

steering wheel carefully, assure there is

Insert forks into the pallet as far as

enough space to steer.

possible.

To raise loads from the ground：

Stopping or parking

① Firstly, lift the forks 5 to 10 cm off

①Slow down and press the brake pedal to

the ground or floor and make sure loads lay

stop the truck.

stably.

② Place the shift lever in neutral.

② Then tilt the mast backwards fully

③ Pull up the parking brake lever.

and lift forks up to 15 to 20 cm off ground

④ Down the forks on the ground, tilt

then start running.

mast forwards fully.

·When handling bulky loads which restrict

⑤ Place the key switch in “OFF” to shut

your vision, operate the truck in reverse

off the battery. Remove the key and

except when climbing grades.

keep it.

Caution

·Don‟t dismount from the moving truck,

never jump from the truck.

·Don‟t parking the truck on the working

road.

The forks should be adjusted properly to

maintain the balance of load.

Place the truck right in front of the load to

Caution:

Stacking load

Decelerate the truck in the situations

following:

·When approaching the deposit area slow

turning;

down your truck.

close the goods or pallet;

Stop the truck right 30 cm far away from

close the deposit area;

enter a narrow passage

the position where your load is to be

the condition of road surface is bad.

deposited.

·Check the condition of the deposit area.

Un-stacking load

Tilt the mast forward until forks become

·When approaching the area where the

to horizontal. Raise forks until they are a

load is to be retrieved, slow down your

little higher than the deposit position.

truck.

·Move forward to place the load directly

Stop the truck 30 cm far from the load.

over the desired area and stop the truck.

·Check the condition of the load.

·Make sure your load is just over the

Tilt the mast forward until forks become

desired area. Slowly lower the load into

horizontal. Elevate forks up to the position

position. Make sure the load is securely

of the pallet.

stacked.

·Make sure forks are positioned properly

·Do necessary lift-tilt operations and then

to the pallet. Move forward slowly to

back away to make the forks leave loads.

insert forks into the pallet as far as

·After making sure the forks leave the load,

possible.

lower the forks to the basic position (15 to

Caution

20 cm off the ground).

If the forks are hard to be fully inserted,

Tilt the mast backwards.

use the following procedure: Move

！ Warning!

forward and insert 3/4 of the forks. Raise

·Never tilt the mast with loads upraised

the forks 5 to 10 cm and move backward

2m or more.

10 to 20 cm with the pallet

on the

·Don‟t leave or dismount from the truck

forks, and then fall the pallet to the stack.

when the load is raised high.

Move forward again to insert the forks

fully.

·Raise the forks 5 to 10 cm off the stack

·Check all around the truck to insure that

the path of travel is unobstructed and back

away slowly.

Lower forks to a height of 15 to 20 cm

above the ground. Tilt the mast backward

fully and move to the desired area.

Check after operation

Clean and check the truck after operation:

·Damage or leakage.

·Add grease if necessarily.

·Check the tire if it is damaged or inset

with foreign body.

·Check the wheel hub nut if it is loose.

·Check the height of electrolyte surface.

·If you haven‟t lift the fork to the max.

height in the day, you should lift it to the

max. height 2～3 times.

！ Caution

·If you find any trouble, must repair it in

time.

Prohibit operate the forklift before

repairing it completely

9.Deposit

！ Warning

Daily Depositing

a. The stow-wood must be single and

hard enough to support the truck.

①Park your truck at the area appointed,

and block the wheels to prevent

b. Don‟t use a stow-wood higher than

accidental roll.

300mm（11.81 inch）.

②Make sure the shift lever on neutral

c. Lift the truck to the height of

position.

placing on the stow-wood.

③Pull up the hand brake lever.

d. Place two same size stow-woods

④Shut off key switch and operate the lift

and tilt lever several times so that the

under the left and right sides of the truck.

inner pressure in the hydraulic tube will

e. After supporting the truck with

decrease.

stow-wood, swings the truck forward,

⑤Cramp out the electrical outlet.

backward, left and right, check its safety.

⑥Take out the key and deposit it in a safe

① Operate the forklift once a week,

position.

and be required to lift the forks to its max.

Deposit the truck for a long time

height many times .

On the basic of the “daily depositing”

② Check the proportion and the level

you should do these checks and

of electrolyte once a month

③ Charge the battery equally once a

maintenance additional:

month.

①Take out plug to prevent discharge and

place in shade.

②Brush antirust oil on those parts which

Working after long deposit

is exposed such as piston rod and axle

① Get rid of antirust oil.

easy-rusted.

③Cover breather hole and so on which

② Discharge the gear oil from driving

humidity easy to enter.

axle, decelerator box, and clean up the

④Cover the whole truck with mantle

internal of them. Add new oil.

⑤All lubrication points add the oil

③ Charge the battery then install it to

(grease).

truck, and do not forget to connect the

⑥Fill up the truck body and counter

down-lead.

weight with stow-wood to reduce

④ Check carefully before starting,

bearing of the two rear wheels.

include start, advance, and back off,

turning, lift, fall, tilt and so on.

·When electrolyte level is low，you must

10.Storage battery

add distilled water to the level appointed.

Attention for using battery:

1. No firing

Warning

Explosive gas can be produced in the

1. The shortage of the electrolyte will

internal of battery，smoking，flame and

cause the storage battery overheated,

sparkle ,each can easily cause battery

even cause the system part of storage

explosion.

battery and electric combustion.

2. Vitriol include in the electrolyte can

create burns, see doctor for emergency

treatment quickly if touch it un-carefully.

Splashing to the skin or eyes：wash with

water 15~20 minutes;

Splashing to the clothes ： take it off

immediately

·Careless drinking：Instead of plenty of

2. Protection against electric shock

water and milk.

3 Wearing glasses、rubber overshoes and

Warning

rubber glove.

·Battery has high voltage and energy.

·Do not bring short circuit.

Remaining clean battery

·Do not approach tools to the two poles of

Keep dryness and cleanness on the

the battery，which can cause the sparkle.

surface of battery .the poles for

connection are also dry and clean.

3. Correct wire connection

Operator must screw down the vent-cover

Not allowing instead anode of

of battery.

cathode，otherwise，resulting in sparkle or

burning or explosion.

Warning

1. Do not use dry cloth or fiber cloth to

4. Do not over-discharge

clean the battery，avoiding static to cause

If you use the energy of battery till the

the explosion.

forklift can‟t move, you will shorten its

2. Pull out battery plug.

working hours.

3. Cleaning with wet cloth.

·When the display of battery shows low

4. Wearing glasses、rubber overshoes and

capacity, please charge it quickly.

rubber glove.

5. Inspection for electrolyte

Forbidden to use the truck when the

electrolyte is shortage.

Inspection for electrolyte level every

week.

· Check connections whether there is

loosen, fasten if any.

· When wire or electrical outlet was

damaged，please do not charge.

Measure in summer

In summer，water in the electrolyte is

easy to evaporate，therefore，electrolyte

must often be inspected if electrolyte is

low，you must add distilled water to the

level appointed.

4. Open forklift cover and battery lid when

charging，in order to release the explosive

！ Warning

gas .

5. In the progress of charging，electrical

Filling with distilled water beyond the

source switch and battery pin are not to

regulated range, Spilt electrolyte will

pull out，otherwise will destroy pin and

electrical units. The normal procedure is

cause corrosion and electricity leakage.

that:

Measure in winter

press down the stopping button firstly，

·Keep effective and good surrounding for

and then pick out the pin.

charging.

·To prevent discharging，when it is

Charger

cold ，pull out the battery pin.

1. The battery group is equipped with

JCD-35A-24 type automatic high frequency

·Take measures，such as，covering battery

computer to charge. The input power supply

for warmth.

is AC single-phase with 220V, input current

·Charge in time after work.

is not lower than 15A. The output voltage is

DC36V and its max. charge current is 35A.

The charging process is automatic, the detail

Attentions for charging

of using method please refer to the charger

operate manual.

1. Please charge in the well-ventilated and

2. Connect with earth wire when the charge

appointed site.

is used.

2. Mark „no smoking‟ when charging.

3. To replace fuse，make sure that the input

3. Inspect wire and electrical outlet.

and output circuits are disconnected.

4. Only professional person is allowed to

·Before charging，please examine wire

disassemble the cover to check and repair.

and electrical outlet whether been

5. Do not rebuild or disassemble charger.

damaged.

6. In high temperature season, pay attention

to prevent the charge from destroy caused

Specification for distilled water:

by high temperature. Stop the charge in

Ingredient

Index

short time when it is necessary.

Appearance

No color crystal

7. If a non-automatic charger is used, the

Dry residue

≤0.005

charge voltage, current and charge time

Resistively(25⁰C)Ω·cm

≥7×10⁴

should be adjusted, and check the rate of

battery electrolyte timely, so as to make sure

≤0.0004

that the charge of battery group is in good

≤0.0005

condition. The adjust parameters please

≤0.00002

refer to “battery charging” in the follow.

Organic

compound

8. Do not continuously charge.

≤0.0002

(calculating oxygen)

·Continuously charge several batteries will

Magnesium

oxide

cause charger overheat even be damaged.

You can use the charger again after it has

calcium

≤0.005

been rested for an hour.

oxide

9. Select the charger according to battery‟s

voltage and capacity (refer to parameter

Ammonium

table)

≤0.0008

Nitrate or nitrite

≤0.0005

Battery charging

1. There are two charge mode can be

Confect course

adopted, including intelligent charging

① Wear the blinkers, rubber overshoes

and constant current charging. For the

and rubber glove.

first charging, adopt the constant current

② Please pay attention to add the acid

charging.

to water slowly, churning up at the

·All the batteries of the new truck are not

added electrolyte.

same time, make it mix equality.

Electrolyte confect

！CAUTION

Type

D-500

Don‟t pour the water to the acid, in

Parameter

D-420

D-630B

order to avoid the temperature of liquid

Name

D-700

surface turning high suddenly to cause

Specific gravity

boiling and splashing out to hurt

1.265g/cm³

1.275g/cm³

of acid

someone.

Volume

③ When the electrolyte is cooled to

Water

3.1:1

2.6:1

ratio

30℃, pour it into battery. It is proper

and

Quality

to pour the electrolyte

15-20mm

vitriol

1.7:1

1.65:1

Ratio

above the protection piece (without a

Vitriol Ratio

1.835g/cm³

dobber) or 1mm distance between

dobber and cover (with a dobber).

Suitable

for

④ Only when the temperature of the

Vitriol standard

GB4554-84 or special

electrolyte is below

35 ℃ (after

for battery

about

3-5 hours), can be first

charged.

4.5-5 times than rated capacity.

Caution

Charging current(A)

Charging

The time that is from pouring the

Truck

Battery

voltage

1st

2nd

electrolyte into the battery to starting

type

(V)

phase

first charging can‟t be exceeded

hours.

1-1.8t

D-420

⑤ The specific charging cable should

2-2.5t

D-630B

be connected to charging machine.

3t,3.5t

D-500

120

Caution

Be sure to notice that the polarity

4-5t

D-700

120

sign on the plug must keep comfortably

to the out specific charging end node.

Charging time（h）

35-45

When the charging cable is

connected to the storage batteries, please

c. Adjusting the specific density and

pay attention to keeping comfortably on

height for the electrolyte

the polarity sign. Otherwise maybe you

If the specific gravity is smaller, it will

will damage your battery.

be adjusted as follow: then take out

some electrode from the battery, pour

the compounded sulfuric acid that its

⑥ Inspect

specific gravity is 1.400g/cm^3.

The voltage value that the power

needed is the number of the serial

If the specific gravity is larger, it will be

battery three times.

adjusted as follow: then take out some

Battery voltage

electrode from the battery, pour some

Truck type

Battery

（V）

distilled water, but you must keep the

1-1.8t

D-420

electrode height accord with demand

d. After adjusting, you should keep

2-2.5t

D-630B

charging on 1 hour; make the density

3t,3.5t

D-500

of electrode even upper and under. At

this time we have finished the first

4-5t

D-700

charging.

Inspect the charging machine.

e. Close the pouring plug and clean the

·Inspect every battery‟s polarity.

battery surface acid, then you can use

it.

⑦ Charging ways

（time, current as the

Caution

form）

During the charging, the temperature

a. 1^st phase：most of the single battery‟s

of electrolyte should not be exceeded

terminal voltage steps up to 2.4 V；

45℃。 Otherwise you should low the

b. 2^nd phase：the electrode give off a

temperature. If the temperature do not

large number of bubbles, the voltage

lowing, you should stop recharging，

and the specific gravity steadies

till the temperature drop down.

hours and the charging value gets to

occur disequilibrium among the voltage,

Daily charging

the density and the capacity.

The battery that has been made the

·Compared to most of the batteries ,

first charging and used regular, then

often finds that single battery‟s

charged again, is named daily charging.

proportion of voltage and electrolyte

Its way is almost same as the first

rises slowly during the course of charge

charging.

and during the course of discharge, its

The recharging value is 1.2 times

battery‟s proportion of voltage and

than the last electric discharging. But the

electrolyte declines faster than most of

electric-change for new battery‟s fore

other batteries.

five times should be 1.5 times than the

·Make equilibrium charge in the

last electric discharging.

following case：

·During any charge, the temperature

a. discharge voltage often drop down

of electrode should not be exceeded

ending voltage；

45⁰C， otherwise it should be taken

b. discharge current is often larger；

measures such as reducing artificially

c. Not charge in time after discharge

charging current or lowing the

d. The electrolyte is mixed with

temperature. If the temperature doesn‟t

impurity with a little harm.

drop, you should stop charging, till the

e. It often be charged deficient or has

temperature dropping down.

not been used for a long time；

f. After taking out the battery group

Charging current(A)

Charging

Truck

Battery

for checking or cleaning settling.

1st

2nd

voltage

type

(V)

phase

The method of Equilibrium Charge：

① Firstly, charge the battery normally,

1-1.8t

D-420

and then rest for 1 hour after the

end of charge.

2-2.5t

D-630B

② Charge it again with the current

3t,3.5t

D-500

120

belongs to the second normally

charge until the electrolyte gives

4-5t

D-700

120

off a large number of bubbles, then

stop charging for 1 hour.

Charging time（h）

4-6

6-10

③ Repeat it several times as

Adopt intelligent charging for the

mentioned above until the voltage and

daily charging. The first five charging

the density keep invariable and the

should using Equilibrium Charge

battery gives off a large number of

according to the intelligent charger

bubbles immediately when charge

operate manual.

again.

Equilibrium Charge

Complementarity Charge

·If one day‟s work cannot be fulfilled

·During using of the battery, it often

with one charge, carry out opportunity

5. Use the proper tools to pull up the

charge during breaks.

·When the temperature of circumstance

battery

is low, carry out opportunity charge.

Charge for long-term storage

·Carry out equilibrium charge before

storing.

·Carry out equilibrium charge once

every 15 to 30 days during the storage

period.

The weight and dimension of Battery

· The special orders storage battery

Model

carries on the charge according to

1-1.8t

"Accumulator Instruction for use".

Weight (kg)

Min.

700

Max.

900

Battery replacement

Dimension(mm)

465×980×780

Caution

Be sure that the voltage, the

Model

capability, the size and the weight of

2-2.5 t

Weight (kg)

the new battery are according with the

forklift truck before replacing the

Min.

800

battery.

Max.

1000

Forbid to use battery with

Dimension(mm)

570×1028×780

different voltage or capacity or weight

except being promised by factory.

Model

3 -3.5t

Weight (kg)

Min.

1200

Replacement step

Max.

1500

1. Stop the forklift truck on the plain

Dimension(mm)

710×1028×780

ground， pull up the hand brake lever.

2. Open the hood cover.

3. Disconnect the battery plug.

Model

4-5 t

Weight (kg)

Min.

1900

Max.

2200

Dimension(mm)

800×1128×780

4. Remove the lock pin.

Caution

The box must be pulled up with

using 4 holes of the pothook at the same

time. It is not allowed to pull up with

only two holes. Otherwise, the

asymmetric power will cause the battery

damaged.

The steering wheel and other

equipment should not be bumped, avoid

being damaged when pulling up the

battery box.

2． Replenish the distilled water

6. After exchange the full electricity of

·Wear the blinkers, rubber overshoes

battery, plug into the lock pin, shut to

and rubber glove.

the hood cover, and plug into the pin of

① Using the measuring cylinder to

the battery hard.

take out the distilled water with a

The waste electrolyte of the

certain quantity.

replaced battery should be dealt

② Open the battery cover for every

according to environment and protection

law rather than reject at will.

battery cell.

③ Imbibe distilled water with injector

The proportion and level of electrolyte

and then supply it into the battery.

The battery with a dobber

Caution

When the red dobber rises, the

If the level of the electrolyte is low,

white line is appeared, please stop to

using the battery will cause the

replenish the distilled water.

battery over-heat and shorten the

battery‟s life.

1． Inspect electrolyte

The battery without a dobber

It is proper to pour the electrolyte

15-20mm above the electrode plate.

The battery with a dobber

Depending on the dobber of the

winded cover, and read the level

position of the electrolyte.

The battery without a dobber

When the electrolyte is above

15-20mm of the electrode plate, stop

replenishing the distilled water.

④ After replenishing the distilled water,

close the pouring plug and battery

cover.

⑤ Using the damp cloth to clean the

surface of every battery cell.

CAUTION

It is not permitted to overrun the

appointed tiptop level when replenishing

the distilled water. Adding it too much

will result in leakage of electrolyte, and

it will damage the truck when charging

2）Specific gravity measure

and discharging.

Using the densimeter to measure the

Draw it out with injector if adding

specific gravity.

it too much.

3． Read the specific gravity

1 ） The specific gravity of the

electrolyte should change follow the

temperature.

① Use thermometer to measure the

temperature of electrolyte.

② Put the straw of densimeter into

electrolyte uprightly, extrude rubber tube

with hand and the electrolyte will be

3）Conversion of the specific gravity

sucked into the glasses tube and then the

The specific gravity at the

floater of the densimeter will float.

standard temperature of 30⁰C should be

③ Numerate the reading of the

densimeter.

converted as follow：

Notice：The dobber of densimeter must

D30= Dt + 0.0007(t - 30)

rise uprightly without depending on the

Where ：D30 --the specific gravity at

glass pipe.

the standard temperature of 30⁰C

Dt --the specific gravity at

the temperature of t⁰C.

t -- the temperature of the

distilled water during convert.

· The specific gravity that was refered

in this book is measured all at the

temperature of 30℃.

The Automatic Watering System of the Forklift Battery

1. Automatic Watering System

Makeup of the Automatic Watering

System：

 Automatic Watering Plug

 End Plug

 Floater

 T-piece & L-piece

 Flow Indicator（with filter）

 6mm, 8mm ,10mm watering pipe

 Male & Female couplings (Kv10 and KV6, etc.)

 Water Tank

2. Application Specification & Installation

During the period of development and long-term practical

usage, the leak tightness of automatic watering system has received

complete recognition.

But when you use it, you need to keep the automatic watering

system clean and there can‟t be any filth on the surface.

How to properly install the automatic watering system：

Our automatic watering system is easy to operate, no need to finish

watering the electrolyte in the storage battery by hand,

time saving and labor saving, besides, it can extend the service life.

How to correctly install the water tank, choose proper floaters,

how to confirm the specification & quantity of the installed

accessories according to different types of battery, including correct

application rules for automatic watering plug, watering pipe, T/L-

pieces and male/female couplings as well as the cleaning of the flow

indicator. We will give you a brief introduction for the above items

as follows:

Meanwhile we will offer detailed installation drawings to ensure that the clients can

correctly install and standardize the operation.

battery

Watering head

T-piece

Flow

6mm

10mm

end

Male/female

Water tank

spec.

（6-10-6）

indicator

Waterin

Watering

plug

K10

specification

T-piece

（filter）

g pipe

pipe

24V

12 pcs

1 pcs

2pcs

1pcs

30L 1pcs

48V

24 pcs

1 pcs

2pcs

1pcs

30L 1pcs

80V

40 pcs

1 pcs

10m

2pcs

1pcs

60L 1pcs

Automatic Watering System of Forklift Storage Battery-48V battery group

Floater

How to choose proper floaters correctly：

 According to different storage battery, we have five kinds of floaters for you to choose. In

order to achieve our expected standard and completely reflect the effectiveness of the

automatic watering system, the most important thing is to choose proper floaters.

At present our company can offer a rule for the client to make judgment and choose the type

of floater. (see diagram)

 The diagram the installation way of the floaters：

T =T1-(5~17mm)

T approaching

50.5

Float

16.5

Watering Pipe

 Our company offers watering pipes of different types and the clients can choose what

they need according to the specification of the battery.

The watering pipe must be perfectly sealed with T-piece and L-piece.

Notes during the filling process:

1．In order to ensure a safe watering process, we hereby recommend you to use flow

indicator (with filter), the flow indicator with filter can not only timely indicate whether it

finishes watering, but also avoid unclean impurities entering the battery to result interruption.

2．The watering pressure should be within the range of 0.2-0.6, no less than 200mbar。

3．You‟d better conduct watering within the specified periods, because frequent filling

will lead to overflowing for too much water, which will do great damage to the storage

battery.

Note：Filling after finishing charging is the best ideal state, besides, do not filling before

charging.

Cleaning

During the period of development and long-term practical application, the leak tightness

of automatic watering system has been completely approved.

When you use it, you must pay much attention to keep the automatic watering system

clean. No filth remaining on the surface.

The users should regularly clean the watering plug for the plug is a kind of plastic good.

Clean the surface directly with tap water and no need to use other detergent.

Structure Diagram of the Watering Plug：

open

Characteristics of the Automatic Watering System

 No need to water by hand, labor saving.

 No malfunction factor leading to damage the battery.

 Easy & safe operation.

 Ensure a precise electrolyte level in every battery cell.

 Prevent leakage when watering.

 Effectively avoid the acid liquid to erode the storage battery and the electrolytic bath.

 Extend the service life of the battery.

 Environment protection.

 Save energy.

Function Introduction：

Function of the automatic watering system: the floater of the automatic watering plug can

reach correct water level, when the level rises in the cell, the pressure closes the valves and

prevents further water entering the cell. When the system finishes watering, the flow indicator

will stop running and you can see the water-level indicator clearly through the top of the

watering system.

Besides, the material of floater can avoid damage and ineffectiveness.

As for the structure of automatic watering system, there is a terraced step, when the

electrolyte gas rises to the watering plug, the terraced part can prevent the leakage of the

electrolyte gas as well as quickly cool the electrolyte gas to make them go back to the storage

battery in time.

11.Maintenance summarization

·The fork lift truck needs inspection and maintenance periodically so as to make it in

good working condition.

· Inspection and maintenance are usually ignored; you‟d better find the problems and

solve it in time.

· Use the orthodoxy spare part of ZHEJIANG HANGCHA ENGINEERING

MACHINERY CO., LTD.

· Don‟t use different oil when changing or adding oil.

· Forbid to repair the fork lift truck if you haven‟t been trained.

· Don‟t rave about oil and electrolyte used at will, and carry on handling according to the

local environmental protection laws and regulations.

·Maintenance on schedule.

· After you make maintenance, you‟d better make a record.

Notice

·No smoking.

·You should shut off key switch and pull off the plug before service（except some trouble

shooting）.

·Clean the electric part with compress air, do not with water.

·Do not place your hands, feet or any part of body into the gap between the mast and

instrument.

The weight and dimension of the counterweight:

Tonnage

1-1.5t

1.8t

2-2.5t

Weight (kg)

426

600

770

743

1000

Dimension

294×1070×912

329×1070×912

382×1134×940

(mm×mm×mm)

Tonnage

3.5t

4-4.5t

Weight (kg)

1175

1495

1358

1522

1918

Dimension

382×1134×940

462×1134×940

465×1280×978

(mm×mm×mm)

The dimension of mast

Model

1-1.5t

2-2.5t

3.5t

Dimension

1895×1072×480

1915×1118×555

1955×1120×580

1955×1120×585

(mm×mm×mm)

Model

3.5t

4-4.5t

Dimension

1955×1120×585

2245×1350×550

2395×1350×555

(mm×mm×mm)

Preventive maintenance schedule

Battery

〇 - Check, revise, adjust

× - Replace

Checking

Daily

weekly

Monthly

Trimonthly

Semiannually

Service required

Tools

item

(8 hrs)

(40 hrs)

(166hrs)

(500 hrs)

(1000 hrs)

Electrolyte level

Eyeballing

〇

Electrolyte proportion

Densimeter

〇

Battery quantity

〇

Terminal

〇

looseness

Looseness of connecting

〇

wire

Storage

cleanness of the battery

〇

battery

surface

If there are tools on the

〇

battery.

The tightness and

smoothness of

air

〇

cap

Far away from firing

〇

Controller

Daily

weekly

Monthly

Trimonthly

Semiannually

Checking Item

Service Required

Tools

(8 hrs)

(40 hrs)

(166hrs)

(500 hrs)

(1000 hrs)

Check connector

〇

for worn

Check contactor

〇

for running

Check

micro

move switch for

〇

running

Controller

Check

the

connection

among

motor,

〇

battery

and

power unit.

Check

the

First time 2

controller error

diagnose system

years

Motor

Daily

weekly

Monthly

Trimonthly

Semiannually

Checking Item

Service Required

Tools

(8 hrs)

(40 hrs)

(166hrs)

(500 hrs)

(1000 hrs)

Clean the foreign

body on the

〇

motor

Clean or replace

〇

the bearing

Check

the

carbon brush and

commutater for

〇

Motor

worn, whether

spring is normal

Whether

the

connection

〇

correct and firm.

Brush

carbon

powder on shift

〇

plate and shift

device.

Driving system

Checking

Daily

weekly

Monthly

Trimonthly

Semiannually

Service required

Tools

(8 hrs)

(40 hrs)

(166hrs)

(500 hrs)

(1000 hrs)

Item

Check for noise

〇

Check for oil

〇

leaks

Change oil

heck wheel

Check wheel hub

hub bolts for

bearing

for

〇

tighten

looseness，noise

torque

Clean

and

replace grease

Check

wheel

hub bolts for

〇

tighten torque

Wheels (Front, Rear Wheels)

Checking

Service required

Tools

Daily

weekly

Monthly

Trimonthly

Semiannually

Item

(8 hrs)

(40 hrs)

(166hrs)

(500 hrs)

(1000 hrs)

Check for charge

Barometer

〇

pressure

Check

for

abrasion ， cracks

〇

or damage

Check for spikes ，

stones or foreign

〇

Tyre

matter

Check the wheel

〇

hub for damage

Check the split

Test

body

wheel

hammer

〇

hub-bolts

for

looseness

Steering System

Daily

weekly

Monthly

Trimonthly

Semiannually

Checking Item

Service required

Tools

(8 hrs)

(40 hrs)

(166hrs)

(500 hrs)

(1000 hrs)

Check for

〇

clearance

Check for radial

〇

looseness

Steering wheel

Check for axial

〇

looseness

Check for

〇

operation

Check mounting

Steering Gear

bolts for

〇

box and valve

looseness

Check king pins

for looseness or

〇

damage

Check for

Steering axle

deflection,

〇

deformation ,cra

cks or damage

Check for fixing

Test

〇

condition

hammer

Check for

〇

operation

Check for oil

Steering

〇

leaks

cylinder

Check for

looseness when

〇

fixing or hinging

Brake system

Checking

Daily

weekly

Monthly

Trimonthly

Semiannually

Service required

Tools

item

(8 hrs)

(40 hrs)

(166hrs)

(500 hrs)

(1000 hrs)

Check for free travel

Scale

〇

Check for pedal travel

〇

Brake

Check for operation

〇

pedal

Check for air mixed in

〇

brake piping

Check for lever is securely

locked and has sufficient

〇

Parking

lever stroke

brake

Check for operation

〇

Check for operation

〇

Check connections for

Rod,

〇

looseness

Cable,

Check decelerator

etc

connector lug for

〇

abrasion

Check for damage, leakage

〇

Hoses

or collapse

and Pipes

Check connection or

〇

clamping parts for looseness

Check for leakage

〇

Check for fluid level,

〇

Change brake fluid

Brake

Check master cylinder and

〇

master

wheel cylinder for operation

cylinder

and

Check master cylinder and

wheel cylinders for fluid

〇

wheel

leaks or damage

cylinder

Check master cylinder

piston cup, and check valve

for wear or damage change

Hydraulic system

Checking

Daily

weekly

Monthly

Trimonthly

Semiannually

Service required

Tools

item

(8 hrs)

(40 hrs)

(166hrs)

(500 hrs)

(1000 hrs)

Check for oil level,

〇

Change oil

Hydraulic

reservoir

Clean suction strainer

〇

Clean foreign matter

〇

Check levers for

〇

Control

looseness

lever

Check for operation

〇

Check for oil leak

〇

Check relief valve

Control

and tilt lock valve

〇

valve

for operation

Oil

Measure relief

press

〇

pressure

gauge

Check for oil leak,

Hose,

looseness, collapse,

〇

Piping Hose

deformation and

Reel &

damage

Swivel Joint

Replace hoses.

1-2 years

Check hydraulic

pump for oil leak or

〇

Hydraulic

noise

Pump

Check pump drive

〇

gear for wear

Lifting system

Checking

Daily

weekly

Monthly

Trimonthly

Semiannually

Service required

Tools

item

(8 hrs)

(40 hrs)

(166hrs)

(500 hrs)

(1000 hrs)

Check chain for tension, damage or rust

〇

Add lubrication for chains

〇

Chains &

Check connection of chain anchor pin and

〇

Sheave

chain for looseness

Check sheaves for deformation or damage

〇

Check sheave bearings for looseness

〇

Attachment

Perform general inspection

〇

Check piston rod, rod screw and connection

Test

〇

for looseness deformation or damage

hammer

〇

Lifting

Check cylinders for operation

〇

cylinder and

tilting

Check for oil leak

〇

cylinder

Check pins and cylinder bushings for wear or

damage

〇

Check forks for damage, deformation or

〇

wear

〇

Fork

Check for stopper pins for damage or wear

〇

Check fork base and hook welding for

〇

defective cracks or wear

〇

Check weld between cross members with

outer and inner masts for defective, cracks or

〇

damage

Check tilt cylinder bracket and mast for

〇

defective weld ,cracks or damage

〇

Check outer and inner masts for defective

〇

weld, cracks or damage

〇

Check for defective weld, cracks or damage of

〇

lift bracket

〇

Check roller bearings for looseness

〇

Mast &

〇

Lift

Check mast support bushings for wear or

Bracket

damage

〇

Test

(for 1st

Check mast support cap bolts for looseness

〇

hammer

time

only）

〇

Check lift cylinder tall bolts, piston rod head

Test

(for 1st

bolts, U-bolts, and piston head guide bolts for

hammer

〇

time

looseness

only）

Check rollers, roller pins and welded parts for

〇

cracks or damage

〇

Others

Daily

weekly

Monthly

Trimonthly

Semiannually

Checking item

Service required

Tools

(8 hrs)

(40 hrs)

(166hrs)

(500 hrs)

(1000 hrs)

Check for tight

Test

〇

installation

Overhead Guard

hammer

& Load Backrest

Check for

deformation, cracks

〇

or damage

Check for proper

Turn signal

operation and tight

〇

installation

Check for proper

Horn

operation and tight

〇

installation

Check for proper

Light & Lamps

operation and tight

〇

installation

Check for proper

Buck-up Buzzer

operation and tight

〇

installation

Check meters for

Meters

〇

proper operation

Wire damage or

〇

looseness

wire

Looseness of

〇

Electric circuit Joint

Replace the key safe parts termly

·Some parts should be checked periodically to detect the damage, for improving the

safety, users should replace the parts periodically which are listed in the table as follows.

·If the parts are abnormal before the replacing time is coming, it should be replaced

immediately.

Key safe part’s description

Term of using (year)

Brake hose or tube

1~2

Hydraulic hose for lifting system

1~2

Lifting chain

2~4

High-pressure hose ，hose for hydraulic system

Brake oil cup

2~4

Brake master cylinder，brake slave cylinder cover and dust sleeve

Inner hermetic，rubber matter

Table for bolt’s tight torque

Unit N

Bolt’s

Grade

diameter

4.6

5.6

6.6

8.8

4～5

5～7

6～8

9～12

10～12

12～15

14～18

22～29

20～25

25～31

29～39

44～58

35～44

44～54

49～64

76～107

54～69

69～88

83～98

121～162

88～108

108～137

127～157

189～252

118～147

147～186

176～216

260～347

167～206

206～265

245～314

369～492

225～284

284～343

343～431

502～669

294～370

370～441

441～539

638～850

441～519

539～686

637～784

933～1244

Note:

Use entirely 8.8 grade bolt in the important joint position.

·Bolt‟s grade can be found in the head of the bolt, if it can‟t be found, the grade is 8.8.

Table for oil used in the truck

Name

Trademark, code name

capability（L）

Remark

22-25

1-1.8t

Normally: L- HM32

Hydraulic oil

cold environment :L-HV32

25-35

2-3.5t

40-45

4-5t

Use in driving axle and

Gear oil

GL-585W/90

gear-box

Brake Fluid

(Choice) HZY3 or DOT3

1.5

Industrial Vaseline

Electrode of storage battery

Automobile general lithium

Lubrication grease

base lubricant

12.Truck’s convey, lifting, towing

Convey

The Fork Lift Truck is designed for material handling only, It is inappropriate for

long-distance transportation. If needed, the Fork Lift Truck must be transported by ship, train

or lorry, of 5T loading. Use a lifting pallet to hoist the truck.

• Use the steel wire ropes to tie the holes in the two side of the outside mast‟s beam and

the rear of truck‟s body, and then use the lifting device to hoist the truck.

Hoist the truck

·Use the steel wire ropes to tie the holes in the two side of the outside mast‟s beam and

the hook of the counter balance, and then use the lifting device to hoist the truck. The steel

wire rope attach to the counterweight should through the safeguard gap, and make the

safeguard not be distorted.

Warning

·When hoist the truck, don‟t coil the overhead guard with the steel wire.

·The steel wire ropes and the lifting device must be very firm to support the truck because

the truck is very heavy.

·Don‟t lift the truck by hoist the overhead guard.

·When lifting the truck, don‟t take yourself below the truck.

Towing

·The towing rod on the bottom of the counter balance is used to pull and drag the truck.

Loosen the brake lever and turn off key switch.

Set switch lever to neutral position

Warning

a. Don‟t tie the steel wire ropes on the unfixed position.

b. Don‟t carry a load to steel wire ropes suddenly.

c. The truck would be damaged if you tow it with the electric lock working.

13.Parameters

Parameters of CPD10/15/18J

NO.

Item

Units

CPD10J

CPD15J

CPD18J

Ratio capacity

1000

1500

1800

Load centre

500

Max.

3000

Lifting height

Free

135

Max.

Lifting

Fully loaded

mm/s

290

270

velocity

Tilting angle

front/rear

5/10

Max. Traveling

Fully loaded

mm/s

velocity

Max. Crawling

Fully loaded

slope

Turning radius

Min.

1780

1815

Ground

Min.

110

clearance

Stopping

Max.

2.5

distance

2080

2115

Overall Dimension

1090

1138

2075

Include

Weight (self)

2770

2940

3090

battery

Standard

V/Ah

48/420

Battery

Optional

V/Ah

48/480

Driven

Motor

Lifting

7.8

Type

MOSFET

Tow

Danaher

Controller

Manufacturer

Lifting

Danaher

Front ×2

6.00-9/2

21×8-9/2

Tyre

Rear ×2

5.00-8/2

Parameters of CPD10/15/18JC1

NO.

Item

Unit

CPD10JC1

CPD15J C1

CPD18J C1

Ratio capacity

1000

1500

1800

Load centre

500

Max.

3000

Lifting height

Free

135

Max.

Lifting

Fully loaded

mm/s

290

270

velocity

Tilting angle

front/rear

5/10

Max. Traveling

Fully loaded

mm/s

velocity

Max. Crawling

Fully loaded

slope

Turning radius

Min.

2090

1780

1815

Ground

Min.

110

clearance

Stopping

Max.

2.5

distance

2080

2115

Overall Dimension

1090

1138

2075

Include

Weight (self)

2940

3090

battery

Standard

V/Ah

48/420

Battery

Optional

V/Ah

48/480

Driven

6.8

Motor

Lifting

8.2

Type

MOSFET

Tow

CURTIS

Controller

Manufacturer

Lifting

CURTIS

Front ×2

6.00-9/2

21×8/2

Tyre

Rear ×2

5.00-8/2

Parameters of CPD10/15/18JD1

NO.

Item

Unit

CPD10JD1

CPD15JD1

CPD18JD1

Ratio capacity

1000

1500

1800

Load centre

500

Max.

3000

Lifting height

Free

135

Max.

Lifting

Fully loaded

mm/s

290

270

velocity

Tilting angle

front/rear

5/10

Max. Traveling

Fully loaded

mm/s

velocity

Max. Crawling

Fully loaded

slope

Turning radius

Min.

2090

1780

1815

Ground

Min.

110

clearance

Stopping

Max.

2.5

distance

2080

2115

Overall Dimension

1090

1138

2075

Include

Weight (self)

2940

3090

battery

Standard

V/Ah

48/420

Battery

Optional

V/Ah

48/480

Driven

6.8

Motor

Lifting

7.8

8.2

Type

MOSFET

Tow

Danaher

CURTIS

Controller

Manufacturer

Lifting

Danaher

CURTIS

Front ×2

6.00-9/2

21×8/2

Tyre

Rear ×2

5.00-8/2

Parameters of CPD20/25/30J

No.

Item

Unit

CPD20J

CPD25J

CPD30J

Ratio capacity

2000

2500

3000

Load centre

500

Max.

3000

Lifting height

Free

140

145

Max.

Lifting

Fully

mm/s

250

230

velocity

loaded

front/rea

Tilting angle

5/10

Max.

Traveling

Fully

mm/s

velocity

loaded

Fully

Max. Crawling slope

loaded

Turning radius

Min.

2090

2230

Ground clearance

Min.

120

Stopping distance

Max.

2.5

2275

2325

2490

Overall Dimension

1265

1240

2100

Include

Weight (self)

3800

4020

5050

battery

Standar

V/Ah

48/630

80/500

Battery

Optional

V/Ah

48/700

Driven

Motor

Lifting

8.6

Type

MOSFET

Controller

Tow

CURTIS

Manufact

urer

Liftin

CURTIS

Front ×2

23×9-10/2

Tyre

Rear ×2

18×7-8/2

Parameters of CPD20/25/30/35JC1

No.

Item

Unit

CPD20JC1

CPD25JC1

CPD30JC1

CPD35JC1

Ratio capacity

2000

2500

3000

3500

Load centre

500

Max.

3000

Lifting height

Free

140

145

Max.

Lifting

Fully

mm/s

250

230

210

velocity

loaded

front/rea

Tilting angle

5/10

Max.

Traveling

Fully

mm/s

velocity

loaded

Fully

Max. Crawling slope

loaded

Turning radius

Min.

2090

2230

2310

Ground clearance

Min.

120

Stopping distance

Max.

2.5

2275

2325

2490

2570

Overall Dimension

1265

1302

2100

Include

Weight (self)

3800

4020

5050

5400

battery

Standar

V/Ah

48/630

80/500

Battery

Optional

V/Ah

48/700

Driven

9.1

11.75

Motor

Lifting

8.6

Type

MOSFET

Controller

Tow

CURTIS

Manufact

urer

Liftin

CURTIS

Front ×2

23×9-10/2

23×10-12/2

Tyre

Rear ×2

18×7-8/2

Parameters of CPD20/25/30/35JC2

No.

Item

Unit

CPD20JC2

CPD25JC2

CPD30JC2

CPD35JC2

Ratio capacity

2500

3000

3500

Load centre

500

Max.

3000

Lifting height

Free

145

Max.

Lifting

Fully

mm/s

250

230

210

velocity

loaded

front/rea

Tilting angle

5/10

Max.

Traveling

Fully

mm/s

velocity

loaded

Fully

Max. Crawling slope

loaded

Turning radius

Min.

2090

2230

2310

Ground clearance

Min.

120

Stopping distance

Max.

2.5

2325

2490

2570

Overall Dimension

1265

1302

2100

Include

Weight (self)

4020

5050

5400

battery

Standar

V/Ah

48/630

80/500

Battery

Optional

V/Ah

48/700

Driven

9.1

11.75

Motor

Lifting

8.6

Type

MOSFET

Controller

Tow

CURTIS

Manufact

urer

Liftin

CURTIS

Front ×2

23×9-10/2

23×10-12/2

Tyre

Rear ×2

18×7-8/2

Parameters of CPD20/25/30/ 35J D1

CPD20J

No.

Item

Unit

CPD25J D1

CPD30J D1

CPD35J D1

Ratio capacity

2000

2500

3000

3500

Load centre

500

Max.

3000

Lifting height

Free

140

145

Max.

Lifting

Fully

mm/s

250

210

velocity

loaded

front/rea

Tilting angle

5/10

Max.

Traveling

Fully

mm/s

14.5

velocity

loaded

Fully

Max. Crawling slope

loaded

Turning radius

Min.

2040

2090

2230

2310

Ground clearance

Min.

120

Stopping distance

Max.

2.5

2275

2325

2490

2570

Overall Dimension

1265

1302

2100

Include

Weight (self)

3800

4180

5050

5460

battery

Standar

V/Ah

48/630

80/500

Battery

Optional

V/Ah

48/700

Driven

10.5

10.6

Motor

Lifting

12.8

Type

MOSFET

Controller

Tow

Danaher

Manufact

urer

Liftin

Danaher

Front ×2

23×9-10/2

23×10-12/2

Tyre

Rear ×2

18×7-8/2

Parameter of CPD40/45/50J D1

No.

Item

Unit

CPD40J D1

CPD45J D1

CPD50J D1

Ratio capacity

4000

4500

5000

Load centre

500

Max.

3000

Lifting height

Free

145

150

Max.

Lifting

Fully

mm/s

260

230

velocity

loaded

front/rea

Tilting angle

6/12

Max.

Traveling

Fully

mm/s

13.5

velocity

loaded

Fully

Max. Crawling slope

loaded

Turning radius

Min.

2650

Ground clearance

Min.

219

226

Stopping distance

Max.

2.5

3015

Overall Dimension

1380

2280

Include

Weight (self)

6550

6800

7250

battery

Standar

V/Ah

80/700

Battery

Optional

V/Ah

Driven

16.6

Motor

Lifting

25.4

Type

MOSFET

Controller

Manufact

Danaher

urer

Front ×2

250-15-16/2

Tyre

Rear ×2

7.00-12-12/2

Parameter of CPD40/45/50J C2

No.

Item

Unit

CPD40J C2

CPD45J C2

CPD50J C2

Ratio capacity

4000

4500

5000

Load centre

500

Max.

3000

Lifting height

Free

145

150

Max.

Lifting

Fully

mm/s

260

velocity

loaded

front/rea

Tilting angle

6/12

Max.

Traveling

Fully

mm/s

13.5

velocity

loaded

Fully

Max. Crawling slope

loaded

Turning radius

Min.

2650

Ground clearance

Min.

219

226

Stopping distance

Max.

2.5

3015

Overall Dimension

1380

2310

Include

Weight (self)

6550

6800

7200

battery

Standar

V/Ah

80/700

Battery

Optional

V/Ah

16.6@3100r

16.6@3100rp

Driven

Motor

25.4@1620

Lifting

rpm

Type

MOSFET

Controller

Manufact

CURTIS

urer

Front ×2

250-15-16/2

Tyre

Rear ×2

7.00-12-12/2

1、tonnage label

The inner and outer mast, fork frame are

all lifting slip parts. The hands are not

allowed to reach the place between the

inner and outer mast.

If the part needs to be check or repaired,

the inspection and repair should be carried

out after shutting off the power. Nobody

The word “30”means the rated load is 3.0

is allowed on the truck, and the man

ton. If the lifting height increases or adds

outside the truck is not allowed to operate

attachment, the rated load will decrease.

the truck, preventing from accident caused

2、typeface label

by miss operating the mast handle.

6、danger label：adhibit to the outside of

mast

3、ac label（only fro ac motor）

No allowed to stand on or down the mast,

or it is dangerous to your life.

4、danger label （NO entering label）

7、CE label（only for truck exporting to

Europe or option）

Warning: It is dangerous of your life. If

the body is clamped among the mast ,

instrument frame and shield cabane, your

life will be dangerous. If the part needs to

be check or repaired, the inspection and

repair should be carried out after shutting

off the power. Nobody is allowed on the

8、hang label：It shows the hang position

truck, and the man outside the truck is not

and method. When hanging, the rope

allowed to operate the truck, preventing

should not touch the light and even destroy

from accident caused by miss operating the

it.

mast handle.

LIFT METHOD

5、danger label

9、10 danger label

13、product nameplate

WARNING

14、hydraulic oil label

11、load curve scutcheon

It shows relation among the position of

the load center, max. load and max. lifting

height.

If it has side moving and attachment,

the load decreases. If the lifting height

15、tight point label（only for truck

increases, the load decreases. Before

exporting to Europe or option）

loading, check whether the load and the

center distance of load are in the allowed

range show in the diagram of load capacity.

If the shape of load is complicated, make

the most heavy part place in the center of

the fork and approach the stop fork frame.

16、hand brake label（only for truck

exporting to Europe or option）

12、warning label

17、urgent stop label

W A R N I N G

SERIOUS OR FATAL INJURY MAY RESULT TO YOURSELF OR OTHERS IF NOT FOLLOWED

This lift truck should not be operated by anyone who is not authorized and properly trained.

Read the Operators Manual and all warnings carefully,and make yourself familiar with your lift truck.

Operator's Manual and Service Manual are supplied with this truck or available from our forklift truck dealers.

Inspect and check your lift truck daily before and after use.Do not operate faulty or damaged lift trucks.

Repair work should be done by authorized and trained persons only.

To protect from falling objects,make sure that the Overhead Guard and Load Backrest Extension are correctly mounted

and in good condition.

Check the capacity of the battery and the condition of all kinds of switch,connecting plug,operating level, pedal,

tyre pressure and fastener.

Starting forklift truck:Realase parking brake and turn on the switch. After moving the shift lever to Forward

(or Reverse), depress the accelerator pedal to start truck. If making an error by procedure, the truck can not start.

When unloading, the weight and diemension should be within the permitted range on the capacity chart. Overload is

prohibited and set the cargo at the center of mast to avoid departure.

When traveling with loading, it is necessary to lift fork up to 300mm, tilt backward most and set the load closed

to the backrest. It is Pohibited to brake and turn suddently when travelling with loading.

Stop the truck steadily, turn the key to OFF position and remove it, move the shift level to "NEUTRAL" and set the

fork to ground.

When hoisting the battery case, it should take by four holes in the each side of the case. It is prohibited to hoist

only by two holes, otherwise, the case will be deformed to damage the battery.

15.The use, assembly and safe rules of attachment

HANGCHA will choose attachment that according with International standard ISO2328《Forklift

pothook fork and install size of carriage》,such as clamp, rotator, paper roll clamp, carrying ram,

side-shifter ect.

1、Attachment use.

（1） Know well the content of nameplate on attachment, read the instruction manual before

Usage.(Especially the manual from attachment company)Before operate the attachment, the people should

be trained and obtain the qualification.

(2) It should be understand the basic capability and operate methods of attachment. Especially the

admit load, lift height, size of cargo and adapt range of attachment.

（3）Operate the multi-functional attachment, such as with side-shifter, clamp or rotator, it is not

allowed that two action at one time. Operate one functional then do another one.

（4）Prohibit the cargo at a high position when truck move with attachment. If the size of cargo is too

big, prohibit the truck move on. Transport the cargeo, make sure that the distance of bottom of cargo and

ground is less than 300mm and mast incline back.

（5）The weight of cargo couldn‟t exceed the limited value of combination carrying capacity of

forklift and attachment. It is not allowed that partial load at high position. It is a short time work for

attachment with side-shifter. Partial load is around 100mm (Above 5 ton (including 5 ton),the side-shifter

movable within 300mm.

（6）In the range of the projection forth 2m of the lower of attachment and cargo, prohibit stand to

avoid the suddenness except the driver position under overhead.

（7）It is not allowed that an emergency brake in moving. Run slowly with load.

（8）Prohibit outside force when attachment working.

（9）It couldn‟t be use at malfeasance situation and overstep normal work range

（10）When the attachment failure, prohibit use without check.

Check and maintenance:

（1）Check the clearance of carriage beam and below catch of attachment if accord the attachment

manual.

（2）Check the rise catch is right on the flute of fork carriage.

（3）Use the auto currency lithic-grease per 500 hours to bearing surface.

（4）If the tighten firmware become flexible.

（5）Check the tie-in of hydraulic pressure loop, if tube attaint. Prohibit use after repair.

（6）Check the drive of attachment timing or turn the component if fray or block, change betimes.

（7）Check each element if in normal under load attachment is work in gear. If not, check the

hydraulic pressure loop, find out the broken part, change air poof or whole loop part.

2、Attachment assembly

！Caution

1、Untempered technology licence of our company, any refit at safety and capability to attachment

is strict prohibit.

2、Fact rating load capacity should be the least of rating load capacity, the load capacity of

attachment, colligate load capacity of truck. Generally speaking, the colligate load capacity of

truck is the least. Attachment load capacity just a count value of attachment pressure.

3、Assembly go to in reason, credibility, safety to avoid the attachment glide around carriage in

using.

4、After hang attachment, embed the rise catch block to the gap of top beam, let the offset of

centre line of attachment and carriage is less than 50mm.Otherwise,it will be affect the landscape

orientation stability of forklift.

5、To these attachment with rotating function, such as paper roll clamp, bale clamp, muti-purpose

clamp, drum clamp, it needs to weld chock block in the joint of carriage beam and attachment to

prevent move from side to side in the operation.

6、Assembly the attachment of below catch orientation, it need to adjust the clearance between

below catch and beam of carriage.

16.Related safety instruction and standard (for trucks exporting

to Europe or option)

The model by CE certification which according to the following instruction and standard:

DIRECTIVE 2006/42/EC OF THE EUROPEAN PAMENT AND OF THE COUNCIL,

DIRECTIVE 2000/14/EC OF THE EUROPEAN PAMENT AND OF THE COUNCIL,

EN1726-1:1998(Engineering Industry truck safety standardize), EN12053:2001,

EN1175-1:1998, EN13059:2002 coordinate standard.

 Main safety factor will be according with DIRECTIVE

2006/42/EC OF THE

EUROPEAN PAMENT AND OF THE COUNCIL and EN1726-1:1998、EN1175-1:1998

standard.

 The design and manufacture of electrical element comply with the low voltage standard

2006/95/EC.

 Noise will be according with EN12053:2001 and 2000/14/EC.

 Vibration parameters are measured according to standards of ISO5349-2:2001,

EN13059:2002, ISO2631-1:1997, and the result meets the requirement of 2002/44/EC.

 Electromagnetism compatibility is measured according to standard of EN12895:2000，

and meets the requirement of 2004/108/EC.

浙江杭叉工程机械集团股份有限公司

Zhejiang Hangcha Engineering Machinery Co.,Ltd.

地址：杭州市石桥路 398 号邮编：310022

Website: http//www.zjhc.cn

Add：398 Shi Qiao Road, Hangzhou

310022

E-Mail：sales@zjhc.cn

Tel：+86-571-88926666

Fax： +86-571-88144682

EC DECLARATION OF CONFORMITY

MANUFACTURE

Name:

Zhejiang Hangcha Engineering Machinery Co., Ltd.

Address:

398 Shiqiao Road, Hangzhou 310022, P. R. China

THE TECHNICAL DOCUMENTATION WAS COMPILED BY:

Name:

Address:

Post:

HEREBY DECLARES THAT THE PRODUCT DESCRIBED BELOW:

Description:

Industrial truck -Battery counterbalanced forklift truck with charger

Name:

Electrical forklift truck

Model:

Serial number:

Rated power:

Manufacturing year:

COMPLIES WITH THE PROVISIONS OF THE FOLLOWING EUROPEAN

DIRECTIVES:

2006/42/EC

Machinery Directive

2004/108/EC

EMC Directive

2006/95/EC

LVD Directive

COMPLIES WITH THE PROVISIONS OF THE FOLLOWING HARMONIZED

STANDARDS:

EN 1726-1:1998

Safety of industrial trucks-Self-propelled trucks up to and

+A1:2003

including 10 000 kg capacity and industrial tractors with a

drawbar pull up to and including 20 000 N- Part 1：General

requirements

EN1175-1:1998

Safety of industrial trucks-Electrical requirements-Part 1：

General requirements for battery-powered trucks.

Annex I of Machinery Essential health and safety requirements relating to the

Directive 2006/42/EC

design and construction of machinery

Done

at ZHEJIANG HANGCHA ENGINEERING Name

the

(place):

MACHINERY CO.,LTD.

signatory:

Title:

Technical Director

(date):

Signature: