Hangcha CBD20 Electric Pallet Truck Operator's Manual PDF

Basic Range
ELECTRIC PALLET
PALLET TRUCK CBD20-AEC1
CBD20-AEC1S
OPERATION AND MAINTENANCE MANUAL
Original Instruction
HANGCHA GROUP
7/2015
CO., LTD.
https://www.besttruckmanuals.com/
FOREWORD
Thank you very much for purchasing the A series basic range electric pallet truck of Hangcha
Group .
A series basic range electric pallet truck is a newly developed product for warehou
warehouse
se logistic, it
owns characteristics as advanced performance, comfort operation, safety and security, low
maintenance cost, and is an ideal tool for handling goods in warehouse, supermarket and
workshop.
Before use the truck, relative persons must read and understand the manual, get to know how to
safely operate and maintain the truck.
Part one of this manual is about the brief introduction and correct operation of the basic range
electric pallet truck, which will tell you how to operate safely and maintain preventively; part two
will tell you the structure, working principle
principle and maintenance of the electric pallet truck.
Because of the update and improvements of our products, there may be some differences
between this operation manual contents and your forklift truck.
If you have any questions, please contact Hangcha Group Co., Ltd. sales company or the agent.
© 7/2015 HANGCHA GROUP CO., LTD
Content
Part : Operation and maintenanc
maintenance e ................................................................
...........................................................................................
........................... 1
1 Truck Introduction.......................................
Introduction........................................................................
....................................................................
............................................
......... 1
1.1 General ..................................................................
...................................................................................................
..................................................................
................................. 1
1.2 Use occasion and condition..............................................................
.................................................................................................
.......................................
.... 1
1.3 Main part
part name .................................................................
....................................................................................................
.......................................................
.................... 1
1.4 Display and control
control .................................................................
...................................................................................................
.................................................
............... 3
1.4.1 Display ..................................................
...................................................................................
...................................................................
..................................................
................ 4
1.4.2 Control ...................................................................
....................................................................................................
..................................................................
................................. 5
1.4.3 Others ...................................................
....................................................................................
...................................................................
..................................................
................ 7
1.5 Standard
Standard technical
technical data data ...............................................................
..................................................................................................
............................................
......... 9
1.6 Product plates and warning labels labels location ....................................................................
............................................................................
........11
2 Safety Rules ...............................................................
.................................................................................................
...........................................................
......................... 13
3 Transport
Transport ...............................................................
................................................................................................
................................................................
............................... 16
3.1 Lifting by crane.................................................
crane...................................................................................
...................................................................
....................................
... 16
3.2 Securing the truck during transport transport ..............................................................
.......................................................................................
......................... 17
3.3 How to remove a broken truck................................................................
...............................................................................................
............................... 18
4 Battery ...................................................................
....................................................................................................
................................................................
............................... 19
4.1 Attention for using
using battery..................................................................
....................................................................................................
....................................
.. 19
4.2 Dimension/Service
Dimension/Service Weight ...............................................................
..................................................................................................
.....................................
.. 21
4.3 Charging the battery
battery ..............................................................
.................................................................................................
................................................
............. 22
4.4 Replacing the the battery.............................................................
...............................................................................................
................................................
.............. 26
5 Truck breaking-in....................................................................
......................................................................................................
...............................................
............. 27
6 Operation...............................................................
................................................................................................
................................................................
............................... 28
6.1 Check before
before operation
operation ...............................................................
..................................................................................................
..........................................
....... 28
6.2 Start
Start up...................................................................
....................................................................................................
................................................................
............................... 30
6.3 Travelling........................
Travelling..........................................................
....................................................................
...................................................................
....................................
... 31
6.4 Braking ...................................................................
....................................................................................................
................................................................
............................... 33
6.5 Steering
Steering ..................................................................
...................................................................................................
................................................................
............................... 33
6.6 Stopping
Stopping .................................................................
..................................................................................................
................................................................
............................... 33
6.7 Loading ..................................................................
...................................................................................................
................................................................
............................... 33
6.8 Unloading...............................................................
................................................................................................
................................................................
............................... 34
6.9 Parking ...................................................................
....................................................................................................
................................................................
............................... 35
7 Deposit the truck ....................................................................
......................................................................................................
...............................................
............. 36
7.1 Deposit the truck for long long time ................................................................
...............................................................................................
............................... 36
7.2 Start
Start running after deposit
deposit for a long time ...............................................................
.............................................................................
.............. 36
8 Maintenance...............................................................
.................................................................................................
...........................................................
......................... 37
8.1 Maintenance general .............................................................
...............................................................................................
................................................
.............. 37
8.2 Periodic maintenance schedule........................................
schedule.........................................................................
.....................................................
.................... 38
8.3 Truck used oil and lubrication
lubrication .................................................................
................................................................................................
............................... 42
8.4 Replace hydraulic
hydraulic oil..............................................................
.................................................................................................
................................................
............. 43
8.5 Replace wheels ................................................................
...................................................................................................
.....................................................
.................. 44
8.5.1 Replace drive wheel ...................................
....................................................................
....................................................................
..........................................
....... 44
8.5.2 Replace load wheels .......................................
.........................................................................
....................................................................
....................................
.. 46
8.5.3 Replace Auxiliary Wheels..................................................................
....................................................................................................
....................................
.. 47
8.6 Replace the key safe parts periodically periodically....................................................................
.................................................................................
............. 48
9 Relevant safety directive or standard (CE) ....................................................................
...........................................................................
....... 49
Part : Structure, Priciple and Maintenance ....................................................................
...........................................................................
....... 51
1 Drive Unit...............................................................
................................................................................................
................................................................
............................... 51
1.1 Drive unit structure
structure and principle ..................................................................
...........................................................................................
......................... 51
1.2 Assemble and use use notice
notice ..................................................................
....................................................................................................
....................................
.. 53
1.3 Fault and troubleshooting
troubleshooting ..................................................................
....................................................................................................
....................................
.. 53
1.4 Drive motor ..................................................................
...................................................................................................
..........................................................
......................... 54
1.5 Electromagnetic
Electromagnetic brake .................................................................
....................................................................................................
..........................................
....... 57
1.5.1 Electromagnetic brake working principle .......................................................................
..............................................................................
....... 58
1.5.2 Electromagnetic
Electromagnetic brake installationinstallation .....................................................................................
........................................................................................
... 59
1.5.3 Maintenance .........................................
...........................................................................
...................................................................
...............................................
.............. 60
1.5.4 Adjust the Air Gap of the Brake ..............................................................
.............................................................................................
............................... 61
1.5.5 Common fault and troubleshooting
troubleshooting ..................................
...................................................................
.....................................................
.................... 62
2 Hydraulic system ....................................................................
......................................................................................................
...............................................
............. 63
2.1 Hydraulic system
system working
working principle
principle ..............................................................
.......................................................................................
......................... 64
2.2 Hydraulic unit ....................................................................
.....................................................................................................
.....................................................
.................... 66
2.3 Hydraulic unit dismantle ..............................................................
...............................................................................................
..........................................
......... 68
2.4 Dismantle the lifting cylinder
cylinder from the truck or or replace .........................................................
......................................................... 69
2.5 Hydraulic system
system fault diagnosis
diagnosis and and correction
correction .................................................................
...................................................................
.. 72
3 Electric system .................................................................
....................................................................................................
.....................................................
.................. 73
3.1 Electrical schematic
schematic diagram
diagram ..................................................................
.................................................................................................
............................... 74
3.2 AC motor controller
controller.................................................................
...................................................................................................
...............................................
............. 75
3.2.1 Maintenance .........................................
...........................................................................
...................................................................
...............................................
.............. 75
3.2.2 Diagnosis and troubleshooting
troubleshooting ...............................................................
..............................................................................................
............................... 76
3.2.3 LED Status
Status Indicator..............................................................
.................................................................................................
................................................
............. 80
3.2.4 Fault code table ................................................................
...................................................................................................
.....................................................
.................. 81
Attachment：
Attachment ：Table for bolt’s tightening torque .................................................................
..............................................................................
............. 87
Part : Operation and maintenance
1 Truck Introduction
1.1 General
A series basic range electric pallet truck described in this manual should work under moderate
intensity working strength.
According to different
different operation way,
way, it has two types as pedestrian type and stand-on type. Uses
can get relevant information as rated load from the product model.
CBD20-AEC1
Mode
CBD20-AEC1S
CBD Electric pallet truck
20 Rated load capacity×100kg
A Product serial
serial number
E Basic Range
C1 Controller type
S Stand-on type
Truck body system
– Beautiful and compact outline, concise and fluent line.
– High strength steel frame structure chassis provide larger residual load capability and longer
working life.
– Chassis adopts 5-wheel structure, including one central driving wheel, two lateral auxiliary
wheels as stabilization and two load wheels. It can make sure stable and safe driving.
Auxiliary wheel
wheel gets damping
damping design.
design.
– Hanging foldable damping pedal.
Driving system
– Drive unit adopts wheel type, with compact and simple integral structure.
– The adopted unique floating supension system ensures good driving wheels`s grip and
excellent stability.
– AC travelling motor applied to provide excellent acceleration, good gradeability,
gradeability, low heat, no
carbon brush and maintenance free.
– High performance electromagnetic brake.
Braking system
–
It owns three emergency braking functions as release brake, reverse brake and
electromagnetic brake to ensure travelling safety.
– It owns slope anti-slide function to ensure safety.
Operation steering system
– New ergonomics designed control handle owns acceleration, reversing, horn, braking,
lifting/lowering, emergency reverse functions, thus makes operation easier.
– Emergency reversing button on the control handle head can prevent driver from hurt when
encountering emergency in backward driving.
– Turtle speed function can keep the slow move when the tiller is vertical direction, the truck
can stack goods even in narrow space.
– Steering angle +/- 90°.
Hydraulic system
– Modularization hydraulic power unit owns low noise, low vibration, stable and reliable lifting
and lowering.
Electric system
– 24V Electric system
– CURTIS latest AC control system provides accurate and atable control to work more efficient.
– Multi-function meter, has the power display, timing and fault self-diagnosis function.
– Emergency stop switch.
– The standard equipped electronic lifting limitation and soft landing system protect working
motor and loads from damaging.
1.2 Use occasion and condition
Truck in this manual is only for lifting and transporting loads.
It must be used, operated and maintained
maintained according to the information in this manual. Any other
uses are outside the design envelope and can lead to injury to persons or damage to equipment
and property.
condition：
Only used in specified place and condition：
– Use in specified rated load.
– Used in specified area as factory, tourist attraction and recreation place. 。
– Used on the flat ground, that is fixed and owns enough carrying capacity.
– It is prohibtted to pass the bulge or cavity as the small wheel diameter may cause truck
tipping over.
– Used on the road with good vision and equipment use license.
– Max. uphill grade when driving is 6%.
– It is prohibited to travel crosswise or obliquely. When go uphill with loads, keep the loads in
front; when go downhill, keep people in front.
For truck operation, the following normal climatic conditions apply:
– Average ambient temperature
temperature for continuous
continuous duty:
duty: ＋25℃;
– Maximum ambient temperatur
temperature,
e, short term (up to 1h): ＋40℃;
40℃
– conditions:＋5℃;
Lowest ambient temperature for trucks intended for use in normal indoor conditions:＋
– Lowest ambient temperature for trucks intended for use in normal outdoor conditions:－20
conditions:－ ℃;
20℃
– Altitude: up to 2000m.
Please read others safety rules in this manual, it is important to your personal safety, working staff
and goods safety.
WARNING
 Do not carry people.
 Do not over load.
 Do not push and pull loads.
1.3 Main part name
12
11 1
10
9 2
7 5
CBD20-AEC1(Pedestri
CBD20-AEC1(Pedestrian
an type)
1 11
12
10 9
2
13 7
6
5
CBD20-AEC1S(Stand-on type)
14
Item Description Item Description

1 Control handle 8 Fork
2 Control lever 9 Load wheel
3 Key switch 10 Battery cover
4 Hood 11 Instrument
Instrumen t
5 Auxiliary wheel 12 Emergency stop switch
6 Drive wheel 13 Pedal
7 Rear frame 14 Fence(optional)
1.4 Display and control
20
21 21
22 22
19 19
16 18
17
1 11
12
1.4.1 Display recharged.
Instrument [11] Hourmeter indicator(green LED)

Said when the green LED light is normally on
the timer is timing, the smallest unit of time for
0.1 hours.
Every time when starting the vehicle LCD
screen will display the vehicle's total run time,

this time is for regular maintenance on the
basis of the vehicle.
Low speed indicator [18]
Dot-matrix LCD display
The display screen is 8 alphanumeric

characters, dot-matrix LCD liquid crystal
display, can display vehicles fault code,
battery soc and total running time.
Vehicles when the normal operation of the
display shows the battery remaining power. When the indicator light shows that the truck
Service indicator(red LED) is in low speed operation mode.
When the controller to detect fault information,
the red LED indicator light flashing, at the
same time LCD display shows two digits of
the fault code.When there are multiple fault
fault code alternates between interval of 2
seconds.Fault code corresponding fault
information to view in this paper, the fault code
table.
BDI indicator(yellow LED)
When battery remaining power less than 20%,
the yellow LED indicator lights flashing,
warned "depleted", at the same time LCD
display shows "20%" for 1 seconds after into
"Low BDI".
When the yellow LED indicator lights flashing,
vehicle lifting by automatic locking function,
running speed is reduced.At this time should

be immediately available for vehicles
1.4.2 Control
Control handle[1]
This switch is at the head of control lever,

once touch this button, the truck moves
Control truck steering and braking. forward. It is used to protect people from
When turn the control handle right and left, it being clamped by the control handle.
turn 。The
can realize the truck right and left turn。 This switch is also called belly switch.
max turning angle of this handle is about 175°. [17]]
Low speed travel button [17
When press the handle to horizontal position
or push up to vertical position, it can realize
the truck brake. These two positions are set Press this button, the maximum speed of the
by brake inching switch. Normal is open circuit, truck to reduce to 2.4 km/h. Release this
working status is closed, brake inching switch button, the truck travels in normal speed.
at horizontal or vertical position is normal. Direction and speed control button[19
button[19]]
Key switch [3]
Turn on the key switch, and the power is on. Turn

off the switch, and the power is off. Turn off the
This button is at both sides of control lever
key switch before charging.
head, one linkage per left and right. It is to
Emergency stop switch [12]
control travelling direction and travelling
speed.
Truck travels to the fork side
– Press this control handle downwards.
– Turn this button from the side of body to
outside gradually with thumb.
– Truck travels to the fork side.
Press this switch, power is off. Press it when
emergency or no ise. If re-start needed, pull
upward.
Emergency reverse button [[16
16]]
Truck travels to the handle side(or pedal)
– Press this control handle downwards.
Turn this button towards the side of body
gradually with thumb.
– Truck travels to the handle side(or
platform).
Caution
 After the finger is released, the
direction and speed button will
reset itself and the truck will stop
by brake. So do not loosen the
knob when the truck is requested to
continue driving.
Horn button [20]
The button is located on the front of the

control handle upper surface. Press down the
button, and the horn sounds.
Lifting button[21], lowering button[22]
The lifting button and the lowering button are

located on both side surface of the middle
control handle. Press the lifting button, and
the forks move up; press the lowering button,
the forks go down.
When battery power less than 20%, lifting
function will be locked up, at this time should
be recharged as soon as possible.
1.4.3 Others
Hood [4]
There install main parts as hydraulic unit, main drive unit and electric system etc. under the hood.
When check or maintan, please take down the protective shield and then open the rear hood.
Fork [8]
Forks can be lifted or lowered to fetch goods. Because of four-bar mechanism, forks assembly will
move horizontally a distance when forks lift or lower.
CAUTION
 It is forbidden to put hands, feet or any part of the body between lift assy and truck
frame when lifting or lowering.
Load wheel [9]

There is one load wheel under each front outrigger to ensure longitudinal stability.
Check the load wheel to find if there is disrepair or abnormal wear according to necessity. If there is
disrepair on the load wheel or its inner bearing, suspend the truck off the ground or jack the front
outrigger off the ground, replace the worn load wheel or the worn bearing, and renew sufficient
multi-purpose grease on the bearing.
Battery cover [10]
There is a handle in the front of the battery cover, and you can open the battery cover by pushing
this handle.
When check battery, take out the plug, charge or replace the battery, you can easily open the
battery cover.
CAUTION
 When closing the battery cover,
cover, protect your fingers from being clamped.
Pedal（Only for stand-on type）[13]

This pedal can be folded so that you can put down the pedal and stand on it when operating the
truck for a long distance. When transporting at a narrow space, folding the pedal, stand on ground to
operate the truck.
Fence [14] (optional)
In order to further enhance the security of standing drive forklift, prevent the operator body out of
balance was thrown, the user can optional fence.When open or put fence, need to first filed a
guardrail slightly upward, then rotate to open or folded up barriers.
1 3
3 1
1.5 Standard technical data
The following technical data are all standard data. Our company reserves the right of alteration
and extension.
Model CBD20-AEC1 CBD20-AEC1S
s
tic
Operator type Pedestrian Stand-on
s
ri
te
rc a Load capacity Q (kg) 2000 2000
a
h Load center c(mm) 600 600
C
Wheelbase y(mm) 1415 1415
Weight Service weight with battery kg 490 540
Tyre type PU PU
Tyre size/Quantity,operator
size/Quant ity,operator side mm Φ250×80/1 Φ250×80/1
s
re
y
T Tyre size/Quantity,load
size/Quant ity,load side mm Φ85×70/4 Φ85×70/4
ls
e Auxiliary wheel size/Quantity mm Φ100×40/2 Φ100×40/2
e
h
W
Tread, operator side b10(mm) 530 530
Tread, load side b11(mm) 370 370
Lift height h3(mm) 125 125
Fork height, lowered h13(mm) 85 85
Overall length(fold the pedal) L1(mm) 1770 1820
Overall length(unfold the pedal) L1(mm) / 2252
s Overall width b1(mm) 750 750

n
io
s
n Fork size s/e/L(mm) 64×170×1150 64×170×1150
e
im
D Outside fork width b5(mm) 540/680 540/680
Ground clearance, center of wheelbase, min m2(mm) 25 25
Min, right angle stacking aisle width1000×1

width1000×1200
200 across forks Ast(mm) 1980 2040
Min, ringht angle stacking aisle width 800×1200 across forks Ast(mm) 2030 2090
Outer turning radius, min Wa(mm) 1610 1670
Travel speed, laden/unladen km/h 5.0/5.0

5.0/5.0 5.0/5.0
e
c
n Lift speed, laden/unladen mm/s 30/45 30/45
a
rm
o
rf Lowering speed, laden/unladen mm/s 50/
50/35
35 50/
50/35
35
e
P
Max Gradeability
Gradeability,, laden/unladen % 6/15 6/15
Drive motor power kW 1.1 1.1

ry
tte
a Lift motor power kW 0.8 0.8
B
r
to Battery voltage, rated capacity V/Ah 24/165 24/165
o
M
Optional battey voltage, rated capacity V/Ah ～240
24/210～
24/210 24/210～240
24/210～
Controller mode Curtis AC Curtis AC
0
2
4
1
L
C
Q
3
h
7
4 3
1 1
h
m2
y
432 L1
Wa
5 1
b b
L6
a/2 a/2
Ast
10
1.6 Product plates and warning labels location
Plates and labels, such as nameplate, load curve plate, warning labels must be legible, if
identification is unclear, and must be replaced.
The figure below shows the approximate location of the various identity resides. Before operating
the truck, please understand
understand the meaning of the various identities.
WARNING
ELECTRIC PALLET TRUCK

MODEL-TYPE
SERIALNO. RATED CAPACITY kg
LOADCENTER
mm WEIGHT WITHOUTBATTER
Y kg
BATTERY VOLTAGE V MAX.ALLOWABLE BATTERY WEIGHT kg
RATED DRIVE POWER kW MIN.ALLOWABLE BATTERY WEIGHT kg
YEAROF MANUFACT
URE
HANGCHA GROUP CO.,LTD.

Add: Lin'an Economic Development Zone,Zhejiang,China License No.：TS2510002-2016
11
Item Description
Nameplate: The rated capacity on the nameplate is the max. load capacity by the
25 label listed equipment. Any change to the forklift or other equipment may change rated
capacity.
26 Manufacturer’s
Manufacturer’s logo
27 Hoist label: Strap points for crane lifting.
28 Hazard label: Risk of trapping when cylinder extended.

Emergency stop label
label:: press this button when in emergency, thus the truck power is
29
off.
30 switch：“OFF”position is off，“ON”position is on.
Key switch：
31 Hydraulic oil label: Add hydraulic oil.
32 Series tonnage label: A series 2.0 T
12
controller B+ and B- to discharge the
2 Safety Rules
controller capacity.
1) Only trained and authorized operator
7) Whenever you find the forklift abnormal,
shall be permitted to operate the forklift.
stop the truck, put on the DANGEROUS
or FAULT sign to the truck, remove the
key, and report to the managing person.
Only after eliminating the fault can you

use the truck.
– If there occurs to fault, battery electrolyte,
hydraulic oil or brake fluid leakage when
2) Operator must wear helmet, working lifting loads, going up and down the slope,
shoes and uniform please organize staff to repair.
3) It is not allowed to reconfigure the truck 8) Internal battery may generate explosive
without manufacturer’s permission.
permission. gas, it’s prohibited any flame close the
4) Do not work in flammable and battery. Never allow the tools close two
combustible environment.
environment.
poles of the battery to avoid spark or
5) Check the oil, fluid leakage, deformation,
short circuit.
flexibility in certain time. If neglected,
service life of forklift will be shorter and in
serious condition there will be accident.
– Make sure change the “safety parts”
during the schedule maintenance.
– Wipe off the oil, grease or water on the
soleplate, foot pedal and control stick.
– No smoking or any spark, smoke near the 9) The work ground of forklift shall be solid
battery when checking. and smooth concrete surface or similar
– Be careful of scald when checking motor ones. Pre-check the ground condition of
and controller. working site. Tidy the working site, clean
6) The controller equips with energy obstacle, sweep macadam, muddy sand
accumulator, do not touch between B+ and wipe off greasy dirt.
and B- to avoid electric injury. If you need 10) Do not overload. Before operation, first
check or clean the controller, connect know the curve chart on the load curve
load(like contactor coil or horn) between plate well, which indicates the relation
13
between rated load and load center. clipped, it is dangerous to your life. It’s
11) Before start, press the horn and make forbidden to put the head, hand, foot or
sure no people around. body into the space between fork and link
12) Goods are not allowed to deviate the fork mechanism.
center, when goods is deviating the fork
center, turn or pass uneven road, you are
easily to fall. Meanwhile, possibility of

turnover will increase.
19) Make the loads in front when climbing the

slope. It’s prohibited
prohibited to turn on the slope,
or there’s danger of tipping over. Avoid
working on the slope.
20) Do not use truck under the weather of
13) Avoid sudden
sudden drive, stop
stop or turn. sand, snow, thunder, storm, typhoon, etc.
14) Do not drive the truck when the forks in Avoid using the truck when the wind
high position. speed is larger than 5m/s.
15) When handling bulky loads, which restrict – The weather condition: temperature:
your vision, please operate the machine -5℃～40
-5℃～ ℃, wind speed: less than 5m/s;
40℃
in reverse or have a guide.
air relative humidity: less than 90%（20℃）
20℃）
.
16) Cause the wheels of pallet truck is small,
Altitude should
should not exceed
exceed 2000m.
it is not allowed to run on the street, and
21) After
．．
．．．power
．．．．．off,
．
．．．brake
．．．．．works
．．．．and
．．．．the
．．．．．．．
only for driving in specified stacking
truck
．．．．．can．not
．．．be
．．．．．．towed(dragged)
．
．．．．．．．
．．．．．．
place.
22) As
．．．
．．to
．stand
．
．．．．-on
．．．．
．．truck,
．．．．．stand
．．．on
．．．．．．．
．．firmly
．．．．．
17) It’s forbidden to put the head, hand, foot
and
．．． hold
．．．
．．the
．． handle
．．．．． tight
．．．．．．．ly.
．． When
．．．．
or body under the forks. Never stand on
turning,
．．．．．．．．．the
．． speed
．．．．． should
．．．．．． be
．． lower
．．．．．
the fork. than
．．3km/h
．．．．．．．．．
23) There’s warning and operation method on
truck label. Please obey the requirement
in this manual and the truck label when
operation. Check label, identification plate,
replace damaged or fallen ones.
24) Fire extinguisher shall be equipped at the
work site. Users can choose truck
equipped with fire extinguisher. Driver
18) It’s forbidden to put the head, hand, foot and manger should be familiar with the
or body into the space between the fire extinguisher position and application
chassis and lifting component, once method.
14
25) Use tray when carrying small items, do
not place on the fork directly
26) Do wash the inner of the truck, do not
place the truck outdoors and exposed to
the rain.
27) Before dismantle or repair the truck, take
down the battery plug firstly.
28) Only in the event that the truck
manufacturer is no longer in business and
there is no successor in the interest to the
business, may the user arrange for a
modification or alteration to a powered
industrial truck, provided, however, that
the user.
– arranges for the modification or alteration
to be designed, tested and implemented
by an engineer(s) expert in industrial
trucks and their safety,
– maintains a permanent record of the
design, test(s) and implementation of the
modification or alteration,
– approves and makes appropriate
changes to the capacity plate(s), decals,
tags and instruction handbook, and
– affixes a permanent and readily visible
label to the truck stating the manner in
which the truck has been modified or
altered, together with the date of the
modification or alteration and the name
and address of the organization that
accomplished those tasks.
15
3 Transport
The forklift truck is designed for short-distance lifting,lowering and transporting load units, not
suitable for long-distance travel. If needed, the forklift truck must be transported by using lifting
device or platform to place on truck or trailer.
3.1 Lifting by crane
WARNING
 Only use lifting gear with sufficient capacity (for truck weight see truck nameplate).
 Do not stay under the truck when hoisting the truck.
 When hoisting or laying down, it should be stable and slow to avoid collision or
accident.
Procedure:
– Park the truck securely
securely..
– Secure the lifting slings to the strap point, and prevent them from slipping. Crane slings
should be fastened in such a way that they do not come into contact with any attachments
when lifting.
– Load the truck and park it securely at its destination.
16
3.2 Securing the truck during transport
Correctly fix the forklift truck to avoid move when using truck or trailer.
trailer.
Procedure:
– Park the truck securely
securely..
– Sling the tensioning belt around the truck and attach it to the fastening rings of the
transporting vehicle.
– Use wedges to prevent the truck from moving.
– Tighten the tensioning belt with the tensioner.
WARNING
 The truck or trailer must have fastening rings.
 Use wedges to prevent the truck.
 Only use tension belt or fastening belt of good nominal strength.
17
3.3 How to remove a broken truck
It’s not allowed to tow the forklift truck on the ground directly when the truck is broken down or
damaged since the brake of the truck is closed under normal circumstances. Appropriate vehicles
should be used to remove the broken trucks.
WARNING
 Do not tow the broken trucks on the ground directly, or else the braking system
would be damaged.
18
When electrolyte level is low, you must
4 Battery
add distilled water to the level appointed.
4.1 Attention for using
WARNING
battery
 The shortage of the electrolyte will
1) No firing cause the storage battery
Explosive gas can be produced in the internal overheated, even cause the system
of storage battery, smoking, flame and sparkle part of storage battery and electric
can easily cause storage battery explosion. combustion.
 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;
2) Protection against electric shock Splashing to the clothes：take it off
immediately.
CAUTION
Careless drinking ： drink plenty of
· Storage battery has high voltage
water and milk.
and energy.
 Wearing glasses, rubber overshoes
· Do not bring short circuit.
and rubber glove.
· Do not approach tools to the two
Keep battery clean
poles of the storage battery，which
Keep dryness and cleanness on the surface of
can cause the sparkle.
storage battery. The poles for connection are
3) Correct wire connection
also dry and clean. Operator must screw
Never allow wrong connect of battery anode
down the vent-cover of storage battery.
and cathode, otherwise it may cause sparkle,
burning or explosion. CAUTION

4) Do not over-discharge  Do not use dry cloth or fiber cloth
– Never charge only when the forklift can’t to clean the storage battery, avoid
move, this will shorten the battery working static to cause the explosion.
hours.  Pull out storage battery plug.
– When two flasing lights of the power  Clean with wet cloth.
indicator flash, please charge  Wearing glasses, rubber overshoes
immediately. and rubber glove.
5) Inspection for electrolyte

electrolyte
– It is forbidden to use the truck when the
electrolyte is in shortage.
– Inspect electrolyte level every week.
19
Measures in summer
In summer, water in the electrolyte is easy to
evaporate, therefore, electrolyte
electrolyte must often be
inspected if electrolyte is low, you must add
distilled water to the level appointed.
CAUTION
 Do not over fill distilled water. Spilt
electrolyte will cause corrosion and
electricity leakage.
Measures in winter
– Keep effective and good surrounding for
charging.
– When it is cold, pull out the storage
battery pin to prevent discharging.
– Take measures such as covering storage
battery for warmth.
– Don’t park the truck in cold outdoor or
cold storage for a long time.
– Charge in time after work.
20
4.2 Dimension/Service Weight
CBD20-AEC1
Item
CBD20-AEC1S
（L）
Length（
Length mm 650
Width（
Width （W） mm 201
Height（H）
Height（ mm 570
Allowable lightest
lightest kg 150
Allowable
kg 220
heaviest
L W
WARNING
 Battery weight and dimensions have considerable influence on operational safety of
the truck.
 When installing or replacing battery, be sure that battery in the fixed position.
21
4.3 Charging the battery
Procedure:
– Drive the truck to appointed
appointed charging place, park the truck and render if safe.
– Open the battery cover (10).
– Remove the battery plug from the truck socket (38
(38).
).
– Open the fill cap of each battery cell.
– 39)) to battery plug (38
Connect the charging plug ((39 (38).
).
– Start the charging procedure according to the charger operation instructions.
– End charging according to the charger operation instructions after the battery fully charged.
– Remove the battery plug (38
(38)) from the charger.
– Close the fill cap of each battery cell.
– plug（38
Connect the battery plug（）with truck socket and cover the battery hood(10).
38）
After charging,
charging, the truck can be used.
10
38
39
WARNING
 Please charge in the well-ventilated and appointed site.
 Mark ‘No smoking’ when charging and prepare extinguisher.

 Before charging, please examine wire and electrical outlet for damage, otherwise do
not charge.
 Open the hood and storage battery lid to release the explosive gas when charging.
 Never place metal object on the battery.
 In the progress of charging, do not pull out power switch and battery plug,
otherwise it may damage plug and electrical units. Generally press down the
stopping button firstly, and then take out the plug.
22
d. the electrolyte is mixed with impurity
Daily charging
with a little harm;
·The storage battery that has been made first
e. It often be charged deficient or has
charging and used in normal condition, then
not been used for a long time;
charged again, it is named daily charging.
f. After taking out the storage battery
·Its way is almost same as the first charging.
·The recharging volume is 1.2 times than the group for checking or cleaning
last electric discharging. But the new storage settling.

battery’s former five times’ charging volume
The way of equalizing charging：
should be 1.5 times than the last electric
(PCA Automatic Charger Ooperation
discharging.
·During any charge, the temperature of Instruction）
Instruction）
electrode should not exceed 45 0C, otherwise ①Firstly, charge the storage battery
it should be taken measures such as reducing normally, and then rest for 1 hour after
artificially charging current or lowing the the end of charge.
temperature. If the temperature still does not ②Charge it again with the second phase
drop, you should stop charging till the
current of normally charge until the
temperature drops down.
electrolyte gives off a large number of
Adopt intelligent charging to do daily charge, bubbles, then stop charging for 1 hour.
the former five times of new battery should do ③Do it several times as mentioned above
equalizing charging according to operation until the voltage and the density keep
instructions of intelligent charger.

charger. invariable and the storage battery gives
Equalizing charging off a large number of bubbles

·During using of the storage battery, it often immediately when charge again.
occurs to disequilibrium
disequilibrium among the voltage, Additional charge
· If one day’s work
work cannot be fulfilled in one
density and capacity.
charge, carry out additional charge during
·Compared to most of the batteries,
breaks.
battery’s proportion of
several storage battery’s
· When the temperature of circumstance is
voltage and electrolyte rises slowly during
low, carry out additional charge.
the course of charge and discharge, its
storage battery’s proportion of voltage and Charge for long-term storage
electrolyte declines faster than most of ·Carry out equalizing charging before storing.
·Carry out equalizing charging once every 15
other batteries.
to 30 days during the storage period.
·Make equalizing charging in the following The proportion and level of electrolyte
case：
case：
a. discharge voltage often drop down WARNING
 If the level of the
the electrolyte is low,
low,
final voltage;
using the storage battery will cause
b. discharge current is often larger; the storage battery over-heat and
c. not charge in time after discharge;
discharge;
23
shorten the storage battery’s life.
1． Inspect electrolyte
The storage battery without a dobber
It is proper to pour the electrolyte 15-20mm
above the electrode plate.
The storage battery with a dobber

According to the dobber of the ventilation
cover, read the level position of the
electrolyte.
The storage battery without a dobber

When the electrolyte is above 15-20mm of the
electrode plate, stop replenishing
replenishing
④After replenishing
replenishing the distilled water,
water, close
the ventilation cover and box cap.
⑤Use the damp cloth to clean the surface of

storage battery cell.
2． Replenish the distilled water
·Wear the blinkers, rubber shoes and WARNING

 It is not permitted to exceed the
rubber glove.
appointed top level when
①Use the measuring cylinder to take out
replenishing the distilled water.
the distilled water with a certain quantity.
② Open the battery ventilation
ventilation cover or fill Adding too much will result in
cap. leakage of electrolyte, and it will
③Imbibe distilled water with injector and damage the truck when charging or
then supply it into the storage battery. discharging.
The storage battery with a dobber  Draw it out with injector if adding
too much.
When the red dobber rises, the white line
appears, please stop replenishing. 3． Reading the specific gravity

1）The specific gravity of the electrolyte will
24
change as the temperature changes. The specific gravity at the standard
① Use thermometer to measure the 0
temperature of 30 C should be converted as
temperature for electrolyte. follow:
② Put the straw of densimeter into electrolyte D30= Dt + 0.0007( t - 30 )
uprightly, extrude rubber tube with hand and Therein to ：D30 ——
——the the specific gravity at
the electrolyte will be sucked into the glasses the standard temperature of 300C
tube and then the floater of the densimeter will Dt ——

——the
the specific gravity at the
float. temperature of t0C.
③Numerate the reading of the densimeter. t —— the temperature of the distilled
Caution： The dobber of densimeter must rise water during convert.
·The specific gravity referred in this book is
uprightly without depending on the glass pipe.
30 ℃。
measured all at the temperature of 30℃。
Charger：
Storage battery of this truck equips with PCA
Automatic Charger
Charger Operation
Operation Instruction.
1． The charger is automatic high
frequency charger. The capacity voltage is

220V AC. The input current is not less
than 15A. The output voltage is DC 36V.
Maximum charge current is 35A. The total
charge procedure is automatical. For more
information please refer to charger
manual.
2． Connection with earth wire for using.
3． Replacement
Replacement fuse, first plug out the
plug.
4． specialized person can’t open the
Non-specialized
Non-
2） Measuring the proportion hood to check or repair.
Use gravimeter to calculate the electrolyte 5． Do not rebuild or disassembly charger。
proportion. 6． Prevent charger overheat in high
temperature seasons, that will hurt charger,
if necessary can pause charge.
If you don’t want use automatic option, you
should adjust the charge current, charge
voltage, charge time and etc. manually. And
you should measure the specific gravity of
electrolyte on time to assure the battery can
be charge at best state. To adjust the
parameter of charger, please see the following
3） Co
Conversion
nversion of the specific gravity
battery charging.
25
4.4 Replacing the battery
Procedure:
– Park the forklift in a safety place as required.
– Open the battery cover(10).
– Pull the battery plug (38) from the forklift socket. Put the plug and cables into the battery box
(37). Do not scratch the cables when taking out the battery.
– Remove the grub screw (40) and fixed block (41).
– Connect the lifting device with the two lifting holes of the battery box (37) and fasten them.
– Pull the battery out of the box vertically by using of a crane.
– Install the battery in the reverse sequences. Pay attention to the loading position of the
battery and the wiring. Make sure they are correct.
37
38
41
40
10
WARNING
 Battery box is very heavy, be careful to avoid damage.
 Make sure the lifting capacity of the crane is larger than battery weight.
 Disposal to the waste battery should accord with local environment regulation.
 When replacing the battery, ensure that a battery of the same specification,
dimension and weight is fitted.
26
5 Truck breaking-in
We recommended operating the truck 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 truck
operation：
is in a stage of 100 hours of operation：
– Avoid the new
new battery over
over discharging
discharging in early period.
period.
– Perform specified preventive maintenance services completely.

– Avoid sudden
sudden stop, start
start or turn.
– 70～80% of the rated load.
Limited load is 70～
– Often check and fasten the fasteners of each joint part.
– After the break-in
break-in ends, replace
replace hydraulic
hydraulic oil.
27
6) Battery check
6 Operation
Check the battery cover board. See whether
6.1 Check before operation the battery fixed reliable.
In order for the safety truck operation and Check proportion of electrolyte. Refer to
keep the truck in good condition, before “battery” section.
starting the truck, you must check it carefully. Check the terminal for loose or damage.
1) Oil leak and liquid leak check Otherwise it will be adjust or replace.
Check the truck for hydraulic oil, gear oil or
electrolyte leak.
2) Fork check
Check the fork and see whether bending or
crazed.
3) Front/rear wheel and balance
balance wheel
check
Check the wheel and see whether there is any
Plug in and turn on the key switch.
crazed, damaged, or abnormal wearing. 7) Instrument display check
Check the wheel fastners for looseness. Refer to instrument part.

Inspect whether there is rope on the wheel. 8) Lifting and lowering button
4) Check front fork and linkage Press the lifting button and check the fork
mechanism lifting condition. Press the lowering button,
Check the fork and linkage mechanism, see check the fork lowering condition. Check if the
whether bending or crazed. lifting system has abnormal sound.
Whether appear interfere when move, 9) Forward and reverse running
movement point wear whether severe. condition
5) Hydraulic oil check Tilt the handle to some degree, gradually
Open the hood press the accelerator button to the outside of

the body with thumb, and inspect the forward
Loosen the hydraulic oil filler cap, pull out
dipstick, and check if the oil level within the running condition; gradually press the
scales. Add oil when insufficient.

insufficient. accelerator button to the inside of the body
with thumb, and inspect the reverse running
condition.
10) Brake system
When the truck run forward or backward, push
the handle to vertical position or press to level
position to check the brake condition.
11) Steering system
Left or right turn the handle to make the truck
Close the hood, and open the battery cover run around 3 turns, and then check if the
steering system is normal.
28
12) Horn
Press the horn button to check sound.
13) Appearance
Check the truck appearance for clean, rust or
paint spalling.
14) Others
Check whether there is any abnormal noise,
whether wiring is regular or fastner loosens
etc.
29
6.2 Start up
Procedure:
– Plug into the plug.
– switch （3）.
Turn on the key switch（
– Pull up the emergency disconnect switch （12

disconnect switch（）.
12）
If you need to stand on the peda to operate for the stand-on type truck, you need open the pedal
and coaming.
12
CAUTION
 Make sure the work ground is hard enough to support the truck.
 Be careful to control
control the truck’s speed.
30
6.3 Travelling
Pedestrian-type
Driver should walk in front of the truck and keep at the side front of the truck when travelling.One
hand holds the handle, and operate travel switch with thumb. Always watch moving direction and
guide truck. Or hold the handle with both hands and push the truck go forward.
CAUTION
 Operator must wear protective boots.
 When enter narrow area as lift, first get fork go.
 Keep road clean and wipe greasy dirt, water or other easiy causes slipping dirty.
dirty.
Travelling on the slope：
When going uphill and downhill without load, keep the fork to downhill direction; when going uphill
and downhill with load, keep the fork to uphill direction.
WARNING
 No turn, inclines when going uphill and downhill.
 Never park on the slope.
 Slow down when going downhill and ready for braking.
 Travel according to regulated route.
 The road should keep clean, no slipping
31
17
0 B1
B2
Slow down
– Slowly loosen the thumb, the direction speed control button will return automatically and the
truck slows down.
Stand-on type
– Start up the truck
– Open the pedal
– Step on the pedal
– Swivel the control handle to driving range (F).
– Adjust the direction
direction speed control button (17)
(17) to the desired
desired direction
– Control truck speed by direction speed control button (17). Speed is controlled by rotating the
driving switch, and the maximum rotation can get fast speed.
Others refer to pedestrian-type
pedestrian-type contents.
32
6.4 Braking
– When the thumb off the direction speed control button, pull the handle to braking range (B1 or
B2) position or vertical postion, the truck brakes.
CAUTION
 When release the control handle, the handle swivel into the braking range slowly or
nor enter braking range, do check the reason and eliminate the fault. Replace gas
spring if necessary.
6.5 Steering
– Hold the left and right handle of control handle with both hands, and decline to some degree,
move the handle to left or right to release truck steering.
When turn to left, the truck turns left.
When turn to right, the truck turns right.
6.6 Stopping
– Release the direction-speed knob. Decrease the speed.
– Return the control handle to vertical position.
– Drop the fork to the lowest position.
– Turn off the switch to “OFF” position, press down the emergency disconnect switch, pull out
the battery plug, and take off the key.
– Fold up.
6.7 Loading
Procedure:
– Drive the truck carefully up to the loads.
– Adjust fork height

height to make the forks are in the tray
tray..
– Raise the loads several centimeters to make sure if the loads are firm.
33
– Travel the truck off the area.
– Drop the load to lower position.
6.8 Unloading
Procedure:
– Approach the
the deposit area.
area.
– Raise the loads to correct height.
– Travel forward, put the load on the unloading positon and then stop.
– Make sure the load are right above, drop the forks slowly until the forks are out of the load.
– Travel backward
backward and make the fork
f ork out of the load.
– Drop down the forks to proper position.
34
6.9 Parking
After daily work,
work, park the truck according to the following
following steps.
– Drive the truck to safe area or appointed area.
– Fully lower the forks.
– Turn off the key switch(3), and remove the key.
– Press the emergency stop switch(12).
– Fold pedal(13) .
– If park for long time, remove the battery plug.
12
13
35
7 Deposit the truck
7.1 Deposit the truck for long time
– Fully check the truck, especially check the wheel damage.
– Check fluid oil and electrolyte for leakage.
– Apply lubrication
lubrication grease.
– Check the joint face of cylinder piston rod for looseness, and if scratch on the piston rod
surface. Apply
Apply anti-rust oil to piston rod or easily rusty axle.
– Cover the whole truck.
– Check specific gravity of electrolyte and liquid level once a month.
– Do equalizing charge to the battery once a month.
7.2 Start running after deposit for a long time

– Remove rust preventive oil on exposed parts.
– Clean impurity and water of the hydraulic oil tank.
– Recharge battery, fit on truck and connect.
– Carefully check before start. Inspect starting, travelling, slowing down, steering, braking and
parking etc. function.
36
8 Maintenance
8.1 Maintenance general
– The forklift truck needs inspection and maintenance periodically, to make it in good working
condition.
– Inspection and maintenance are usually ignored, you’d better find the problems early and
solve it in time.
– Use authentic parts of Hangcha
H angcha Group.
– Don’t use different oil when changing or adding oil. Don’t rave about oil and electrolyte used
at will, and carry on handling according to the local environmental protection laws and
regulations.
– Draw up complete maintenance plan.
– After you make
make maintenance, you’d better make a record.
maintenance, you’d
– Forbid to repair the forklift truck if you haven’t been trained
trained..
CAUTION
 No fire.
 Y
You pu ll off the plug before service. （except some
ou should shut off key switch and pull
trouble shooting）.
 Clean the electric part with compress air, and do not with water.
 Do not stretch your hands, feet or any part of body into the gap between the mast
and instrument.
 When the working environment is severe, maintain in advance.
37
8.2 Periodic maintenance schedule
D= work every 8 hours(or per day)
W= work every 40 hours(or per week)
M= work every166 hours(or per month)
T= work every 500 hours(or 3 months)
S= work every 1000hours(or 6 months)

〇 —Check, revise, adjust
× —Replace
Battery
Service
Service required Tool D W M T S
item
Eyeballi
Electrolyte level 〇〇〇〇
ng
Densim
Electrolyte proportion 〇〇〇〇
eter
Battery quantity 〇〇〇〇〇
ry Terminal looseness 〇〇〇〇〇
tte
a
b
e Looseness of connecting wire 〇〇〇〇〇
g
ra
to Cleanness of the battery surface 〇〇〇〇
S
If there are tools on the battery 〇〇〇〇〇
The tightness and smoothness of

〇〇〇〇
air cap
Far away from firing 〇〇〇〇〇
Controller
Service
item Service required Tool D W M T S
Check wear condition of connector 〇〇
r Check the running condition of

lle 〇〇
o contactor
tr
n Check interlock inching switch for
o 〇〇〇〇
C running
Check the connection among motor,
〇〇
battery and power unit
38
Motor
Service
item
Clean the foreign body on the motor 〇〇〇〇
Clean or replace the bearing 〇

r
to Check the carbon brush and
m
o commutater for worn, whether spring 〇〇or× 〇or×
C is normal
D
Whether the connection is correct and
〇〇〇
firm.
Brush carbon powder on shift plate
〇〇
and shift device.
Clean the foreign body on the motor 〇〇〇〇
Clean or replace the bearing 〇

r
to
o Check if there is abnormal vibration,
m 〇〇or× 〇or×
noise, if pedestal is firm.
C
A Whether the connection is correct and
〇〇〇
firm.
Check if the temperature or current is
〇〇
normal.
Driving system
Service
item
x 〇〇〇〇〇
o Check for noise
b
n
o Check for oil leakage
ti 〇〇〇〇〇
c
u
d
e Two
R Add lubricating grease
years
m Bearing lubrication 〇〇〇〇
is
n
a
h 〇〇〇〇〇
c Check if the steering flexible
e
m
irg
n Check for noise 〇〇〇〇〇
e
te Control handle swivel angle 〇〇〇〇〇
S
Wheel（Drive wheel, auxiliary wheel, load wheel）
Service
item
Eyeballi
Check for abrasion or cracks 〇〇〇〇〇
ng
l
e
e Check for bolt fastening and
h 〇〇〇〇
W re-tighten.
Check if there is foreign body like rope
〇〇〇〇〇
on the wheel
39
Brake system
Service
item
Check for brake condition when the
eg h control handle on horizontal position 〇〇〇〇〇
k in c
ti
r h
a c w and vertical position.
B in s Check the inching switch for
〇〇〇
looseness or damage.
Check the installation for fastening. 〇〇〇
itc
e Check the surface abrasion for
n 〇〇
g e equality.
a k
m a
r Check if the clearance is proper and
rto b 〇〇
c adjust, if necessary.
le
E Check the brake for flexibility and
〇〇〇〇〇
effective.
Hydraulic system
Service
item
Check for oil level, change oil 〇〇〇〇 ×

ri
lic o
u v
a r
dr
y s Clean suction strainer
e 〇
H e
r
Clean foreign matter 〇
d Check for block, return spring stuck or

i e damage 〇〇〇
o v
n l
le a
v
o
s Check for wiring looseness. 〇〇〇
Check for oil leakage 〇〇〇〇〇

e
lv Check for safety valve operation
〇〇〇
a
v condition.
ty
fe Oil
a pressur
S Measure safety valve pressure 〇
e
gauge
tin Check for oil leak, looseness, 〇〇〇

jo collapse, deformation and damage
,
g ×
in
ip Replace hoses. 1-2year
P
s
il
u p Check hydraulic pump for oil leakage 〇〇〇〇〇
ra m or noise
u
d p
y
H c Check pump drive gear for wear 〇
Check for inching switch work

g 〇〇〇
g in h condition.
n
it h c
ti
fi c w Check inching switch for looseness or
L in s damage. 〇〇〇
40
Lifting system
Service
item
Check link mechanism for tension,
〇〇〇〇〇
damage or rust
Check if there is abrasion between
shaft and bearing of front and rear 〇〇〇
m fork.
in
s Check if there is deformation or
a
h fracture on the upper and down 〇〇〇
c
e connecting rod.
m
k Check if there is crack or fracture on
in
L front fork or rear fork.
Check for looseness of each joint. 〇〇〇
Add lubricat
lubricating
ing greas
grease
e to the pin oil
〇〇〇
cup.
Check piston rod, rod screw and Test
connection for looseness, deformation hamme 〇〇〇〇〇
r
e or damage r
d
iln
y Check cylinders for operation 〇〇〇〇〇
c
g
itn
f Check for oil leak 〇〇〇〇〇
Li
Check lifting cylinder fixed bolt for
〇〇
looseness.
Check forks for damage,
〇〇〇
k
r deformation or wear
o
F Check fork base and hook welding for
〇〇〇
defective cracks or wear
Others
Service item Service require

requiredd Tool D W M T S
Wire damage or looseness 〇〇〇〇

Wire
LOOSENESS OF CIRCUIT
〇〇〇
JOINT
Emergency
disconnect Check for work condition 〇〇〇〇〇
switch
Direction and
speed control Check for work condition 〇〇〇〇〇
button
Lifting, lowering
Check for work condition 〇〇〇〇〇
switch
Check for work and
Horn 〇〇〇〇〇
installation condition
Check meters for proper
Meters 〇〇〇〇〇
operation
Pedal(only for Check the pedal if folded up
〇〇〇〇〇
stand-on type) and down normally.
41
8.3 Truck used oil and lubrication
D
C
C
C
Filler plug for hydraulic oil

Gliding surfaces
Grease nipples
Code Designation
Designatio n Mark, code Remark
Normally：
Normally ：L-HM32
A Hydraulic oil
oil environment：
High and cold environment： Hydraulic system
L-HV32
Automobile general
general 3 # lithium
C Grease Nozzle and lubrication
base lubricant
D Grease SHELL AL
ALVA
VANIA
NIA R3 Reduction box
42
8.4 Replace hydraulic oil
Procedure:
– Remove the hydraulic unit from the truck.
– Place a container under the hydraulic unit
to pick hydraulic oil.
– Loosen hoop (2).
1
– Take out the hydraulic power assembly (1)
from oil tank (3).
– Pour the hydraulic oil from the oil tank (3)
into the appointed waste oil collect
container, and then clean the oil tank.
– Install the hydraulic power assembly to the
oil tank and then retighten with the hook
（T= 9N.m）
9N.m）.
2
– Screw out the filler cap (4) of the oil tank,
4
add hydraulic oil to specified mark with the
help of funnel.
– Re- screw on the filler cap, and clean the
residual oil on the outside of the hydraulic MAX
3
MIN
unit.
Replacing oil finishes. Then install the hydraulic
unit to the truck.
43
8.5 Replace wheels
8.5.1 Replace drive wheel
Procedure:
– Dismantle the drive unit from the truck.
（Refer to part of ”dismantle the drive unit
from the truck”）

– Remove the 12 socket hexagon screws
which is used to fix the driving wheels
with a S=5mm hex wrench.
– Strike the edge of the driving wheels with

a rubber hammer and remove the old
driving wheels from the drive unit.
CAUTION
 Use equal strength to unscrew the
bolts. Do not overexert which might
do damage on the thread.
 Loosen the bolts in a symmetrical
CAUTION
way when unscrewing the bolts and
 Strike the edge of the driving wheels
remove the bolts respectively.
evenly and symmetrically.
symmetrically.
– Remove the fixation clamp of the motor
 Do not scratch the outer surface of
signal wire.
inner ring gearbox and the inner
surface of the driving wheels.
– Install new driving wheels. Apply
lubricating oil to the outer surface of inner
ring gearbox and the inner surface of the
driving wheels in favor of fast installment.
44
– Locate the installing holes and Strike the
edge of the driving wheels evenly and CAUTION
symmetrically to the perfect match of the Screw up the bolts in a symmetrical
new driving wheels. way by 2 times.
Apply appropriate torque to screw

up the bolts. Do not overexert which
might do damage on the thread or
lead to future removing problem.
– Apply the fixation
fixation clamp of
of the motor
signal wire back and fix it.
– Screw the 12 socket hexagon screws

which is used to fix the driving wheels
with a S=5mm hex wrench.
The replacement of driving wheels is

completed.
45
8.5.2 Replace load wheels
Procedure:
– The fork rises a certain height.
height.
– Hoist the truck frame safely or place the truck on firm iron stand.
– Screw off the bolt.
– Remove the wheel shaft.
– Remove the load wheels.
– Install new wheel in opposite order.
46
8.5.3 Replace Auxiliary Wheels
Procedure:
– Open the hood.
– From the frame above four groups of fixed auxiliary wheel assembly bolts removed.
– Frame - safely lift a certain height, remove auxiliary wheel assembly.
– From the old wheels on auxiliary wheel assembly to be removed, and replaced with new
wheels.
– The auxiliary module in the reverse order in forklift truck wheel assembly.
47
8.6 Replace the key safe parts periodically
Users should replace the parts periodically according to the following table. If the part is abnormal
before the replacing time, it should be replaced immediately.
Key safe part’s description Term of using (year)
Hydraulic hose for lifting system 1-2
High-pressure
High-pressure hose, hose for hydraulic system 2
Inner sealing element, rubber matter of the hydrulic system 2
48
9 Relevant safety directive or standard (CE)
After CE certificated
certificated , the truck
truck meets the following
following directive
directive and standard:
standard:
– directive（namely Directive of the council of the laws of the member
2006/42/EC machinery directive（
states concerning machinery ）, 2000/14/EC Noise Directive（Namely Directive of the council
of the laws of the member states concerning noise radiation of outdoor equipment ）;
– EN ISO3691-1:2012
ISO3691-1:2012（（ Industrial trucks -- Safety requirements and verification -- Part 1:
Self-propelled industrial trucks, other than driverless trucks, variable-reach trucks and
burden-carrier trucks ）、 EN16307-1:2013 （ Industrial trucks. Safety requirements and
verification. Supplementary requirements for self-propelled industrial trucks,other than
driverless trucks,variable-reach trucks）.
trucks,variable-reach trucks and burden-carrier trucks）
– EN1175-1:1998+A1:2010（
EN1175-1:1998+A1:2010 （ Safety of industrial trucks - Electrical requirements - Part 1:
General requirements for battery powered trucks

trucks））、EN1726-1:1998
EN1726-1:1998（（Safety standard for
vehicle）, EN12053:2001, EN1175-1:1998, EN13059:2002, EN1757-2：

machinery industrial vehicle） EN1757-2：
2001 harmonized standard;
–
Main safety elements are in accordance with 2006/42/EC machinery directive as well as
EN1726-1:1998,EN1757-2：2001 standard;
EN1175-1:1998+A1:2010, EN1726-1:1998,EN1757-2：
Electronic components design and manufacture meet low-voltage apparatus directive
2006/95/EC;
Noise is calculated according to EN12053:2001+A1:2008:
EN12053:2001+A1:2008: pallet truck noise, sound pressure
value
Lifting: right ear73.4dB, left ear72.5dB
Going forward: right ear72.4dB, left ear71.5dB
– Vibration data are calculated according to the EN13059:2002+A1:2008
EN13059:2002+A1:2008（（Safety of industrial
trucks - Test methods for measuring vibration ） ,ISO5349-2:2001 and ISO2631-1:1997

2
standard, meet 2002/44/EC directive: handle vibration amplitude is 0.2977m/s .
– Electromagnetic compatibility is calculated according to EN12895:2000 and meet
2004/108/EC
2004/108/EC directive.
49
50
Part : Structure, Priciple and Maintenance
1 Drive Unit
1.1 Drive unit structure and principle
This truck adopts hub-type drive unit(see fig.2-1). This structure owns high efficiency, large drive
ratio range, compact structure and small volume.

1.Housing 2.Bearing 6006 3.Gear shaft 4.Driven gear
5.Flat key 6.Circlip for hole 55 7.End cap 8.Oil seal
9.Screw M6×16 10.Baffle 11.Circlip for shaft 14 12.Circlip
12.Circli p for shaft
13.Driving gear 14.Flat key 15.Driving motor 16.Bolt M8×60
17.Bearing 6002-2RS 18.Circlip
18.Circli p for hole 32 19.Electromagnetic
19.Electroma gnetic brake 20.Bolt M5×16
21.Paper washer 22.Annular gear 23.Bearing 24.Check ring
25.Space ring 26.Bearing 27.Round pin 28.Drive wheel
Fig.2-1 Drive unit structure
51
Drive unit deliver route
route(see fig.2-2): drive unit directly drives by driving the driving gear directly
(see fig.2-2):
through motor. Delivery sequence is from 15

15(drive
(drive motor) to 13(driving
13(driving gear) to 4(driven gear) to
3(gear shaft) to 22
22(annular
(annular gear),
gear), and then drive the driving wheel output. Drive system does not
need gear shift, and reversing operation directly relies on positive inversion of motor to realize
forward or reverse shifting.
3. Gear shaft
4. Driven gear
13.Driving gear
15.Drive motor
22.Annular gear
Fig.2-2 Drive diagram of drive unit

Data
Speed ratio of reduction gear box 31.4

Max. wheel torque N•m 300
Max. wheel load kg 1000
Grease
Greas e SHELL ALV
ALVANIA
ANIA R3
Weight kg 37
Rated voltage V 16
Rated power kW 1.1
Rated current A 64
Drive motor Rated speed r/min 3395
Working system S2=60min
Insulation grade F
Protection grade IP54
Rated voltage V 24
Rated braking torque N•m 8

Brake
Max. braking torque N•m 12
Insulation grade F
52
1.2 Assemble and use notice
– When assemble, scrub the oil seal on the product. Avoid product damage, no disassemble at
will.
– Avoid each
each fitting surface and exposed gear impact,
impact, thus influence installation.
installation.
– Normal working oil temperature is ≤70℃.

≤70℃
– Drive wheel is maintenance free drive device, if need grease, dismantle the drive unit, add
from the top.
– Added amount
amount of grease(SHELL
grease(SHELL ALV
ALVANIA R3) is 2/5-2/3 space
space of the inner
inner chamber.
chamber.
1.3 Fault and troubleshooting
Fault Probable cause Corrective action
Over large gear clearance Adjust
Abnormal
Abnormal gear noise when
Lack grease Replenish
travelling
Over large gear wear Replace
Rotary rolling bearing damage Replace

Abnormall noise when turning
Abnorma turning
Insufficient rotary rolling bearing
Add grease
grease
Inching switch loosen or
Fasten or replace
damage
Over large brake clearance Adjust
Brake ineffective or invalid Brake disc over wear Replace
Brake loosen Fasten
Circuit damage Repair
Large vehicle vibration Damper assembly damage Replace
53
1.4 Drive motor
Traction motor is three phase AC motor, maintenance free, but need check and clean
periodically.
It needs dismantle motor wiring board when replace drive wheel. Tightening torque of lower nut
T=4.05～4.95N.m, while the upper nut is T=10.2～

of wiring board is T=4.05～ T=10.2 ～12.4N.m. When fastening
the upper nut, lock the lower nut to avoid looseness.
Motor use notice

– Keep clean and dry around the motor, place no other material on its inner or outer.
– It’s prohibited to use with overload.

o verload.
– It’s prohibited to coexist with strong magnetic object.
– Make sure the correct of input voltage grade.
– If there is abnormal odor in use, park to check immediately.
– The cabling between motor and controller should be as short as possible.
– During motor travelling, if there happen electric leakage, speed drops suddenly, severely
vibrate, too hot with smoke, or electric contact sparking smoke, turn off the power
immediately for check.
– Often check if the motor over heats.
– Often check motor wiring contact screw for looseness, sparking smoke or insulation aging.
54
Motor fault diagnosis
Fault Probable cause

①Power is not on(at least two phase off)
After power is on, the motor does not
②Fuse fusing(at least two phase fusing)
rotate, but without noise, odor or
③Overcurrent relay adjusts too small
smoke.
④Wiring error of control equipment
①Lack one phase power, or reverse connection of
stator coil one phase
After power is on, the motor does not ②Short circuit of stator winding；
winding；
rotate and fuse burnout. ③Grounding of stator winding
④Wiring error of stator winding
⑤Fuse section too small.
①Open circuit of stator, rotor winding(one phase
disconnection)
disconnectio n) or one phase power is off.
②Start and end of the winding outgoing line wrongly
connect or internal winding oppositely connect.
③Power return contact loosens and contact resistance
After power is on, the motor does not
is large.
rotate with buzzing noise.
④Motor load too large or rotator locks.
⑤Power voltage too low.
⑥Small motor assembles too tight or bearing grease
too hard.
⑦Bearing seizing-up.
①Power voltage too low.
②△ Motor wrongly connected to Y
③Cage rotor open weld or crack
Motor starts hard, and the motor
④Local coil of stator and rotor wrongly or oppositely
speed is much lower than rated
connected.
speed with rated load.
⑤Add too much number
number of windings
windings when repair
repair motor
winding.
⑥Motor overload.
①When rewind, numbers of stator three-phase winding
is not equal.
Current is unbalance when motor
②Two ends of winding wrongly connected
without load and three phases differ
③Unbalance power voltage.
a lot.
④There is interturn short circuit or coil oppositely
connected in the winding.
Motor without load, while loaded, ①Guide bar of cage rotor open weld or crack
ammeter indicator is unstable and ②Wound rotor fault(one phase open circuit) or bad
swings. brush and collecting ring short circuiting device contact.
①Reduce too much number of stator windings when
repair motor winding.
②Power voltage too high.
③Y connected motor wrongly connect to Δ
Motor without load, current is
④During motor assemble, rotor oppositely connects,
balance, but the value is large
make stator core unaligned, effective length shortens.
⑤Air gap over
over large or uneven.
uneven.
⑥When remove old winding for overhaul, use improper
way that burn the iron core.
55
Fault Probable cause
①Insulation paper of rotor and stator or slot wedge
rubs.
②There is foreign body as sand in oil or bearing wear.
③Stator and rotor core loosen.
Abnormall noise when motor
Abnorma motor runs ④Bearing lack oil.
⑤Air duct stuffing
stuffing or fan rubs the fan housing.
housing.
⑥Stator and rotor core rub.
⑦Power voltage too high or imbalance.
⑧Wrongly stator winding or short circuit.
①Too big wear bearing clearance
②Uneven air gap
③Rotor imbalance
④Revolving shaft bend.
Big motor vibration during running ⑤Iron core deforms or loosens.
⑥Housing or basic capacity is insufficient.
⑦Motor foot screw loosen
⑧Open circuit of cage rotor open welding, open circuit
of wound rotor, or winding fault with stator.
①Over much or few grease
②
③Bad oil quantity
Mismatch and contains
between bearing impurity.
and journal or end
cap(too loose or too tight)
Bearing overheat. ④Eccentricity of bearing bore, rub with the axle.
⑤Motor end cap or bearing cap not even assembled
⑥Coupling between motor and load not adjust
⑦Too large or too small bearing clearance
⑧Motor axle bend.
①Too high power voltage, greatly increase the core
heating.
②Too low power voltage, the motor drives rated load,
over large current heats the winding.
③When remove winding for overhaul, use improper
way that burn the iron core.
④Rotor and stator core rub.
Motor overheating or smoking
⑤
⑥Motor overloads
Cage rotor break.or start up frequently.
⑦Motor lacks phase, two phases run.
⑧After rewinding, dipping paint of stator winding is
improper.
⑨In high temperature, much dirt on the motor surface
or ventilation duct block.
56
1.5 Electromagnetic brake
The spring-loaded electromagnetic brake is applied in the truck which is a single disk brake with
double friction surfaces. By use of the pressure spring, powerful braking torque would be
generated when power off. The brake could be released by the electromagnetic effect.
4
3
1.Mounting Bolt of the Brake 2.Stator Module

3.Brake Pad 4.Shaft Sleeve
5.Friction Disk 6.Dustproof Cover
Fig. 2-3 Electromagnetic
Electromagnetic brake parts
57
1.5.1 Electromagnetic brake working principle
Motor shaft (9) is connected with shaft sleeve (4) by passing through the flat key. And shaft
sleeve (4) is connected with brake pad (3) by passing through the splines. When the stator (11) is
block out, the force produced
produced by the pressure spring
spring (10)
(10) would act on the armature
armature (8) which
which
makes rotated the brake pad (3) driven by the motor shaft connected closely between the
armature (8) and cover plate (5). As a result the braking torque is created. There will be a air gap
Z between the armature and the stator at that moment. When the brake needs to be relaxed, the
stator is applied with direct current and the magnetic field would attract the armature (8) to move
towards the stator. The movement of armature compresses the pressure spring (10) which cause
the loosening of the brake pad (3) by that time and the brake is released.
Z
5
1.Mounting Bolt of the Brake
3 3. Brake Pad
8 4. Shaft Sleeve
5. Friction Disk
9
6. Dustproof Cover
4 7. Hollow Screw
10 8. Armature
11
9. Motor Shaft
10.Pressure Spring
11.Stator
12.Mounting Bolt of Friction Disk
12 6 Z. Air Gap
Fig.2-4 Electromagnetic
Electromagnetic Brake Structure
58
1.5.2 Electromagnetic brake installation
– Put the flat key (13) into the key groove of the motor shaft 13
(9). Press the shaft sleeve (4) to the motor shaft (9) and
4
fasten it with the inner spring. 14
– Install the friction disk (5) to the end face of the motor by 9
using three mounting bolts of the friction bolts (12).
5
12
– Cover the shaft sleeve with the friction disk (3). 3
– Install the stator module (2) to the friction disk (5) with three
mounting bolts of the brake (1).
Note: Remove the three rubber mats of the stator module
which is for stable transportation. 1
– Screw down the three mounting bolts (1) with a torque

16
wrench (15) and check the air gap (Z) of the brake with a
Z
feeler gauge (16).
15
– Put on the dustproof cover(6). 6

– Connect the brake wiring.
59
WARNING
 No broken wire sheath, or else the circuit might be damaged.
 Do not process the locating surface or the holes of the production without
authorization, or else the magnet loop would be influenced.
 Do not over press when fitting the motor shaft. Make sure no damage on the friction
surface and wipe off the burr of the mounting holes and surfaces. Put the shaft
sleeve on the motor shaft and fasten the axial clamp spring.
 Measure the direct voltage of the connecting brake and compare the value to the
rated voltage on the nameplate. Deviation should not be more than 10%.
 Make sure it is free from oil and dirt when installing and using the brake.
U=x V DC±10%
OIL
1.5.3 Maintenance
– Avoid rusting When

W hen truck is used in a high temperature for a long time. The actuation side
with rust would affect the performance.
– Do not touch the friction surface with your hand directly.

directly. Make sure it is free
f ree from oil and dirt,
or else the maximum torque could not be achieved.
– Generally the working environment temperature -10℃～+40

temperature is around -10℃～ ℃.
+40℃
Conduct a periodical inspection. It concludes the items as follow. Is it smooth to switch? Is there
any noise or any abnormal heating? Is there any dirt or grease that came to the section of friction
and rotation? Whether the gap is appropriate between the frictions? Any problem with the
exciting voltage ?
60
1.5.4 Adjust the Air Gap of the Brake
Rated air gap Z grows with the friction. In order to there is sufficient braking torque, the air gap
must be set before it reaches to the maximum value. The air gap can be adjusted by several
times. When the thickness of brake pad becomes the minimum value(see the specification table
below), the brake pad must be replaced.
Once the air gap reaches the top value, the brake might not be released and the brake pad
would be burn out. It will also cause the decrease of braking force and the retention and the
noise increase and even big accidents. It is prominent to do the periodical inspection and adjust
the air gap. Disconnect the power. Through adjusting 3 hollow bolts (8) and the mounting bolts of
stator (9), set the air gap between stator (1) and armature (2) to the rated Z by a feeler
gauge.Ensure air gap at all directions are same.
Specification Table
Rated Rated Rated Air Maximum Minimum Pre-tension Torque of

Torque Power Gap Air Gap Thickness of Rotor the Mounting Bolt
8 N.m 25 W 0.2mm 0.5 mm 6.4 mm 5.5 N.m
On the condition of power disconnected, through adjusting 3 mounting bolts of brake (1) and the
hollow bolts (7), set the air gap between stator (11) and armature (8) to the rated Z by a feeler
gauge. Ensure air gap at all directions are same.
Set the air gap in the following sequence:
– Unscrew the mounting bolts of brake (1) with a hex wrench.
– Adjust the hollow

hollow bolts (7)
(7) with a spanner
spanner..
– Screw up the three mounting bolts of brake (1).
– Check if the air gap Z is within the standard range with a feeler gauge.
– Adjust the mounting bolts and hollow bolts respectively according to the following figures.
Set the air gap and screw up the mounting bolts of brake.
-
7 Z
Under the general operating conditions, the first set of the air gap is usually after 1500 to 2000
hours service of the brake and it is suggested to adjust the air gap every 6 months. If it comes to
a poor working condition, such as frequent use of brake and repeated emergency stops ，the air
gap should be set when the brake the shorten the adjustment interval for the first time.
61
1.5.5 Common fault and troubleshooting
Power is obstructed
obstruct ed Connect
Too low exciting voltage Check voltage and adjust.

Brake does not
work Improper air gap Adjust air gap
Stator coil breaks Replace stator
Oil dirt mixed in Clean oil dirt
Install the switch to the DC circuit

Switch installed to AC circuit
after rectifying
Long brake time
Improper air gap Adjust air gap
Unstable operation in previous use Breaking-in for a while
Slipping Reduce load or replace large

Large load
specification
Adjust load peak or large the

Large load change
specification
Too high exciting voltage Check voltage and adjust.
Clutch or motor interfere to the Check control circuit, eliminate

brake interference
High temperature
High environment temperature Set ventilation
ventilatio n
High operating frequency Adjust to proper frequency
Over large load Reduce load

Product service environment needs
Silence design
silence
Impurity mixed in. Clear away the impurity

Large noise
Bad mounting Replace mounting surface or shaft
Large rotational inertia or dynamic Reduce rotational inertia or

unbalance value dynamic unbalance value.
62
2 Hydraulic system
Hydraulic system is mainly composed of hydraulic unit, rubber tube and lifting cylinder.
1. Bolt
2. Washer
3. Pin shaft
4. Composite bushing
5. Lifting cylinder
6. Screw
7. Hydraulic unit
8. Washer
9. Bolt
10.Washer
11.Hose assy
12.Bolt
Fig.2-6 Hydraulic system
63
2.1 Hydraulic system working principle
Lifting the Loading
Press the lifting button of the control lever and the oil pump motor starts. It passed the torque
from motor to gear pump through the transmission shaft. The gear pump absorbs the hydraulic
oil from the fuel tank and passes the oil to the lifting cylinder through non-return valve. High
pressure oil push the piston rod forward which give rise to the lifting of forks and the loading.
Release the lifting button and the oil pump motor stops. The gear pump stops absorbing the oil.
And the non-return valve is closed which can keep the lifting cylinder and the loading in its
original lifting position. When the lifting cylinder reaches the end or the truck is over loaded, the
working pressure is exceeding the safety pressure defaulted in the system, the overflow valve
will be open and the hydraulic oil returns back to the fuel tank.
Lowering the Loading
Press the lowering button of the control lever and the oil pump motor starts. When the closed
electromagnetic valve is applied with electricity, the hydraulic oil in the lifting cylinder will flow
back to the fuel tank due to gravity. Both the cylinder and the loading start to lower. Governor
valve is used to prevent the trucks and loadings from being damaged due to the rapid lowering
speed.
64
65
2.2 Hydraulic unit
The truck adopts combined hydraulic unit(see fig.2-6), which mainly consists of DC motor,
coupling , flange, cartridge, pump, tank and other components.
1. Anchor ear
2. Electric wire
3. Motor
4. Coupling
5. Flow control valve
6. Plug
7. Flange
8. Pump
9. Shaft
10. Bolt
11. Suction tube
12. Filter
13. Anchor ear
14. Tank
15. Tube
16. Filter cap
17. Return tube
18. Connector
19. Cartridge
20. Electric relay
21. Electric wire
Fig.2-7 Hydraulic unit parts
66
Adjust Safety Pressure of Overflow Valv

Valve
e
The default safety pressure of overflow valve in the system is 18.0MPa. It has been set before
the delivery and users do not need to adjust. Here below states the adjusting method of the
safety pressure.
Procedure:
– Remove the oil choking of the pressure hole.
– Connect the oil pressure gauge to the pressure hole.
– Take out the cap of the overflow valve.
– Loosen the nut of the main safety valve.
– Adjust the pressure and the bolts

bolts with a hexagon wrench. The pressure of main safet
safety
y valve
increases when adjusting the screws clockwise; and the pressure decreases when adjusting
the screws counterclockwise

counterclockwise
– Adjust the pressure

pressure to the requested
requested range.
range.
– Once completed, apply back the fastened nut and the oil choking and clean it up.
-
2
4
1 +
3
67
2.3 Hydraulic unit dismantle

Procedure:
– Dismantle the hood.
– Dismantle the connector of the hydraulic unit
and the cylinder.
– Remove the wiring on the motor, contactor and

control valve.
– Remove the tightening bolt that fix hydraulic

unit.
– Take down hydraulic unit.

Assembling order is opposite
opposite to the disassembling
disassembling order.
order.
68
2.4 Dismantle the lifting cylinder from the truck or replace

– Turn off the key switch, pull out the battery plug.
– Take apart the hood.
– Instrument panel: first four pieces of screws;

then switch the red mushroom head to the left,
take it down; and then dismantle instrument
wiring.
– Dismantle piping joint from the cylinder.
69
– Dismantle the pin shaft from the cylinder

supporting point.
– Loosen battery fixed pin and hoist out the

battery.
– Loosen two cylinder fixed bolt from the battery.
70
– Hoist the front truck frame slightly, and then take

out lifting cylinder.
Caution: when hoisting the front truck frame, hold
the control handle to avoid tipping over of the rear
truck.
Assembling order is opposite

opposite to the disassembling
disassembling order.
order.
71
2.5 Hydraulic system fault diagnosis and correction
No oil Low oil level Fill to the specified oil level

pumps from
Clean oil pipe and oil tank. If hydraulic oil is
the pump Blocking of strainer dirty, please change it.
Bearing worn; retainer, O-ring
Change the bad spare parts
Low oil damage
pressure of Adjustment failure of safety
oil pump Rise pressure with pressure gage
valve
output
Fill hydraulic oil to the oil tank, use the pump
Air in the oil pump
pump
after bubble vanishing
Cavitation arising from the Adjust or replace soft tube and clean the
strainer blocking strainer
Replace new hydraulic oil, whose viscosity suits
Noise of oil Cavity caused by the high
pump running speed
pump viscosity of hydraulic oil
Work only when the oil temperature is normal
Check the reason for the bubble and then take
Bubble in the hydraulic oil measures
Gear
F
o pump Oil way block or damage Repair or replace
r
k
s works
c
a Gear Lifting inching switch loosen or
n Re-fix or replace
’t pump damage
li
ft no
work Motor or circuit fault Repair
Forks do not Solenoid valve block or

Repair or replace
drop down damage
Pressure adjusting screw
Re-adjust and lock.
loosen
pressure of Pressure adjusting spring
Replace
safety valce
is unstable deformation or damage.
or can’t be Safety valve spool wear or
Replace or clean to reassemble.
adjusted sticking
Pump failure Repair pump
72
3 Electric system
Electric system of this truck is double wire system, all circuits do not ground. Working voltage is
DC24V.
1. Instrument 6. AC motor controller

2. Emergency stop switch 7. Contactor
3. Key switch 8. Fuse protector
4. Electric horn 9. Fuse
5. Lifting limit switch 10. Main wiring harness
Fig. 3-1 Electric system
73
3.1 Electrical schematic diagram
74
3.2 AC motor controller
3.2.1 Maintenance
AC motor controller,
controller, fuse protector and fuse are installed on the electronic control mounting
bracket, when mounting the controller, apply heat conduction silicon grease to its bottom.
Maintenance
Controller has no user repair parts. Do not try to open, repair or alter the controller. Otherwise it
may damage the controller and also invalid the guarantee.
It’s suggested to keep the con
controller
troller clean and dry, periodically check and get rid of diagnose
historical files.
Cleaning
Periodically clean the outside controller is good for preventing corrosion or other controller fault
from dirty, dust and chemical, which is part of the environment and always exist in battery power
supply system.
Be careful when operating the truck power supplied by battery. Including but not limit to the
following: correct training, wear goggles, do not wear loose clothing and jewelry.
Carry out maintenance according to the following cleaning procedure. Never clean the controller
with high pressure washer.
– Remove battery to disconnect power.
– Connect load(like contactor coil or horn) between controller B+ and B- to discharge
controller capacity.
– Clean dirt or corrosive on the power and signal binding post. Wipe the controller with
wet cloth, dry the controller before connecting the battery. Controller can’t suffer the
water impact with pressure.
– Make sure the wiring is correct and fastened.
WARNING
 Strictly prohibit water in the product. Strictly prohibit operating with electricity.
Strictly prohibit reverse polarity.
polarity. Strictly prohibit motor short circuit.
75
3.2.2 Diagnosis and troubleshooting

Diagnosis procedure
Truck cannot travel
Check if the controller

LED light flashes
Flash
Light is off
If normally flashes
Switch in encoder
Normal flashing way Fault flashing way
Display No display If battery has electricity If motor is normal
Check if Check if If If other Use Refer to

input the output contactor external encoder instructi
Check if the input signal signal absorbs facility to check ons to
end signal of the normal(us from normally is fault check
key switch is able controller normal reason the
normal. encoder) to motor is correspo
normal (if nding
two fault
terminals code of
output LED
after flash.
accelerato
Normal Abnormal r input)
Input Relevant
Eliminate
normal, part fault
key switch Eliminate
external
fault fault
facility
normal,
output
abnormal
Controller Controller
fault fault
Controller
fault
76
ways：
Get the fault information from three ways：
– Get fault information from the instrument: When the truck has fault, the LED3(RED) indicator
light is on, LCD displays fault type and code.
– Get fault information by switching in handheld programmer. Refer to Handheld Programmer.
– Get fault information by observe controller built-in LED indicator lights. Refer to LED Status
Indicator.
77
1311 Handheld Programmer
1311Handheld Programmer is a handheld tool that allows user programming, testing and
diagnosing the traction motor controller, refer to the following picture. Program setting handheld
terminal owns one menu navigation key, one data Inc/Dec key and three bookmark keys to
control all programmable

programmable functions.
Display window includes a seven-line 128 × 64 pixel LCD screen, this screen can show the test
and pictures at the same time, visible in the lightest condition, and adjust program to set menu.
Program is driven by the menu, and enters the next menu by pressing menu navigation button.
When the program is connected to motor controller, all motor controller information uploads to
the handheld programmer.
DISPLAY
SCREEN
MENU
NAVIGATION
KEY DATA
INC/DEC
KEY
1
2 3
BOOKMARK
KEYS
Display screen：It can show seven-line test and pictures at the same time.
Menu navigation key： Move the cursor on the screen up or down to pass the menu list(up or
down arrow),open or close submenu(right or left arrow)
Data Inc/Sec key： Alter data values by display cursor.
Bookmark key：Three bookmark

bookmark keys allow you to return fast or reach your favor or often use
menu interface without through the menu navigation. Press on the relevant bookmark button for 4
seconds, it can store relevant

relevant menu interface to this button. Press the relevant bookmark key
key,, it
can skip to the corresponding menu interface of your chosen bookmark. A

After
fter close the
78
programmer, the bookmark button will not be kept.
79
3.2.3 LED Status Indicator

Controller built in one LED status indicator light(display red or yellow)
Display Information
LED light is off Controller power is not on; or vehicle has dead battery; or other
severe damage.
LED light flashes yellow Controller is in normal working status.

Controller failed to supervise or did not load software. Restart KSI
LED light is often red
cycle, load software if necessary.
LED flashes yellow or red
Controller has detected a fault.
alternately
Red and yellow lights flash alternately in a repeated interval. Each code consists of two digits..
Numbers of yellow lights flash means the figure of the fault code relevant position. Red flashes
once or twice stands for the following yellow flashes stands for the first or second of the fault
code; the yellow LED then flashes the appropriate

appropriate number of times for the first digit. The red LED
flashes twice to indicate that the second digit of the code will follow; the yellow LED flashes the
appropriate number
number of times for the second digit.
For example, fault code “23” LED status indicator light shows as
a s follows:
Red Yellow Red Yellow

✱ ✲✲ ✱✱ ✲✲✲
（the first digit）
digit）
（2）（the second digit）
（3）
digit）
80
3.2.4 Fault code table

This fault codes provide the following information:
– Fault code
– Display fault name on the Curtis programmer
– Display caused by the fault
– Probable fault reason
– Fault deep reason
– Troubleshooting
When there is fault, if it’s affirmed not the wiring error or truck malfunction, you can try to restart
through key switch. If fault still exists, please turn down key switch, check if the connector of pin
35 connects right or gets dirt, after repair and clean , reconnect, and then start again.
Fault code table
Programmer display Deep fault
Code Probable fault reason
Fault display reason/troubleshooting
12 Controller Overcurrent 1. External short of phase U,V,W Reason：Phase current exceeds
Motor stops working motor connections limited current
Main connector disconnects 2. Motor parameters do not Troubleshooting：restart the key
EM brake shutdown match.。 switch
Throttle invalid 3. Controller malfunction
Brake
Pump stops working
13 Current Sensor Fault 1. Leakage to vehicle frame from Reason： Deviation reads out to
Motor stops working phase U,V, or W controller current sensor
sensor..
Main connector disconnects 2. Controller malfunction Troubleshooting：restart the key
Electromagnetic brake disconnects switch
Throttle invalid
Brake, Pump stops working
14 Precharge Failed 1. External load on positive Reason：Key switch input voltage
Motor stops working terminal of the capacitor that failed to charge the capacitor
capacitor..
Main connector disconnects prevents the capacitor from Troubleshooting ： Reset or
Electromagnetic brake disconnects charging. re-input interlock switch through
Throttle invalid VCL function precharge().
Brake
Pump stops working
15 Controller Severe Undertemp 1. Severe controller working Reason：Radiator temperature is
Motor stops working environment. lower than -40℃.
Main contactor disconnects Troubleshooting：Raise the temp
Electromagnetic brake disconnects above -40℃, restart the key
Throttle failure switch or interlock switch.
Brake
Pump stops working
16 Controller Severe Overtemp 1. Severe controller working Reason：Radiator temperature is
Motor stops working environment. higher than 95℃.
Main contactor disconnects 2. Truck overloads. Troubleshooting：Drop the temp
Electromagnetic brake disconnects 3. Incorrect controller mounting below 95℃. Restart the key
Throttle failure switch or interlock switch.
Brake, pump stops working
17 Severe Undervoltage 1. Setup error of battery parameter. Reason： When MOSFEET axle
Too low voltage 2. Power consumption of non working, capacitor voltage is
Driving torque reduce controller system. lower than the minimum voltage
3.
4. Too large
Battery battery impedance.
disconnects. limit.
Troubleshooting ： Raise the
5. Fuse protector disconnect, or capacitor voltage.
the main contactor disconnect.
81

18 Severe Overvoltage 1. Setup error of battery parameter. Reason ： When MOSFEET axle
Overhigh voltage 2. High battery impedance. working, capacitor voltage
Motor stops working 3. Battery disconnects when exceeds the minimum voltage
Main contactor disconnects regenerative breaking. limit.
Electromagnetic brake disconnects Troubleshooting ： Reduce the
Throttle invalid voltage and then restart the key
Brake switch.
Pump stops working
21 Controller Undertemp Cutback 1.Controller works in limited Reason：Radiator temperature is
No fault(unless VCL set the condition. lower than-25℃.
incurred fault) 2. Severe controller working Troubleshooting ： Make the
environment. radiator temperature higher than
-25℃.
22 Controller Overtemp Cutback 1. Severe controller working Reason ： Radiator temperature
Drive or regenerative braking environment. exceeds 85℃.
torque reduces. 2. Truck overloads. Troubleshooting ： Reduce the
3. Incorrect controller mounting temperature.
23 Undervoltage Cutback 1. Insufficient battery power. Reason ： Too low capacitor
Driving torque reduces 2. Setup error of battery parameter. voltage.
3. Power consumption of non Troubleshooting：Raise capacitor
controller system. voltage.
4. Too large battery impedance.
5. Battery disconnects.
6.
mainFuse protector
contactor disconnects or
disconnects.
24 Overvoltage Cutback 1. During regenerative braking, Reason ： When MOSFEET axle
Regenerative braking torque regenerative braking current cause working, capacitor voltage
reduces. the raising of battery voltage. exceeds the maximum voltage
2. Setup error of battery parameter. limit.
3. Too large battery impedance. Troubleshooting ： Reduce
4. When regenerating braking, capacitor voltage.
battery disconnects.
25 +5V Supply Failure 1. External load impedance is too Reason： 5V supply outside the
No fault(unless VCL set the low. 5V±10% range
incurred fault) Troubleshooting ： Bring voltage
within range.
26 Digital Out 6 Failure 1. External load impedance is too Reason： Digital Output 6 current
Digital Out 6 driver is not active. low. exceeds15mA.
Troubleshooting：Adjust load, set
“set_digout()” by VCL, and
restart.
27 Digital Out 7 Overcurrent 1. External load impedance is too Reason：Digital Output 7 current
The Digital Out 7 driver is not low. exceeds15mA.
active Troubleshooting：Adjust load, set
“set_digout()” by VCL, and
restart.
28 Motor Temp Hot Cutback 1. Motor temperature reaches or Reason ： Input voltage value of
Driving torque reduced. exceeds parameter limit, thus motor temperature sensor is 0 or
cause current output reduce. larger than 10V
10V..
2. Motor temperature parameters Troubleshooting ： Return the
incorrect. motor temperature to be within
3. If motor does not apply the permitted limits.
temperature sensor, programming
parameter “Temp compensation”
and “Temp cutback” must set
“OFF”.
29 Motor Temp Sensor Fault 1. Motor temperature sensor is Reason ： Input voltage value of
Max. speed drops to LOS status connected wrongly. motor temperature sensor is 0 or
and motor temperature cutback 2. If motor does not apply larger than 10V 10V..
invalid. temperature sensor, programming Troubleshooting: Adjust input
parameter “Temp compensation” voltage value of motor
82

and “Temp cutback” must set temperature sensor to the normal
“OFF”. scope.
31 Coil 1 Driver Open/Short 1. Connected load open or short. Reason： Driver 1 (pin 6) is either
eithe r
Driver 1 output shut 2. Connecting pin stained. open or shorted. This fault can be
3. Wrong wiring. set only when “Main Enable” set
to “OFF”.
Troubleshooting：Correct open or
short circuit, restart output.
31 Main Contactor Coil Open/Short 1. Connected load open or short. Reason ： Main contactor driver
Motor stops working 2. Connecting pin stained. (pin 6) is either open or shorted.
Main contactor disconnects 3. Wrong wiring. This fault can be set only when
Electromagnetic brake disconnects “Main Enable” set to “ON”.
Throttle invalid Troubleshooting：Correct open
Brake circuit/short circuit, restart output.
Pump stops working
32 Coil2 Driver Open/Short 1. Connected load open or short. Reason： Driver 2 output(pin 5) is
Driver 2 output shut 2. Connecting pin stained. either open or shorted. This fault
3. Wrong wiring. can be set only when “EM brake
Type” set to 0.
32 EM Brake Open/Short 1. Connected load open or short. Reason： EM Brake output(pin 5)
Electromagnetic brake disconnects 2. Connecting pin stained. is either open or shorted. This
Throttle invalid 3. Wrong wiring. fault only occurs when “EM brake
Brake Type” set to 0.
33 Coil3 Driver Open/Short 1. Connected load open or short. Reason：Driver 3 output (pin 4) is
Driver 3 output shut 2. Connecting pin stained. either open or shorted
3. Wrong wiring. Troubleshooting：Correct open or
34 Coil4 Driver Open/Short 1. Connected load open or short. Reason： Driver 3 output (pin 3)
Driver 4 output shut 2. Connecting pin stained. is either open or shorted
35 PD Open/Short 1. Connected load open or short. Reason：PD(pin 2) is either open
PD shut 2. Connecting pin stained. or shorted
36 Encoder Fault 1. Motor encoder error. Reason：Encoder fault
Electromagnetic brake disconnects 2. Wrong wiring. Troubleshooting：Restart key
switch.
37 Motor Open 1. Motor phases is open. Reason：Motor phase, U,V,W
Motor stops working 2. Wrong wiring. detected open
Main contactor disconnects Troubleshooting：Check phase
Electromagnetic brake disconnects and restart the key switch.
Throttle invalid
Brake
Pump stops working
38 Main Contactor Welded 1. Main contactor tips are welded. Reason：Main contactor keep too
Motor stops working 2. Motor phases U and V isis much connecting, capacitor
Main contactor disconnects disconnected or open. voltage can’t discahrge.
Electromagnetic brake disconnects 3. An alternate voltage path is Troubleshooting：Restart the key
Throttle invalid providing a current to capacitor( B+ switch
Brake connection terminal)
Pump stops working
39 Main Contactor Did Not Close 1. Main contactor does not close Reason：When the main
Motor stops working 2. Contactor contacts have contactor is closed, capacitor
Main contactor disconnects oxidized, melted, or connection voltage does not charge B+
Electromagnetic brake disconnects status is unstable. voltage.
Throttle invalid 3. External load on the capacitor
capacitor.. Troubleshooting：Check the
83

Brake 4. Fuse protector disconnects
disconnects.. contactor
contactor,, restart the key switch.
Pump stops working
41 Throttle Wiper High 1. Throttle pot wiper voltage too Reason： Throttle pot w wiper(pin
iper(pin
Throttle invalid high 16) voltage is higher than the
high fault threshold(can be
changed with the VCL function
setup_pot_faults()）
Troubleshooting： Reduce the
throttle pot wiper voltage
42 Throttle Wiper Low 1. Throttle pot wiper voltage too Reason： Throttle pot w wiper(pin
iper(pin
Throttle invalid low 16) voltage is lower than the low
fault threshold(can be changed
with the VCL function
Troubleshooting： Raise the
throttle pot wiper voltage
43 Pot 2 Wiper High 1. Pot 2 wiper voltage too high Reason：Pot 2 wiper(pin 17)
Full brake voltage is higher than the high
fault threshold(can be changed
with the VCL function
Troubleshooting： Reduce the pot
wiper voltage
44 Pot2 Wiper Low 1. Pot 2 wiper voltage too low. Reason： Pot 2 wiper(pin 1 17)
7)
Full brake voltage is lower than the low fault
threshold(can be changed with
the VCL function
Troubleshooting：Increase the pot
wiper voltage
45 Pot Low Overcurrent 1. Potentiometer impedance is too Reason： Pot low end (pin 18)
Throttle invalid low. exceeds 10mA.
Full brake Troubleshooting: Reduce low end
current, restart the key switch
46 EEPROM Failure EEPROM.. It Reason：
1. Error writing to the EEPROM Controller system tries to
Motor stops may be caused by VCL writing to write into EEPROM but failed.
Main contractor stops. EEPROM, or CANBUS, or Troubleshooting：Download
EM brake stops incorrect parameter editing. correct software(OS), set correct
Throttle stops parameter,, and then restart the
parameter
Interlock stops key switch.
Driver1-4 stop
PD stops
Brake
Pump stops
47 HPD/Sequencing Fault 1. Wrong sequence setting of key Reason：The wrong input of key
Throttle invalid start, interlock, direction and start, interlock, direction and
throttle input sequence setting. throttle cause HPD and
2. Wiring, switch key
key,, interlock, sequencing fault.
direction or throttle input fault. Troubleshooting：Re-input
according to correct sequence.
47 Emer Rev HPD 1. Emer Rev already finished, but Reason：After Emer Rev finishes, finishes,
Throttle invalid the throttle, forward or reverse each input does not return to
input and interlock do not return to neutral, that cause the fault.
neutral. Troubleshooting：Re-input
according to correct sequence.
49 Parameter Change Fault safety,, Reason：Parameter change
1. In order to protect truck safety
Motor stops working change of certain special needs restart of the key switch.
Main contractor stops working parameter is only valid after restart Troubleshooting：Restart the key
EM brake stops working the key switch. switch
Throttle invalid
Brake
84

Pump stops working
52 TH PDO Timeout 1. Communication failures. Handle damaged or poor contact

Motor stops communication circuit。
Pump stops
Handle control button all failure
68 VCL
MotorRunTime
stops Error 1. VCL runtime. Reason：VCL runtime error.
Troubleshooting：Edit VCL
Main contactor stops software and correct, check new
EM brake stops software to make correct
Accelerator stops
stops parameter matching; restart the
Interlock stops key switch.
Driver 1-4 stop
PD stops
Brake
Pump stops
69 External Supply Out of Range 1. External load on 5V and 12V Reason：Upper limit of external
supplies too high or too low. power supply(total current: 5V(pin
2. Parameter error in the Checking 26) and 12V(pin 25) is defined by
Menu, like “ExtSupply Max” ，,“Ext External Supply Max and lower
Supply Min” limit is defined by External Supply
Min
Troubleshooting：Adjust external
current.
71 OS General 1. Inner controller invalid. Reason：Inner controller invalid.
Motor stops Troubleshooting：Restart the key
Main contactor stops switch.
EM brake stops
Accelerator stops
stops
Interlock stops
Driver 1-4 stop
PD stops
Brake
Pump stops
72 PDO Timeout 1. Time between CAN PDO Reason：Time between CAN
Interlock stops messages received exceeds PDO PDO messages received
CAN NMT State set to Timeout Period exceeds PDO Timeout Period
Preoperational Troubleshooting：Restart the key
switch, or accept CAN NMT
message
73 Stall Detected 1. Motor is stalled. Reason：No motor encoder is
EM brake
Switch thestops
control mode to 2.
3. Motor
Wiringencoder
damaged.fault. detected.
Troubleshooting：Throttle
LOS(Limited operation status) 4. Problem with power supply for Command=0,Motor
Command=0,M otor RPM=0
motor encoder. Restart the key switch, or detect
the effective signal of motor
encoder in LOS mode, and set
the parameter to Throttle
Command=0,Motor
Command=0,M otor RPM=0.
87 Motor Characterization Fault 1. Refer to the following code Reason： Motor matching
Motor stops during motor matching： process failure.
Main contactor stops 0=Normal Troubleshooting：Correct the fault
EM brake stops 1= Controller receives encoder and restart the key switch.
Accelerator stops
stops signal, but pulse value not defined.
Brake Set pulse value manually
Pump stops 2= Motor temperature sensor
failure
3= Motor high temperature cutback
failure
4= Motor overtemp cutback failure
5= Motor low temperature cutback
failure
85

6= Low voltage cutback failure
7= High pressure cutback f failure
8= Controller can’t detect encoder
signal and passage signal
disappears.
9= Motor parameter setting
exceeds the scope.
89 Motor Type Fault 1. Motor type parameter values Reason：Motor Type parameter
exceed the range setting value is an illegal value.
Troubleshooting：Reset and
restart the key switch.
91 VCl/OS Mismatch 1. The controller VCL does not Reason：The controller VCL does
Motor stops match OS. not match OS.
Main contactor stops Troubleshooting：Update new
EM brake stops VCL and OS.
Accelerator stops
stops
Interlock stops
1-4 output stops
PD stops
Brake
Pump stops
92 EM Brake Failed to Set 1. Truck continues to move after Reason：After EM brake locks,
EM Brake failure the EM brake has been the truck still moves.
Throttle invalid commanded to set
2. Small EM braking force. Troubleshooting ：Check if the
throttle works normal.
93 Encoder LOS (Limited Operating 1. LOS activated due to motor Reason：LOS activated due to
Strategy) installing or encoder fault. motor installing or encoder fault.
2. Wrong wiring. Troubleshooting：Restart the key
3. Truck is stalled switch，if it is caused by motor
installing, make sure encoder
work under normal condition,
Throttle Command=0,M
Command=0,Motor
otor
RPM=0.
94 Emer Rev Timeout 1. Emer Rev timeout activated due Reason：Emer Rev function
EM Brake failure to EMR Timer overdue activated to operate until Emer
Throttle invalid 2. Emer Rev switch is always at Rev timing end.
ON position. Troubleshooting：Check Emer
Rev switch.
98 Illegal Model Number 1. Controller model can’t be Reason：Controller model can’t
Motor stops identified. be identified
Main contactor
EM brake stopsstops 2. Software and hardware do not
match. Troubleshooting：Choose correct
controller, and download correct
Throttle stops 3. Controller damage. controller software.
Brake
Pump stops
99 Dualmotor Parameter Mismatch Enable parameter of dualmotor is Reason：When the dual drive
Close main contactor set as ON, and control mode software enabled, control mode
Close EM brake selecting parameter not set as 0 should set as 0（Speed Mode
Close accelerator （Speed Mode Express) or 1 Express) or 1（Speed Mode）,
Brake and close the pump （Speed Mode） otherwise there will be fault.
Troubleshooting：Adjust to proper
value and switch KSI.
86
Attachment：Table for bolt’s

bolt’s tightening
tighten ing torque
Unit：N·m
Grade
Bolt’s diameter
4.6 5.6 6.6 8.8
6 4～5 5～7 6～8 9～12
8 10～12
10～ 12～15
12～ 14～18
14～ 22～29
22～
10 20～
20 ～25 25～
25 ～31 29～
29 ～39 ～58
44～
44
12 35～44
35～ 44～54
44～ 49～64
49～ 76～107
76～
14 54～69
54～ 69～88
69～ 83～98
83～ 121～162
121～
16 88～108
88～ 108～137
108～ 127～157
127～ 189～252
189～
18 118～147
118～ 147～186
147～ 176～216
176～ 260～347
260～
20 167～206
167～～265
206～
206 ～314
245～
245 ～492
369～
369
22 225～284 284～343 343～431 502～669
24 294～370
294～～441
370～
370 ～539
441～
441 ～850
638～
638
27 441～519
441～ 539～686
539～ 637～784
637～ 933～1244
933～
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.
87
Maintenance Record
Date Repair, maintenance

maintenanc e content Serviceman
88
HANGCHA GROUP CO. , LTD.
■ Address For: OVERSEAS USERS

■ Address: 88 Donghuan
Donghuan Road,
Road, Lin'an Economic
Economic Development
Development Zone,Zhejiang,
Zone,Zhejiang, China
China
■ Fax: 0086-571-88926789
0086-571-88926789 0086-571-88132890 ■ ZIP:311305
■ Web: http://www.hcforklift.com ■ E-mail:
E-mail: [email protected]
[email protected]

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Basic Range

OPERATION AND MAINTENANCE MANUAL

© 7/2015 HANGCHA GROUP CO., LTD

Item Description Item Description

2 Control lever 9 Load wheel

3 Key switch 10 Battery cover

5 Auxiliary wheel 12 Emergency stop switch

6 Drive wheel 13 Pedal

7 Rear frame 14 Fence(optional)

Instrument [11] Hourmeter indicator(green LED)

screen will display the vehicle's total run time,

Dot-matrix LCD display

The display screen is 8 alphanumeric

running speed is reduced.At this time should

This switch is at the head of control lever,

Turn on the key switch, and the power is on. Turn

The button is located on the front of the

The lifting button and the lowering button are

be recharged as soon as possible.

Load wheel [9]

Pedal（Only for stand-on type）[13]

Model CBD20-AEC1 CBD20-AEC1S

Wheelbase y(mm) 1415 1415

Weight Service weight with battery kg 490 540

Tread, load side b11(mm) 370 370

Lift height h3(mm) 125 125

Fork height, lowered h13(mm) 85 85

Overall length(fold the pedal) L1(mm) 1770 1820

Overall length(unfold the pedal) L1(mm) / 2252

s Overall width b1(mm) 750 750

Ground clearance, center of wheelbase, min m2(mm) 25 25

Min, right angle stacking aisle width1000×1

Outer turning radius, min Wa(mm) 1610 1670

Travel speed, laden/unladen km/h 5.0/5.0

Drive motor power kW 1.1 1.1

Controller mode Curtis AC Curtis AC

ELECTRIC PALLET TRUCK

SERIALNO. RATED CAPACITY kg

BATTERY VOLTAGE V MAX.ALLOWABLE BATTERY WEIGHT kg

RATED DRIVE POWER kW MIN.ALLOWABLE BATTERY WEIGHT kg

HANGCHA GROUP CO.,LTD.

27 Hoist label: Strap points for crane lifting.

28 Hazard label: Risk of trapping when cylinder extended.

31 Hydraulic oil label: Add hydraulic oil.

32 Series tonnage label: A series 2.0 T

Only after eliminating the fault can you

easily to fall. Meanwhile, possibility of

19) Make the loads in front when climbing the

3.1 Lifting by crane

burning or explosion. CAUTION

hours.  Pull out storage battery plug.

indicator flash, please charge  Wearing glasses, rubber overshoes

immediately. and rubber glove.

5) Inspection for electrolyte

– Charge in time after work.

 Mark ‘No smoking’ when charging and prepare extinguisher.

last electric discharging. But the new storage settling.

instructions of intelligent charger.

Equalizing charging off a large number of bubbles

The storage battery with a dobber

If there are tools on the battery 〇〇〇〇〇

Far away from firing 〇〇〇〇〇

Check wear condition of connector 〇〇

Clean the foreign body on the motor 〇〇〇〇

Check for oil level, change oil 〇〇〇〇 ×

Check for oil leakage 〇〇〇〇〇

tin Check for oil leak, looseness, 〇〇〇

Check for looseness of each joint. 〇〇〇

Wire damage or looseness 〇〇〇〇