A Series Deluxe Electric Reach Truck

Operation and Maintenance Manual

CQD12-AZ4H
CQD14-AZ4H
CQD16-AZ4H
CQD20-AZ4H

Original Instruction

HANGCHA GROUP CO., LTD.

07/2020
 FOREWORD
Thank you very much for purchasing A series electric reach truck of Hangcha Group.
A series electric reach truck is a newly developed product. The adopted advanced technologies as
electric power steering, electromagnetic brake and armrest fingertip have advantages as comfort
operation, safety and security, low maintenance cost. It also has compact structure, small turning
radius, beautiful shape, low gravity, good stability and superior performance. It 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.
This manual is divided into two parts. Part one of this manual is about the brief introduction and
correct operation of the electric reach truck, which will tell you how to operate safely and maintain
preventively; part two will tell you the structure, working principle and maintenance of the electric
reach truck. To ensure safety and exert the truck’s potential, all the personnel that in charge of
operation maintenance and management must read this manual thoroughly.
Due to the continuous updating and improvement of our products, there may be minor
discrepancies between your forklift truck and this manual.
For any questions, please contact Hangcha or your nearest dealer.
This series truck has been passed CE certification.

○
C 07/2020 HANGCHA GROUP CO., LTD.
 Contents
Foreword
PART ONE OPERATION AND MAINTENANCE ........................................................1
1. APPEARANCE AND MAIN COMPONENTS ........................................................................1
2. DISPLAYS AND CONTROLS ...........................................................................................2
2.1 Multifunction instrument....................................................................................................................... 3
2.2 Controls ................................................................................................................................................. 8
2.3 Seat ...................................................................................................................................................... 16
2.4 Operator Presence System (option) ..................................................................................................... 18
3. USE OCCASION AND CONDITION ................................................................................. 19
4. SAFETY INSTRUCTIONS ............................................................................................. 20
5. ............................................................................................................................... 24
6. DURING BREAK IN ..................................................................................................... 27
7. ROUTINE MAINTENANCE ........................................................................................... 28
8. DRIVE AND OPERATE ................................................................................................ 31
9. STORAGE ................................................................................................................ 35
10. BATTERY ............................................................................................................... 36
11. MAINTENANCE ....................................................................................................... 44
11.1 Maintenance summary....................................................................................................................... 44
11.2 Periodic maintenance schedule.......................................................................................................... 45
11.3 Replace the key safe parts termly ...................................................................................................... 50
11.4 Bolt tightening torque table ............................................................................................................... 51
11.5 Forklift used oil ................................................................................................................................. 52
12. FORKLIFT HOIST AND TRANSPORT ............................................................................ 54
13. MAIN TECHNICAL PARAMETERS LIST ......................................................................... 57
14. NAMEPLATES AND WARNING LABELS ........................................................................ 59
15. THE USE, INSTALL AND SAFETY RULES OF ATTACHMENT ............................................. 61
16. BATTERY AUTOMATIC FILLING WATER SYSTEM(OPTION) ............................................. 63
17. RELATED SAFETY INSTRUCTION AND STANDARD（FOR TRUCKS EXPORTING TO EUROPE
OR OPTION） ............................................................................................................... 67

PART TWO: STRUCTURE, PRINCIPLE AND MAINTENANCE .............................. 69

1. DRIVE SYSTEM ......................................................................................................... 69
2. FRONT WHEEL ASSEMBLY.......................................................................................... 80
3. STEERING DEVICE .................................................................................................... 82
4. HYDRAULIC SYSTEM ................................................................................................. 83
Mutiway valve ........................................................................................................................................... 84
5. MAST SYSTEM .......................................................................................................... 88
6. ELECTRICAL SYSTEM ................................................................................................ 93
6.1Motor .................................................................................................................................................... 93
6.2 Controller fault code............................................................................................................................ 95
6.3 Electric schematic diagram ............................................................................................................... 113
 Part One Operation and Maintenance
1. Appearance and Main Components

7 8

5 9
4

3
10

11
12
13
2 14
1

1. Drive wheel 2. Cover 3. Seat 4. Armrest assembly 5. Housing

6. Overhead guard 7. Spotlight 8. Mast 9. Load bracket 10. Fork
11. Front wheel 12. Reach device 13. Battery 14. Side panel

1
2. Displays and controls

2 3

15

10 4 8
1 11 5 6 7
12

13
9 14

1. Steering wheel 2. Grip 3. Instrument 4. Four integrated 5. Double

rocker switch integrated rocker
switch
6. Parking brake 7. Inching switch 8. Key switch 9. Safety pedal 10. Foot brake
switch pedal
11. Accelerator 12. Fingertip 13. Horn button 14. Emergency 15. Battery plug
pedal stop button

2
2.1 Multifunction instrument

F G H K N

A
I L
B
C
D
E X
J M
P Q

R S T U V W
Item Designation or display or remark Item Designation or display or remark
Character code of target height
A Fork height display L
change
Displayed distance from fork to the
B target height or forklift accumulated M Enter key
travelling time display
C Travel speed display N Number key
D Fork moving direction display P Height indicator key
E Target height character code Q Clear height indicator value
Steering wheel position and
F R Battery low capacity indicator
travelling direction
G Operating mode S Fault indicator
H Auto placement/Up T High temperature indicator
I Auto picking/ decrease/ change U Seat indicator(option)
J Esc key V Parking brake indicator
K Operating mode change/ down W Safety belt indicator
X Battery capacity display

3
Fork height display[A] Target height character code is composed of
two parts: letter and number. Letter can be
changed among A~H letters by pressing ―A-H‖
Real time display the fork height. Truck over
key. Number key can be input by pressing 0~9
4.8M displays this value.
keys on the right of the instrument. When
Caution： starting the height indicator, input ―A3‖, the
 Due to different encoder mounted position
system will pick the corresponding height
and system software, forklifts with
value of ―A3‖.
different masts, the initial fork height
Steering wheel position and travelling
maybe different, so please take the real
direction [F]
forklift as standard.

Displayed distance from fork to the target

height or forklift accumulated travelling The solid black triangle represents the current
time display[B]
driving wheel steering angle. When the truck
Displayed distance from fork to the target starts 360° steering, the instrument displays
height
the whole circle, with 12 triangles. When the
truck starts 180° steering, the instrument
When the truck starts the height recognition displays a semi-circle, left semi-circle or right
function, it real-time displays the distance from semi-circle, total 7 triangles.
fork height to the target height. Operating mode[G]

Forklift accumulated travelling time display

Switch truck travelling mode by pressing

When the truck is without height recognition
operating mode k. There are four operating
function, forklift accumulated travelling time is
modes: ―1‖, ―2‖, ―3‖ and ―crawl speed‖.
displayed, and accumulated as integer hour. Operating mode ―1‖ travels the fastest and
The above forklift has travelled for 6 hours. consumes the most power. Operating mode
―crawl speed‖ limits the maximum travel speed
Travel speed display[C] and is the slowest. Operating mode ―2‖ is
energy saving and economic. Under general
working condition, operating mode ―2‖ is
Real time display forklift travelling speed.
recommended.
Fork moving direction display[D] Auto placement/ up[H]

Display fork moving direction.

Carry out auto placement in the main interface.
Target height character code[E] In the controller system parameter, press this
button, the parameter turns up.

4
Auto picking/ decrease/ change[I] Height indicator key[P]

Carry out auto picking in the main interface. In the main interface, long press this button,
Adjust the controller system parameter. enter height indicator mode and there appears
―P‖ in the instrument.
Esc key[J] In the height indicator interface, long press this
button, exit the interface and letter ―P‖
disappears.
Clear height indicator value[Q]
Press this key, and then exit.
Operating mode change/ down[K]

When setting up height recognition, press this

button, directly delete previous height values,
Choose truck travelling mode by pressing this
press the number key again and input height
key. There are four operating modes: ―1‖, ―2‖,
indicator values.
―3‖ and ―crawl speed‖, press this key to change
among four operating modes.
Battery low capacity indicator [R]

Character code of target height change [L]

When the battery remaining capacity is too low

and is lower than the set value, the indicator
When adding new height indicator, press
will be on.
this button, choose height recognition
character code.
Fault indicator[S]
Call out the height indicator, press this button,
and switch to the corresponding character
code.
The indicator illuminates when the truck
Enter key[M]
malfunctioned.

High temperature indicator[T]

Press this key to confirm or reserve.

Number key[N]
When the detected temperature is higher than
the set temperature, this light flashes.

Seat indicator[U]

5
 started. Press this button again, this symbol
disappears, and the potential energy recovery
is cancelled.
This lamp illuminates whenever the driver
Fault code display
leaves the seat or sit on incorrectly. This
feature requires the seat to be fitted with OPS.
When the truck is operated improperly or has
other fault, there will appear fault code on the
Parking brake indicator [V]
left bottom of the instrument. Use after
troubleshooting. Never use fault forklift.
Application of height indicator
This lamp illuminates whenever the hand 1. In the main interface, long press P ―PRG‖
brake is applied key, until there appears letter ―P‖, and
then enters height indicator.
Safety belt indicator[W] 2. Select target height character code.
Target height character code is composed
of two parts: letter and number. Press L
This lamp illuminates whenever the driver "A-H" key, select target height character
unfastens the safety belt. This feature requires code. Press N number key, input target
the seat to be fitted with safety belt sensor. height character code.
3. Input height value. Press Q ―MAN‖ key,
Battery capacity display [X] clear height values, and then press N
number key to input height value. Due to
Black bars display the battery capacity, each encoder location, the height should be
bar stands for 10% capacity. The more the bar larger than 4.8M, and is invalid when
numbers, the more the battery capacity. lower than 4.8M.
4. Save height value. After inputting the
Caution：
height, press M enter key, once the value
 It is suggested to charge when the battery
flashes once, it is saved. Long press P
capacity is about 30%, otherwise the
battery service life will be influenced. ―PRG‖ key, until letter ―P‖ disappears,
 As to truck deposited for a lone time, then exit the height indicator interface.
charge per month and pull out the battery 5. Callout height value. If it is saved
plug. previously, one height is 6500mm, the
current code is B13. Press L "A-H key,
Potential energy recovery indicator
switch to E and appear letter B, then
press number key to input 13, there will
appear 6500mm at B.
Press the potential energy recovery button, 6. Operate target height indicator. Start the
there appears this symbol on the top right forklift, pull the fingertip, make B real-time
corner of the instrument, and the function is display the distance from forks to the

6
 target height during the mast lifting. When lower. If need to lower, cancel the height
the forks travel to target height, the forks indicator, press Q "MAN" key, D appears
should not surpass the target height or fork up and down two arrows, height
further travel. indicator is cancelled, and then the fork
can lift and lower.

Caution：
 Instrument D displays the fork moving
direction. If the instrument only displays
the up arrow, the fork can only lift, but not

7
2.2 Controls forklift, take your foot off the accelerator pedal,
Steering wheel otherwise fault code will be displayed on the
Left turn 1 instrument.

Caution：
Right turn
 Before starting the forklift, take your foot
off the accelerator pedal, otherwise fault
code will be displayed on the instrument.
Tight
Then take your foot off the accelerator
Loose
2
pedal, the fault code will disappear
Hold steering wheel knob 1 with left hand, automatically.
rotate counterclockwise, the wheels turn left;
whereas rotate clockwise, the wheels turn
Four integrated rocker switch
right.
Steering wheel height adjustment: rotate knob
2, release steering wheel housing and move it
to proper position, and then tighten knob 2.

Caution:
 The forklift steering is drove by the
motor, so when rotating the steering 4
1 2 3
wheel, the wheels do not steer after
Functions of four integrated rocker switch are
the truck is shut down,
as follows：
 Without pressing steering inching
button, it can rotate 180° in place. No. Remark
Press steering inching button, it can 1 Headlight rocker switch
rotate 360°in place.
2 Alarm light rocker switch
Key switch
3 Spot light rocker switch

4 Standby switch

Two integrated rocker switch

The key switch has two positions: ―O‖ and ―▬‖.

Turn the key to ―▬‖, the truck starts up; turn to
―O‖, the truck shuts down. Before starting the
1 2

8
Two integrated rocker switch is standby switch parking brake.
and has no function for present.

No. Remark
Inching switch combination
1 Standby switch 1.
180°/360°
2 Standby switch turn toggle
button
2. Pump
energy
Parking brake button recovery
button

1 2
P
No.1 is 180°/360°turn toggle button, press this
button, change the steering angle between
180°and 360°. Details are as follows:

180°turn

Parking brake is installed on the instrument

panel.

When braking, press the braking button,

generates a braking force on the drive motor
through electromagnetic brake. Meanwhile the
parking brake indicator illuminates.

To cancel, press the braking button,

electromagnetic brake is released, the parking
brake indicator is off, and the parking brake is
cancelled.

Button 1 is not pressed down, only left half

Warning：
round(or right half round) is displayed on the
 If parking on the slope is unavoidable,
instrument, and the truck can be turned 180°.
block the wheels with solid wedge.
The solid black triangle indicated position
 Although after the truck is shut down, the shows the tyre direction.
parking brake engages automatically. But
For 180°turn, the truck needs backup to stop,
it is recommended to press the parking
switch direction and then travel. So it is a bit
brake button before shutting down the
inefficient, but the driver does not need
forklift, develop a habit to start the parking
adaption.
brake before leaving the seat or parking.

 The truck cannot travel under engaged

360°turn

9
 oil in the cylinder drives the gear pump
reversely, thus drives the motor reversely, and
then the motor generates power, transfers the
gravitational potential energy into electric
energy

Pedal
2 3
1 1.Safety
pedal

2.Brake
pedal

Button 1 is pressed down, a round is displayed 3.Accelerat

or pedal
on the instrument, and the truck can be turned
360°. The solid black triangle indicated Safety pedal 1 is a kind of safety device. For
position shows the tyre direction. When the travelling, step on the safety pedal with left foot
solid black triangle turns to right half round, the and accelerator pedal with right foot.
truck changes to reverse automatically, from
When depressing the brake pedal 2, front
former forward(backward) to backward(or
wheel electromagnetic brake works, the more
forward). Due to the automatic reversing of the
the brake pedal is depressed, the faster the
forklift, the efficient is higher, but the driver
wheel decrease, and the brake light is on.
needs to train and adapt for some time.
Accelerator pedal 3, truck travelling speed can
Caution： be variable infinitely adjusted. The truck
 When pressing down 180°/360° inching travels forward or backward, with left foot
button, the solid black triangle on the stepping down the safety pedal and right foot
instrument turns to the half round level the accelerator pedal. The more the
line automatically, and then the tyre accelerator pedal is depressed, the faster the
returns automatically. truck travels.

 No matter where the solid black triangle,

left half round or right half round, when
Display screen
pressing down the direction switch, the
AV2
truck travels in reverse.

No.2 is pump energy recovery button.

Turn to electric energy with gravitational

potential energy. After starting the pump
energy recovery, lowering the mast, pressure

10
― ‖button：display screen switch.

― ‖button：Main menu button. Main

menu includes brightness, contrast,
saturability, acutance, volume, language,
inversion, image, ranging line and reset. User
can adjust these items by pressing down

― ‖ or ‖.

― ‖button ： Press down this button,

video can be changed between V1 and V2.

― ‖button： Volume decrease. Decrease

numbers in the main menu, YES/ON change,
OFF/ON change, position flip over, page
down.

― ‖button ： Volume increase. Decrease

numbers in the main menu, YES/ON change,
OFF/ON change, position flip over, page up.

― ‖button：Character style change.

11
 This fingertip is to control the lifting of cylinder.
Grammer fingertip
Push the fingertip forward to lower the forks.
Pull the fingertip back to raise the forks. The
lifting lowering speed is controlled by the tilting
angle of the fingertip, the larger the angle, the
faster the speed.

９ １０
○
2 .Front and back moving thumb

switch

○
1 Direction ○
2 .Front and . ○
3 Driving

switch back moving direction switch

thumb switch

○
4 Tilt thumb ○
5 Lateral ○
8 . Horn

switch thumb switch button

○
9 connection ○
10 ○
6 、○
7 No
This fingertip controls the forward and
plug Emergency stop buttons. backward movement of the reach device.
button Push the fingertip forward, the reach device
moves forward; pull the fingertip backward, the
reach device moves backward. The movement
○
1 Direction switch speed is controlled by the tilting angle of the
fingertip, the larger the angle, the faster the
speed.

12
 ○
3 Driving direction switch

This fingertip controls the tilting of the fork

carriage.Push forward the fingertip to tilt the
forks forward; pull backward to tilt the forks
backward. The fork carriage tilting speed is
controlled by the tilting angle of the fingertip,
Direction switch lies in the left of finger the larger the angle, the faster the speed.
handrail and is single button cycle switch.
Press this button, and change between ○
5 Lateral thumb switch
forward and backward.

Caution：
 To travel forward or backward, release
parking brake, with left foot stepping down
the safety pedal and right foot accelerator
pedal. If the travel direction is opposite,
press this direction switch.

○
4 Tilt thumb switch This fingertip controls the side shift of the fork
carriage.Push forward the fingertip, the fork
carriage moves to left; pull backward the fork
carriage moves to right. The left/right
movement speed is controlled by the tilting
angle of the fingertip, the larger the angle, the
faster the speed.

Caution：

13
 Sideshifter fork carriage is an option.
Forklift without equipping with sideshifter
fork carriage has no side shift function.

Used when adjusting the spacing of the forks.

Pull up the fork stopper and rotate it 90°, then
adjust the forks to the desired positions

○
8 . Horn button according to the load to be handled.

Caution
 Fork spacing should be adjusted
symmetrically to the truck centreline.
After adjustment, make sure that the
fork stoppers are securely locked.
 The lower crossbar of the fork carriage
has an opening for fitting and removing
the forks.
 Do not secure forks at the opening
position, in order to prevent them falling
through the opening.
In an emergency, press the red mushroom
 There installs one bolt in the middle of
head button to cut off the vehicle's main power
upper beam to avoid forks working
supply.
here. If bolt damaged, replace new one.

Caution
Replace forks
 Do not use the emergency stop switch to
Remove old forks: place the forks in middle,
stop the truck under normal
drop to the ground, tilt forward the mast, then
circumstances as the key switch.
the forks are off the fork carriage and reverse
the truck.
Assemble new forks: place forks on the
ground facing the truck, lower the fork carriage
Fork stopper
to the lowest, truck travels slowly, aim the fork
slot to the top-bottom beam and gap of fork
carriage, then lift the fork carriage and adjust
fork position.

14
Headlight and its button protrudes from the hood. If insufficient,
unscrew the filler cap, and add hydraulic oil
with the same model.

The headlight is installed on the front pillars of

the overhead guard; headlight button is
installed on the housing, and is a rocker switch.
Press down the rocker switch, the light is on.

Oil filler of hydraulic oil

The hydraulic oil tank is located under the

hood, but the filler cap behind the seat

15
2.3 Seat
There are several choices for the seat, general seat adjustable functions: seat weight adjustment,
seat level position adjustment, seat backrest adjustment. Make brief introduction to the following
seat adjustment.

No. Remark

1 Weight adjusting knob

Seat forward-backward
2
adjusting lever

3 Seat back adjusting lever

4 Safety belt

Adjust driver seat according to weight：

In order to get ideal damping effect, adjust the seat according to driver’s weight. Sit on, rotate the
knob according to driver’s weight. For heavy driver, rotate the knob to ―+‖direction; for light driver,
rotate the knob to ―－‖direction

Adjust seat position：

– Pull the forward-backward adjusting lever 2 upward, and move the seat forward or backward to
proper position.
– Release the adjusting lever, lock driver seat automatically.

Warning
 Never adjust seat when driving.

Adjust seat back：

– Pull the seat back adjusting lever 3 upward, and adjust back inclination.
– Release the seat back adjusting lever 3 and lock the seat back.

16
Safety belt
Fasten safety belt 4 before driving. It protects driver when accidents happen. Regularly clean and
check safety belt, avoid dirt.
Correctly use safety belt：
– Sit on the seat correctly.
– Check if the safety belt twisted.
– Place the safety belt on the hip.
– Fasten the safety belt and check safety belt lock.
– Adjust safety belt until it reaches the state that it does not squeeze hip or is unable to fix due to
too much looseness.
Periodically check the safety belt：
– Check if safety belt is off-line, damaged or cracked.
– Check if the metal pieces of safety belt(including anchor point) wear or damage.
– Check if lock catch for safety belt or traction machine functions normally.

Warning
 In any case, if there is damage or flaw(insecure lock, damage, wet light) on the safety belt,
please repair or replace immediately.
 Never do any change to the safety belt. Replace new one after each accident.

Adopted measure when special condition incurred：

– Fasten the safety belt and sit on.

– Never jump from the truck.

– Lean forward, hold the steering wheel with

both hands, and support with feet.

– Lean yourself in the opposite direction to

truck tipping over.

Warning
 When there is danger of tipping over, do not unfasten the safety belt to escape. It may
cause severe bodily injury.

17
2.4 Operator Presence System (option)

OPS (Operator Presence Sensing) system is a safeguard system that installs a sensor in the
driver seat to sense if the driver sits on the seat correctly. If the driver does not sit on the seat
correctly, driving force is cut off, meanwhile, all loading and unloading operations will be stopped. It
helps to reduce accident when the driver leaves. When the driver does not sit correctly, the driver
cannot drive the truck or operate the loading and unloading, thus the accidents by maloperation
will be reduced.
Driving protection function
When the vehicle is travelling, the driver leaves the seat or the safety belt is released (if equip with
safety belt protection switch) over 1 second, truck stops automatically, and the instrument
displayed seat indicator light lights up, meanwhile the buzzer sends out continuous alarm
signal. Only when pulling up the hand brake or the driver sits on the seat correctly and the
direction switch returns to neutral, the seat indicator light goes out, travelling OPS status is
released.
Working protection function
When the vehicle is under working condition, the driver leaves the seat or the safety belt is
released (if equip with safety belt protection switch) over 1 second, working stops automatically,
and the instrument displayed seat indicator light lights up, meanwhile the buzzer sends out
continuous alarm signal. OPS light comes on, buzzer sends out alarm signal, transportation
operation stops automatically. When the driver sits down again, the seat indicator light goes
out, working OPS status is released.
Warning function
Once the seat sensor detects the seat switch is turned off, within 1 second, the buzzer sends out
continuous alarm signal, and the seat indicator light lights up. If the seat indicator light
keeps on when the seat switch is off, it means the OPS in the startup state.
Resume neutral function
If the direction switch does not return to neutral and the seat switch is turned on. The buzzer will
send out continuous alarm signal to remind the driver that the OPS in the startup state.
OPS abnormal function handling
Park the truck in safe place and contact Hangcha agency to check if any below condition is
occurred. a. after the driver leaves the seat, the seat indicator light does not light up; b. when
the driver sits down, the seat indicator light does not go out.

Caution
 As to forklift equipped with safety belt protection switch, driver needs to sit on the seat
correctly and also needs fasten safety belt, and then operate the truck. When driving on the
uphill, starting the OPS will cut off the drive power and make the truck slip. In order to avoid
this accident, the driver must sit correctly when operating on the uphill.

18
Fork locking function after power off
This function means: forks are locked when starting switch is off or power off, forks will not lower
down even operate the control lever.
3. Use occasion and condition
Vehicle use occasion and specified condition：
– Used in specified area as factory, tourist attraction and recreation place.
– Used on the flat ground, that is fixed and owns enough carrying capacity(protect
operation and lifting).
– As the diameter of the wheel is small, it is forbidden to crossing over the bulge or hollow
in case of the truck tipping over.
– Used on the road with good vision and equipment use license.
– Use in specified rated load.
– Max. laden gradeability when driving is 5%.
– It is prohibited to travel crosswise or obliquely. When going uphill with loads, keep the
loads in front; when going downhill, keep people in front.
Please read other safety rules in this manual, it is important to your personal safety, working staff
and goods safety.

Warning
 It’s prohibited to use this equipment in the anti-explosion area.
 Do not over load. Do not carry people.
 Cause the forklift adopts normally closed electromagnetic brake, never drag the forklift. Or it
may damage the brake.
 It is prohibited to lift the mast when the mast reaches.
 It is prohibited to travel forklift when the forks are in high position.

19
4. Safety instructions and notify a manager. The truck may only be
used after the fault has been eliminated.
1. Only trained and accredited operators are
Arrange for immediate repair in the event of a
permitted to operate the truck.
fault when lifting or driving uphill or downhill, or
a leakage of battery electrolyte, hydraulic oil or
brake fluid.

2. Inspect the truck at periodic intervals for

Fault
leaks, deformation, defects, etc. the life of the
truck will be shortened or an accident could
occur.
Make sure to replace the ―key safety parts‖
during periodical inspection. 5. Batteries generate explosive gases. Keep
Wipe off oil, grease or water from the floor sparks and open flames away from the battery.
board and foot and hand controls. Keep tools away from the battery terminals to
Strictly prohibit smoking and spark near the prevent sparks or short-circuits.
storage battery when checking it. 6. The truck is designed to operate on solid
When performing maintenance on the mast, and flat cement, asphalt or concrete surfaces.
front and rear lights, or other high places, be Check the road condition in advance.
safely secured and take care not to slip. The truck is designed to operate in the
Be careful do not be scalded when inspecting following climatic conditions: temperature
the motor, controller and etc. range -20 ℃ to 50 ℃; maximum wind speed
3. Operators must wear a helmet, work shoes 5 m/s; maximum relative air humidity 90% (at
and overalls. 20°C).
The truck is not suitable for use in flammable
or explosive working environments.
7. The overhead guard prevents cargo from
falling onto the operator. The load backrest
ensures the stability of loads. Do not use a
forklift without the overhead guard and load
backrest. Modifications to attachments must
4. Whenever you discover a fault, stop the
be authorized by the manufacturer. Do not
forklift, hang a "DANGER" or "OUT OF
attempt to modify attachments yourself.
ORDER" sign on it, remove the ignition key
8. Clear up the working site, clean obstacle,

20
sweep macadam, muddy sand, and wipe off departures the center. And the truck may turn
greasy dirt and water. over more probably.
9. Use the safety grip when mounting and
dismounting the truck. Not quick jump or jump
out of forklifts.
10. It is forbidden to drive the truck on other
place else operator’s seat. Never put your
hand and foot out of the truck body. Especially,
don’t let your foot outside rear of the truck.
11. It is forbidden to people to enter the
clearance of the mast and truck body, for when 17. Never horseplay.
the mast reaches back, once be clamped, it 18. When the mast of reach truck reaching out,
will cause fatal dangers. do not drive it because of in this status, the
truck has the trend of overturn when a sudden
brake or turning. The truck must be driven
when the mast shrinks to the bottom.
19. It is prohibited to travel with forks in high
position. Keep the forks 30cm above the
ground, drive the forklift with mast tilting
backward in place.
20. When the loads are on the ground, you
cannot make a reaching action.
21. Don’t make a sudden start, sudden brake
or sharp turning. Especially when unlade,
12. Know well the curve chart on the load otherwise it will cause danger of overturning.
curve label, which indicates the relationship 22. In raining days or working on a wet,
between rated load capacity and load centre slippery ground, you’d better turn around truck
distance. Never overload. slowly and avoid sudden brake. Slowly down
13. Other people are not allowed to stand on the reach truck when operating on a slope.
the forks, pallet or operator’s seat. It is 23. Before turning around, take care of the
forbidden to using other things or human as an rear of the truck. Make sure nobody around
additional counterbalance weight. the truck. Slowly down the speed 1/3 of max
14. Before starting the truck, press the button traveling speed when turn around.
to make sure nobody around. 24. Do not stack loads on forks in such a way
15. Use proper size and enough intensity that the top of the load exceeds the backrest
pallets. Avoid loading goods higher than the height. If unavoidable, make the load stable
height of backrest. and secure. When handling bulky loads which
16. Prohibit load off center. The goods is liable restrict your vision, operate the forklift in
to drop turning or passing rough when it reverse or have a guide. When using a guide,

21
make sure you know and understand the
meaning of all hand, flag, whistle or other
signals being used. When transporting long
loads such as lumber, piping and oversized
cargo, or operating vehicles with elongated Warning

attachments, pay close attention to the front

28. It is forbidden to lift goods on an incline.
end when driving around corners or along
Avoid stacking on a slope as possible. It is
narrow aisles and be aware of other people.
forbidden to turn around suddenly on a slope.
25. When operating loaded truck, drive
29. Do not use the truck, when the weather is
forward to uphill and reverse to downhill.
bad, such as sand blowing by wind, snowing,
When operating unloaded truck, reverse to
thunder, flashing, rainstorm and typhoon etc.
uphill and drive forward to downhill. Do not
Especially when the wind speed is higher than
turn on the ramp to avoid tip-over.
5m/s, you should avoid using the truck.
30. Because the wheel diameter of the reach
truck is small, do not run over uneven road or
obstacle, drive carefully when unavoidable.
Dragging the reach truck is not allowed.
31. When parking, shrink back the mast to
bottom of slide slot and lower the fork to
ground, and take away the key switch.
32. The labels and signs on the vehicle
provide warnings and operating instructions.
During operation, adhere to the requirements
of the manual as well as the labels and signs
on the vehicle.
26. It is forbidden to stand or walk under the Inspect the labels and signs, and replace any
fork or the attachment. It is forbidden to stand that are damaged or missing.
on the fork. 33. Controller is equipped with accumulator.
Forbid to touch within B+ and B- to prevent
Warning
from wounding by electricity. Before checking
or cleaning, please connect loads (contactor
circuit or horn for example) between B+ and B-
first to discharge for capacitor of controller.
34. The workplace should be equipped with
fire extinguishers. Drivers and managers need
27. It is forbidden to walk or stand between the
to be familiar with the location and use of fire
frame and battery box.
extinguishers.
35. Electromagnetic brake is adopted in the

22
front and rear wheel for this series forklift, so it 41. The work place should be bright enough.
is not allowed to be towed. At night, turn on the head lamp and work with
36. When conveying small loads, you should enough light.
use pallet, it is not permitted to put loads on 42. Only in the event that the truck
the forks without pallet. Otherwise the small manufacturer is no longer in business and
loads may fall off easily, and hit the driver. there is no successor in the interest to the
37. In the process of installment and assembly, business, the user may arrange for a
there will be noise and vibration. Please modification or alteration to a powered
choose the right tool and assembly method. industrial truck provided, however, that the
Depress the noise and vibration as less as user shall:：①Arrange for the modification or
possible to reduce the noise pollution to alteration to be designed, tested and
circumstance. implemented by an engineer(s) expert in
38. The truck is designed to operate on solid industrial trucks and their safety;②Maintain a
and flat cement, asphalt or concrete surfaces. permanent record of the design, test(s) and
When there are snows, ice accretion, hydrops, implementation of the modification or
or other foreign matter and obstacle, operate
alteration; ③ Approve and make appropriate
the forklift only after cleaning them, otherwise
changes to the capacity plate(s), decals, tags
the truck maybe out of control and even cause
and instruction handbook;④Affix a permanent
safety accidents.
and readily visible label to the truck stating the
39. Move the truck to the place which respects
manner in which the truck has been modified
traffic when it anchors. And then move it by a
or altered together with the date of the
suitable truck(refer to truck transport).
modification or alteration, the name and
40. After removing the overhead, backrest of
address of the organization that accomplished
mast, do not operate the truck or load cargo.
the tasks.

23
5. Structure and stability of truck（Avoid truck tipping over!）
It is very important for operator to know the truck’s structure and relationship between load and
stability.

The structure
Caution
of the truck
The basic structure of the truck is lifting device (include mast
and forks) and truck body.
The lift truck keeps the balance of weight between the truck
body and the load on the forks with the center of the front
wheels as a fulcrum when the rated capacity load is placed
in position.
Due care should be paid to the weight and the center of
gravity of loads to maintain the stability of the truck.

Caution Load center

Forklift transported loads are different, from box to board and

long shape. In order to evaluate the forklift and its stability, it is
very important to distinguish the gravity center of loads in
different shapes.

Warning
If the truck is going to turn over, do not attempt to get out of the truck, because the
speed of overturn is much faster than you. You should hold the steering wheel handle,
and this practice will keep you in the seat. Please tie safety belt.

24
 Gravity and
Caution
stability
The combined center that is composed of the
barycenter
and the load center determine the stability of lift trucks.
When unloaded, the barycenter does not change;
When loaded, the barycenter is determined by the truck
and the load’s center.
The barycenter is also determined by the tilting,
lifting, reaching of the mast. So the combined gravity
center changes as well.
The combined center is determined by these factors:
– Load’s size, weight and shape.
– The lifting height.
– Mast extension
– Mast tilt angle;
– Acceleration, deceleration and turning radius;
– The road and ground tilting.
– The attachment.

Caution The stability zone of the barycenter

In order to make the truck stable, the combined center

must be in the triangle which is made up of two points that
the two front wheels attach ground and the midpoint of the
back driving axle.
If the combined center is in the front driving axle, two
front wheels become two fulcrums, the truck will overturn.
If the combined center departures the triangle, the trucks
shall overturn in the corresponding direction.

25
 the max load（weight and
Caution
load center）
The distance between the load center and the front surface of
forklift or load bracket (select the min) on the forklift is called
LOAD CENTER DISTANCE. The max gravity that the truck can
load is called MAX LOAD on condition that the load is on the load
center distance. The relationship of MAX LOAD and LOAD CENTER
DISTANCE is specified on the load capability chart. If the load
center is moved near the front of forklift, the load should be cut down

The load capability

Caution
chart
This chart shows the relationship of MAX LOAD 载 荷 曲 线 图
RATED CAPACITY AND LOAD DIAGRAM

RATED CAPACITY
起
and the location of LOAD CENTER DISTANCE. Check

重
whether the load and load center distance is in the range

量
referred by the chart. Put the most important parts near the
载 荷 中 心 距 LOAD CENTER DISTANCE

load bracket if the shape of goods is complex.

Caution Speed and acceleration

One object will keep quiescence until force works on it. Also, a moving object will keep moving
until force works on it .This is just inertia.
According to inertia, when truck starts moving, one force works backwards, and when truck
stops moving, one force works forwards. So, it’s dangerous to brake suddenly, because it
causes one large force works forwards, and it’s easy to cause truck overturn or load slide off.
When the forklift makes a turn, it will exert a centrifugal force outward from the curve center.
This strength pushes forklift outwards and causes it to turn over. About stability region is very
small, so decelerate when turning. If the cargo transported at the high position, it’s easier to turn
over

26
6. During break in
We recommended operating the reach 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 machine is in a stage of 100 hours of operation.：

- In general, the battery should be recharged promptly when the charge level has decreased to
20% of its capacity.
- The periodic maintenance must be operated.
- To avoid sudden start, brake or turning.
- Replace all the oil or lubrication grease by schedule.
- Limit the loading weight not overweight than the 70-80% of load capacity.
- Retighten the wheel bolts and other fasteners.

27
7. Routine Maintenance damaged or be enlaced by rope.
Careful, all-round maintenance will keep the Check whether the tire nut loosens or the tire
forklift truck in good working condition. It bearing is damaged.
guarantees the safety of the forklift and your 6. Electromagnetic brake
personal safety at work. Press the parking brake rocker switch on the
instrument stand, and the parking brake
Warning symbol is displayed on the instrument. Press
 In addition to testing lights and
this switch again, then the parking brake
checking operating performance,
symbol disappears, and the parking brake is
before checking the electrical system,
cancelled.
turn off the key switch and disconnect
8. Check hydraulic oil
the battery plug.
 Never use a forklift that has any kind of
fault.
 Even a small fault can cause a serious
accident.
1. Check for leakage of hydraulic oil,
electrolyte and brake fluid
Check for oil spills or leakage around the
hydraulic fittings, battery, and brake systems
by hand feeling or carrying out a visual
inspection. Never use an open flame.
2. Check the load backrest
Hydraulic oil tank is below the cover, and the
Inspect the load backrest and see whether the
filler cap is behind the seat. Check the oil tank,
load backrest is distorted, cracked or any
unscrew the oil filler cap, pull out the dipstick
loose bolts on it.
and check the oil level. Different numbers on
3. Check overhead guard
the dipstick stands for the required hydraulic
Inspect the overhead guard and see whether
oil height of different masts. Add oil if the
there is any crack or deformation on it
actual hydraulic oil level is lower than the mast
4. Check the fork
needed height,
Inspect the fork and see whether there is any
Dipstick scale indication：
distorted or cracked on it. And check the lock
―50‖ means liquid level for mast with 5M lifting
pin and see whether the lock pin lock the forks
height or below(including duplex full free mast)
credibly.
―65‖ means liquid level for mast with 6.5M
5. Check the rear wheel and front wheel
lifting height or below(including duplex full free
Check the front and rear wheel and see
mast)
whether the wheels are cracked, distorted,
―80‖ means liquid level for mast with 8M lifting

28
height or below(including duplex, triplex full your thumb to check whether the tension
free mast) between the left and right chains is
―95‖ means liquid level for mast with 9.5M identical.
lifting height or below(including duplex, triplex - Tension adjustment: loose the lock nut 1
full free mast) and turn the adjuster nut 2 to adjust the
―110‖ means liquid level for mast with 11M chains so that they both have the same
lifting height or below tension, then tighten the lock nut 1.
9. Battery check

14. Safety pedal

Check that the lock pin is securely inserted Put your left foot on the safety pedal, inspect if
and the battery is firmly fixed. all functions are normal when the truck is in
Check the specific gravity of the electrolyte. forward/backward position.
See Battery section. 15. Check the brake pedal
Check where the wiring of both terminals is Step down the brake pedal, and check the
loose or damaged. Adjust or replace the wiring electromagnetic brake of the front wheel.
if necessary. 16. Check the accelerator pedal
10. Instrument display check (power, As the accelerator pedal is depressed through
faults) its full stroke, there should be a clear change in
See Instrument section. the rate of acceleration, and the pedal should
11. Check the fingertip and mast return freely to its original position when
Check if lift fingertip, reach fingertip, tilt released.
fingertip, sideshifter fingertip loosen or return 17. Check the steering system
well. Turn the steering wheel to the left and right to
Press forward or pull backward lift fingertip, check the functionality of the steering system.
reach fingertip, tilt fingertip, sideshifter fingertip, 18. Lamp and horn
inspect if the mast lifting, reaching, fork Turn on the headlamp switch and check the
carriage tilting, and fork left/right movement is lamp whether it is ok.
normal, or there is abnormal noise. Press the horn button to check the sound of
13. Check the chain tension the horn.

- Raise the forks to a height of 10–15cm 19. Emergency stop switch

with the mast vertical. Press down the emergency stop switch and
check the power has been cut-off instantly.
- Press the middle section of the chain with
20. Others

29
Inspect whether there is any abnormal noise.

30
8. Drive and operate
Caution
· Be careful of getting on or off the truck.
Warning Don’t jump out of the truck.
If any damage or fault is found, don’t · Don’t park the reach truck on the
operate truck until being corrected. running route.
Running Pick up
To start the forklift, fist press down the parking
- The forks should be adjusted sidewise to
brake rocker switch to cancel parking brake,
maintain proper balance of load.
then step on the safety pedal with left foot and
- Place the truck right in front of the load to
accelerator pedal with right foot. If the travel
be handled.
direction is in reverse, press down the
direction rocker switch, and change the
direction. .
Steering
The steering wheel of reach truck is rear
wheel.
When steering, decrease the speed of truck.
And rotate the steering wheel to the direction Travelling approach the loads
you want and the steering wheel needs to be
turned slightly earlier than it would in a vehicle
with front-wheel steering.

Caution
Slow down the truck when turning around.
Make sure there is enough place for
turning. Mast reach out
Parking - The pallet should be evenly positioned

- The truck stops when right foot moves across both forks.

from accelerator pedal to brake pedal and - Insert forks into the pallet as far as
step down the brake pedal, and then possible.
press down the parking brake rocker - To raise loads from the ground：
switch, the truck is braked. ① Once lift the forks 350 to 450mm off
- Shrink the mast backward in place. the ground or floor and make sure
- Lower down the forks and tilt forward the loads rest stably.
mast. ② Then tilt the mast backwards fully.
- Turn off the key switch, and plug out the - When handling bulky loads which restrict
battery connector. Be careful of key. your vision, operate the truck in reverse

31
 except when climbing grades. - Make sure your load is just over the
desired area. Slowly lower the load into
position. Make sure the load is securely
stacked.

1. Insert the forks into loads and lift loads

about 350-450mm off the ground;
2. Backward the mast to the end, and travel to
stacking place.
Stacking load
- When approaching the deposit area, slow
down your truck.
- Stop the truck right in front of the area P
where your load is to be deposited.
- Check the condition of the deposit 1. Slowly press the reach fingertip, and move
position. the loads;
2. Put the loads on the shelf, tilt forward or
- Raise forks until they are a little higher backward if necessary.
than the deposit position. - Press down reach fingertip to disengage
forks from the load by using necessary
lift-tilt operation and then back away.
- After making sure the fork tips leave the
load, lower the forks to the basic position
(15 to 20cm off the ground).
- Tilt the mast backwards

Backward the mast to the end and raise the

loads to the required height. Slowly travel if
necessary.

- Press down reach fingertip, and get the

loads move to the desired deposit
position.

32
1. Make sure the loads are placed on the shelf If the forks are hard to be fully inserted,
stably, move the mast backward to the end;
press reach fingertip to insert 3/4 of the
2. Lower the fork and travel the forklift to the
other place. forks. Raise the forks 5 to 10cm and move
backward 10 to 20cm with the pallet or skid
Warning： on the forks, and then lower the pallet or
When mast reaches skid on the stack. Move forward again to
out, it is forbidden to insert the forks fully.
lifting or lowering
- Raise the forks 5 to 10cm off the stack,
loads at a high
move the mast backward to the end.
position without shelf
- Check all around the truck to insure that
protection.
the path of travel is unobstructed and
Otherwise it will
back away slowly
cause fatal
- Lower forks to a height of 15 to 20cm
dangerous.
above the ground. Tilt the mast backward
fully and move to the desired area.
Warning
· Never tilt the mast with loads upraised Warning
2 meters or more.  It is very dangerous for stacking or

· Don’t leave or dismount from the truck unladen loads to/from a high place. If

when the load is raising high. you do not obey the step of stacking, it
maybe cause fatal dangerous for
Remove load operator.
- When approaching the area where the  When loading heavily in high position,
load is to be retrieved, slow down your it is prohibited to tilt mast forward or
truck. backward while operating direction.
- Stop the truck in front of the load so that  It is prohibited to operate sideshifter
the distance between the load and fork handle without protection of fork
tips is about 30cm. carriage when loading in high position.

- Check the condition of the load.  It is prohibited to lift the mast

meanwhile drive the forklift or move
- Tilt the mast forward until forks become
the mast forward/backward when
horizontal. Elevate forks up to the position
loading.
of the pallet or skid.
 It is suggested that the driver should
- Make sure forks are positioned properly
not use united operation, that is, drive
for the pallet. Move forward slowly to
and operate direction while operating
insert forks into the pallet as far as
multi-valve handle, otherwise it may
possible and then stop the truck.
cause severe result.
Caution

33
34
9. Storage height.

Daily storage  Raise the forklift just enough to allow it

to be placed onto the wooden support
- Park the forklift in a designated area,
blocks.
lower the mast and move it backward in
 Place wooden blocks of identical size
place.
under left and right sides of the frame.
- Put the direction switch in neutral, and
 After supporting the forklift with the
engage the parking brake. Then shut
wooden blocks, move the forklift back
down the forklift and block the wheels.
and forth from all four sides to make
- Disconnect the power plug
sure that it is safely secured.
- Remove the key and keep it in secure
- Start the forklift at least once a week.
place.
Raise the forks to their maximum height
Long-term storage several times.
Do the following maintenance and check on
- Measure the specific gravity and level of
the basis of daily storage：
the battery electrolyte on a monthly basis.
- Disconnect the battery plug to prevent - Apply one equalizing charging every
discharge and store the vehicle in a dark month.
place.
Forklift operation after long-term
- Apply anti-corrosion agent to shafts, rods
storage
and other exposed parts.
- Remove anti-corrosion agent from
- Cover the breather and other openings
exposed parts.
where moisture may enter.
- Drain out the gear oil in the drive axle,
- Fully cover the vehicle with a sheet or
then fill with fresh oil.
similar.
- Clear away foreign matter and water in
- Lubricate with oil or grease where
hydraulic tank, and add new hydraulic oil.
necessary.
- Charge the battery, install it on the forklift
- Support the underside of the truck body
and connect to the battery cables.
with wooden blocks to reduce the weight
- Carry out a careful inspection before
on the rear wheel.
using the forklift, checking truck start-up,
Warning forward and reverse drive, steering and
 The wooden blocks must be single the lifting, lowering, forward/backward
pieces that are sturdy enough to movement and tilt functions.
support the weight of the forklift.
 Do not use wooden blocks that are
more than 300mm (11.81 inches) in

35
10. Battery service life of battery, or even burn the
Safety regulations to lead-acid battery use connecting cable.
– User should create a battery profile for – In order to guarantee the normal service
better maintenance. life of battery, its discharge capacity
– Explosive gas can be produced in the should not exceed 80% of the rated
internal of storage battery, smoking, flame volume, charge in time after discharge.
and sparkle can easily cause storage Charging process should be complete,
battery explosion. and interrupted charging may also
influence battery capacity and service life.
– Regularly check if there is hydrops in the
battery box, or suck up with elongated
plastic pipe, meanwhile wipe the battery
surface to avoid short circuit.
– Regularly clean the battery surface with
– Battery for the first time use may not wet cloth, dry cloth may generate static
reach its rated volume, but it will reach electricity and cause accident. It’s
normal volume after full charging, use and suggested to clean the battery surface
discharge cycles for 5 to 10 times. every two weeks.
– Electrolyte in the battery owns strong – If the battery does not use for long time,
corrosion, so operator must wear charge once every two weeks. Carry out
protection equipment. one equalizing charge to the battery per
month.
– Battery should be charged in well
ventilated environment, not in dangerous
area, like open fire, or combustible and
explosive area.
– Make sure no covering on the battery,
– It’s better to use proper lifting tools when open the filler cap of each cell, so as to
assembling the battery, which makes give off the flammable gas generating
battery assembling stable, thus avoid when charging as soon as possible.
battery damage and electrolyte spilling. – Current intensity of the charger must
– Never allow wrong connecting of battery match with the battery charging demand,
anode and cathode, otherwise it may otherwise it will severely influence the
cause sparkle, burning or explosion. battery capacity and service life.
– Avoid overdischarge, high current – Electrolyte temperature during charging
discharge for long time when using the should not exceed 50℃, or try to cool, if
battery, otherwise it may influence the the temperature does not drop, suspend

36
 charging, after the temperature drops,
continue to charge.
– After disconnect the charger, measure the
single voltage at 30℃ reaches 2.1～2.3V
or the electrolyte density reaches 1.28～
1.30kg/L, if the voltage and density do not
reach this value, keep charging until reach – Battery electrolyte has vitriol, it may cause
the above value and keep at least one burn once touch the body. If accident
hour. happens, carry out first-aid immediately
– After charging is finished, check the and see a doctor. ① Spill to skin and eye:
battery level through filler plug strainer, wash with water for 15 ~20 minutes; spill
make sure the liquid is normal and close to clothes: take off immediately; swallow:
the cover. If the level is low, add qualified drink lots of water and milk.
deionized water.

37
Battery specification
Item 1.2t~1.6t 2.0t

Length（L） mm 1223 1223

Width（W） mm 355 427

Height（H） 784 784

Allowable lightest kg 1063 1063

Allowable heaviest kg 1258 1258

Rated capacity Ah/5hr 750 750

Rated voltage V 48 48

Battery box dimension

38
Battery charging outlet.
7. Close each battery filling cap.
Charging procedures：
For this series forklift battery, charge by taking Caution
the battery out. After replacing a fully charged  Charge in appointed and well ventilated
battery, the forklift can work continuously, thus place.
daily work efficiency is improved. Charging  Place No Flame signs when charging.
procedures are as follows:  Before charging, first check if wire or
1. Remove the battery. Battery removing outlet damaged. Check if battery
procedures refer to Battery Replacement connector loosens and tighten.
part.  Electrolyte temperature during charging
2. Open each battery filling cap. should not exceed 50℃, or try to cool, if
the temperature does not drop, suspend
Warning
charging, after the temperature drops,
 There will generate combustible and
continue to charge.
explosive gas when charging, please
Normal charging
open the cover and make sure no
– Batteries that have undergone initial
covering on the battery, make sure each
charging and been used for day-to-day
battery filling cap is opened, keep in good
work can undergo normal charging.
ventilated place and no flame in the
– The procedure for normal charging using
charging area.
the constant current charging method is
3. Insert the battery charging plug into the
basically the same as that for initial
charger plug.
charging.

Warning – The amount of charge given should be

 Output voltage, current and application about 1.2 times the amount of the
range of the charger must match with the previous discharge. However, for new
battery voltage and volume, otherwise it will batteries, the first 5 charges should be
influence battery volume and service life. about 1.5 times the amount of the
 Charging cable polarity must keep the previous discharge.
same with the charger output terminal – During any charge cycle, the electrolyte
polarity. temperature must not exceed 50 ℃ . If
4. Start charging according to the charger necessary, adopt cooling measures or
manual. reduce the charge current. If the
5. After the battery is fully charged, finish temperature remains high, stop charging
charging according to the charger and allow the battery to cool down before
manual. resuming.
6. Take out battery charging plug from – Use smart charging to carry out normal
charger plug, and then connect the truck charging. For new batteries, an equalizing

39
 charge should be carried out for the first 5 is resumed after the 1-hour interval.
charges, based on the smart charger Boost charge
– When a single charge cannot meet the
manual.
demands of a full day's work, provide a
Equalizing charge
– With time, the voltage, density and boost charge during rest times.
capacity of a battery tend to become – A boost charge can be given when the
unbalanced. ambient temperature is low.
– The voltage and specific gravity of some Storage charge
cells increase more slowly compared with – Before storing a battery, give it an

other cells when charging, and decrease equalizing charge.

at a faster rate when discharging. – Apply an equalizing charge every 15–30

– Equalizing charge should be applied days during storage.

when any of the following situations – Charge special ordered batteries in

accordance with the Battery User Manual.
occur：
a. The discharge voltage frequently falls
below the cut-off voltage; Battery replacement
b. The discharge current is frequently 1. Park the truck on the flat ground, and

too high; apply hand brake handle. Remove the key

c. The battery is not charged in a timely and pull out the battery plug.

manner after discharge is complete; 2. Screw out the knob 2, and take down the

d. The electrolyte is mixed with minor panel1.

impurities; 1 3
e. The battery frequently gets
insufficient charge, or hasn't been
used for a long time;
f. The battery plates have been taken
out for inspection or to clean out 2
sediment. 1.Side plate 2.Knob 3.Truck frame
Equalizing charge method： 3. Unscrew nut 4, screw out bolt 3, and then
– Firstly charge the battery normally, then remove battery pressure plate 5. Slot 6 is
let it rest for 1 hour after charging is used for the wheelbarrow alignment to the
complete. battery.
– Continue charging the battery using the
second-stage charge current specified for
normal charging until multiple bubbles
appear, then stop charging for one hour.
– Repeat the above steps several times
until the voltage and density stop rising
and bubbles appear as soon as charging

40
 2 1 1
2

5
3 3
6 1. Battery 2.Wheelbarrow 3.Pedal
4 3
5. Upfold the left/right pedal in front of the
1. Battery tray wheelbarrow. Pull out the wheelbarrow a
2. Battery 3.Bolt
rack
little, switch the baffle 3 straight up, block
5.Battery
4.Nut 6.Slot the battery. And then pull the battery to
pressure plate
desired position.

Caution： 2
 After installing the battery, compress it
with battery pressure plate 5 through bolt 1
3. Screw down nut 4 to prevent bolt 3
looseness.

4
4. Switch the front wheelbarrow baffle
1. Battery 2. Wheelbarrow 3.Baffle 4.pedal
straight down, and then the arrow on the
baffle vertically aligned in the truck frame
Caution：
slot. Step on the left and right pedals in
 When carrying battery with wheelbarrow,
front of the wheelbarrow to prevent the its
block the battery with baffle, otherwise it is
movement. And then pull the battery into
easily slipping from the wheelbarrow,
the wheelbarrow,
6. To replace the battery, installment is
opposite to the dismantlement.

Caution：
 Before replacing a battery, make sure that
the voltage, capacity, weight and

41
 dimensions of the new battery match the and rubber gloves
forklift specifications. （2）Fill a squeeze bulb pipette with a certain
 Do not use replacement batteries with a amount of distilled water.
different voltage, weight or dimensions （3）Open all the vent or filler caps on the
without the manufacturer's permission. battery unit.
 The replaced battery waste cannot be （4）Inject distilled water into battery cells
dumped at will, but dispose according to
using squeeze bulb pipette.
local environmental protection laws.
Battery with hydrometer
Electrolyte level and specific gravity Stop adding water when the red hydrometer

Warning float rises and a white line appears.

 Using a battery when the electrolyte

level is low may lead to overheating
and shorten the life span of the battery.
1. Checking electrolyte level
Battery without hydrometer
Electrolyte is 15-20mm higher than
splashguard level.
Battery with hydrometer
Measure electrolyte level by reading vent cap
hydrometer

Battery without hydrometer

Stop adding water when electrolyte is 15-20
mm higher than splashguard level.
（5）After topping up, tightly fasten the vent or
battery caps.
（6）Use a damp cloth to wipe clean the
surface of each battery cell.

Warning
 When adding distilled water, do not

2. Topping up distilled water exceed the specified maximum level.

（1）Wear protective eyewear, rubber boots Adding too much water may cause

42
 electrolyte leakage and damage the
forklift when charging or discharging
the battery.
Use a squeeze ball pipette to draw off any
excess water.
3. Specific gravity reading
Specific gravity of the electrolyte varies
with temperature.
（ 1 ） Use a thermometer to measure the
temperature of the electrolyte.
（2）Vertically insert the flexible tube of a Specific gravity measurement
pipette-type density meter into the Use a hydrometer to measure the specific
electrolyte and squeeze the bulb. gravity of electrolyte.
Electrolyte will enter the glass tube and
the float will rise up.
（3）Take the density reading.

Caution
 Hold the density meter vertically so
that the float does not touch the sides
of the glass tube.
Specific gravity conversion
Convert electrolyte density at the standard
temperature of 30oC based on the following
formula：
D30＝Dt＋0.0007（t-30）
Wherein：
D30——electrolyte density at 30℃
Dt——measured electrolyte density at t℃
t——electrolyte temperature during
density measurement.
All references to specific gravity in this manual
refer to specific gravity at 30 ℃.

43
11. Maintenance
11.1 Maintenance summary

- Establish and follow a comprehensive maintenance and service schedule.

- The forklift must be regularly checked and maintained to keep it in good working order.

- Inspection and maintenance are often easily overlooked. Early detection enables problems to

be settled in a timely manner.

- Use original Hangcha Group spare parts.

- Do not use different types of oil when changing or topping up oil.

- Waste oil and battery fluid must not be poured away indiscriminately, but recycled or

disposed of in accordance with local environmental laws and regulations.

- Untrained personnel must not attempt to carry out forklift repairs.

- Maintain current and complete records of all maintenance and servicing activities.

Caution
· No open flames.

· Turn off the key switch and disconnect the battery plug before carrying out any servicing or

maintenance.

· Clean electrical parts with compressed air. Do not clean with water.

· Do not put your hands, feet or any part of your body between the mast and dashboard.

44
11.2 Periodic maintenance schedule
〇—check, correct, adjust
×—replace
Battery
Every 3 Every 6
Item
Service Tool
Daily Weekly Monthly
months months
required (8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)

Visual
Electrolyte level
inspection
〇 〇 〇 〇

Electrolyte
specific gravity
Hydrometer 〇 〇 〇 〇

Battery power 〇 〇 〇 〇 〇
Check for loose
connection 〇 〇 〇 〇 〇
terminals
Battery

Check for loose

connection 〇 〇 〇 〇 〇
cables
Clean the
battery surface 〇 〇 〇 〇

Check for tools

left on battery 〇 〇 〇 〇 〇
Check vent caps
are tight, vents 〇 〇 〇 〇
unobstructed
Keep away from
flames 〇 〇 〇 〇 〇

Controller
Every 3 Every 6
Service Daily Weekly Monthly
Item Tool months months
required (8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)
Check contact
wear of the 〇 〇
contactor
Check mechanical
movement of 〇 〇
contactors
Check pedal
microswitches are
〇 〇
Controller

functioning
properly
Check condition of
connections
between motor, 〇 〇
battery and power
unit
Check controller
faults to determine 〇
whether system is 2 years for
functioning first time
properly

45
Motor
Every 3 Every 6
Item
Service Tool
Daily Weekly Monthly
months months
required (8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)
Clear foreign
bodies on motor 〇 〇 〇
housing
Clean or replace
bearings 〇
Check wear
condition of carbon
brushes and 〇or× 〇or×
DC Motor

commutators,
check spring force
Wiring correct and
secure 〇 〇 〇
Brush away carbon
powder from
grooves between
commutator 〇 〇
segments and on
commutator
surface
Clear foreign
〇 〇 〇
AC Motor

bodies on motor
housing
Wiring correct and
secure 〇 〇 〇

Transmission system
Every 3 Every 6
Service Daily Weekly Monthly
Item Tool months months
required (8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)

Check for noise 〇 〇 〇 〇 〇

Transmission

Check for
leakage 〇 〇 〇 〇 〇

Change oil ×

Wheels (Front, Rear Wheels)

Every 3 Every 6
Daily Weekly Monthly
Item Service required Tool
(8 hrs) (40 hrs) (166 hrs)
months months
(500 hrs) (1000hrs)
Check for
abrasion, cracks 〇 〇 〇 〇 〇
or damage
Check wheels
fasteners for 〇 〇 〇 〇 〇
looseness
Wheels

Check for wheel

bearing 〇 〇 〇
pretightening
Check for wheel
bearing lubricate 〇 〇 〇

Check for noise 〇 〇 〇 〇 〇

46
 Check for rope
winding 〇 〇 〇 〇 〇
the wheels

Steering System
Every 3 Every 6
Daily Weekly Monthly
Item Service required Tool months months
(8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)
Adjust the steering
〇 〇 〇 〇 〇
Steerin wheel locking
g wheel Check steering work
〇 〇 〇 〇 〇
condition
Gearwheel and
〇 〇 〇
Gear pinion lubrication
pair If pinion mounting
〇 〇 〇
bolt loosens
Hydraulic system
Every 3 Every 6
Daily Weekly Monthly
Item Service required Tool
(8 hrs) (40 hrs) (166 hrs)
months months
(500 hrs) (1000hrs)
Check for oil level,
change oil 〇 〇 〇 〇 ×
Hydraulic
reservoir

Clean suction strainer 〇

Drain for foreign
matter 〇

〇 〇 〇 〇 〇
Fingertip

If return automatically

Operation condition 〇 〇 〇 〇 〇

Leakage 〇 〇 〇 〇 〇
Multiway valve

Operation of safety
valve and self-locking 〇 〇 〇
tilt valve
Oil
Measure safety valve
pressure 〇
pressure gauge
Leaks, looseness,
connectors

rupture, deformation, 〇 〇 〇
Line

damage
×
Replace pipes
1-2 years
Check hydraulic
Pump pump for oil leaks or 〇 〇 〇 〇 〇
noise
Check for oil leakage
〇 〇 〇
Oil or noise
motor
If work normally 〇 〇 〇
Priority
Operation condition 〇 〇 〇
valve

Braking system

47
 Every 3 Every 6
Daily Weekly Monthly
Item Service required Tool months months
(8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)

Operation condition 〇 〇 〇 〇 〇
Brake pedal

Operation condition of
〇 〇 〇 〇 〇
electromagnetic brake

Truck brake effect 〇 〇 〇 〇 〇

Operation condition of
Parking electromagnetic brake 〇 〇 〇 〇 〇
brake
button If brake is safe 〇 〇 〇 〇 〇
Damage, leakage,
Pipelines

〇 〇 〇
rupture
Connection, clamping
〇 〇 〇
parts, looseness
Operation condition of
〇 〇 〇 〇 〇
Electrom
agnetic
brake

electromagnetic brake
If electromagnetic
〇 〇 〇 〇 〇
brake is safe
Lifting system
Every 3 Every 6
Daily Weekly Monthly
Item Service required Tool months months
(8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)
Check chain tension,
check for
deformation, damage 〇 〇 〇 〇 〇
and corrosion
Chain sprocket

Lubricate chain 〇 〇 〇

Riveting pins and

looseness 〇 〇 〇

Sprocket deformation
and damage 〇 〇 〇

Looseness of
sprocket bearings 〇 〇 〇
Piston rod and piston
rod threading, loose Testing
Reach cylinder, tilting cylinder,

connections, hammer 〇 〇 〇 〇 〇
deformation, damage
lifting cylinder

Operation 〇 〇 〇 〇 〇

Leakage 〇 〇 〇 〇 〇
Wear and damage of
pins and cylinder
steel-backed 〇 〇 〇
bearings
Check forks for
damage, wear or 〇 〇 〇
Fork

deformation
Check for stopper
pins for damage or 〇 〇
wear

48
 Check fork base and
hook welding for
defective cracks 〇 〇 〇
or wear
Cracking and damage
of welding on inner
mast, outer mast and 〇 〇 〇
crossbars
Wear, cracking and
damage of welding on
tilt cylinder brackets 〇 〇 〇
and mast
Wear, cracking or
damage of welding on 〇 〇 〇
inner and outer masts
Wear, cracking and
Mast and fork

damage of welding on 〇 〇 〇
fork carriage

Loose roller bearings 〇 〇 〇

Wear and damage of
mast support bearing
bushes
Check lift cylinder
bottom bolts, piston
rod head bolts, Test
U-bolts, and piston hammer 〇 〇 〇
head guide bolts for
looseness
Check rollers, roller
pins and welded parts 〇 〇 〇
for cracks or damage
Others
Every 3 Every 6
Service Daily Weekly Monthly
Item Tool months months
required (8 hrs) (40 hrs) (166 hrs)
(500 hrs) (1000hrs)
Check
Testing
Overhead mounting is 〇 〇 〇 〇 〇
secure hammer
guard and
Check for
load deformation,
backrest cracking, 〇 〇 〇 〇 〇
damage
Operation and
Turn signal
mounting 〇 〇 〇 〇 〇

Operation and
Horn mounting 〇 〇 〇 〇 〇

Light & Operation and

mounting 〇 〇 〇 〇 〇
Lamps
Operation and
Instrument mounting 〇 〇 〇 〇 〇

Wire damage
or looseness 〇 〇 〇 〇
wire Looseness of
electric circuit 〇 〇 〇
joint

49
11.3 Replace the key safe parts termly

Some parts should be checked termly to detect the damage, in order to fully improve the safety,

users should replace the parts termly according to the following table.

If the part is abnormal before the replacing time is due, replace it immediately

Key safe part’s description Service life (year)

Brake hose or rigid pipe 1～2

Lifting system hydraulic hoses 1～2

Steering, lifting chain 2～4

Hydraulic system high-pressure hoses 2

Brake fluid cup 2～4

Brake cylinder cover and dust cover 1

Hydraulic system inner seals and rubber parts 2

50
11.4 Bolt tightening torque table
Unit :Nm

Grade
Bolt diameter
4.6 5.6 6.6 8.8

6 4～5 5～7 6～8 9～12

8 10～12 12～15 14～18 22～29

10 20～25 25～31 29～39 44～58

12 35～44 44～54 49～64 76～107

14 54～69 69～88 83～98 121～162

16 88～108 108～137 127～157 189～252

18 118～147 147～186 176～216 260～347

20 167～206 206～265 245～314 369～492

22 225～284 284～343 343～431 502～669

24 294～370 370～441 441～539 638～850

27 441～519 539～686 637～784 933～1244

Note： ·Use entirely 8.8 grade bolts 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.

51
11.5 Forklift used oil

No. Description Mark, code Volume（L） Remark

L－HM32 Add to the

1 Hydraulic oil (Cold environment: L－ corresponding Oil tank
HV32) scale mark
Add until the
oil overflows Reduction
2 Gear oil GL-5 85 W/90
from the oil gearbox
filler plug

Industrial vaseline 2# Battery terminal

General purpose lithium

Lubricating grease lubricating grease for
automobile

Replace hydraulic oil in the tank：

Oil drainage：There is one drain plug under the oil tank, unscrew the drain plug, and discharge the
old oil into the container. After being completely discharged, screw down.
Add oil： Screw out the breather plug above the oil tank, add hydraulic oil with the same model
until oil is between the dipstick scale marks.

52
Replace gear oil in the reduction gearbox

Drain oil： Place a container under drain plug,

screw out the drain plug, and the oil flows into

the container. After oil being fully drained, screw

down the drain plug.

1

Add oil： Screw out the oil filler plug, oil flows

into the reduction gearbox with the help of

funner and hose until it overflows. And then

screw down the oil filler plug and clean the 2

spilled oil with cloth.

Caution：
 Waste battery and waste oil should be disposed according to local environmental protection

requirement, but not dump at will.

Apply lubricating grease：

– Apply lubricating grease on the mast channel steel and roller inner channel steel;

– Apply lubricating grease on the truck frame pillar and reach device roller inner channel steel;

– Apply lubricating grease on the plane of action of steering gearwheel and pinion;

– Apply lubricating grease on bearing or turning part.

53
12. Forklift hoist and transport
Forklift trucks are generally used for loading, unloading and short-distance transportation. They

are not designed to be a long-distance mode of transport. A forklift that needs to be transported

over a long distance should be transported in a ship, train or a truck.

Warning
 Front and rear wheel of this series truck is installed with electromagnetic brake, and rear

wheel brake is normally closed. It’s forbidden to drag when hoisting or transporting this

series truck.

Hoist the truck

Procedures：

1. Move the truck reach device backward to the end, lower the mast and shut down the

forklift.

2. Wire rope passes through grooves of two front pillars, and gets stuck in the grooves to

avoid wire rope slipping during hoisting.

3. Another wire rope passes under the rear end of the forklift, and get through inner end of

the bolt to avoid wire rope slipping during hoisting.

4. Slowly hoist the forklift off the ground, and make sure the wire ropes are tied firmly.

Caution：
 Before hoisting the forklift, first move the mast backward in place, lower the mast in place, and

then shut down the forklift. It is suggested to dismantle two forks before hoisting. If the outer

mast is too high, dismantle the mast to avoid accidents.

 The steel wire must own enough strength. After getting through the front truck pillar, the wire

rope must get stuck in the groove. When the rope gets under the rear end of the truck, get

through the inner end of the bolt, and prevent rope slipping with bolt.

 Front and rear wheel of this series truck is installed with electromagnetic brake. Make sure the

rear wheel is off the ground during hoisting. No towing, or the electromagnetic brake maybe

damaged.

 Never walk under a forklift when it is being lifted.

54
1.Groove 2.Bolt

Transport the truck

Forklift for long-distance transportation, needs take advantage of means of transportation as

semi-trailer, trailer or lorry. Tie up the truck body when the forklift is on the transport vehicle, block

the wheel if necessary.

Mast height for this series truck has many choices, if the outer mast is too high, dismantle the

mast assembly to transport. After reaching the destination, reinstall the mast. Refer to Mast

Dismantlement and Installment for detailed procedures.

Caution：
 According to Provisions on the Administration of Highway Management for Over Limit

Transport Vehicles by Ministry of Communications, overall height of loaded truck for

heavy/medium truck and semi-trailer is calculated from the ground, with 4M high limit;

container truck with 4.2M high limit.

Transport the defective truck

Brake of this series forklift adopts electromagnetic brake, which is normally closed type. When the

forklift has travelling fault, the electromagnetic brake will lock the motor shaft of the driving wheel,

55
so the fault forklift cannot be dragged directly on the ground, otherwise it may damage the

electromagnetic brake. Generally the defective truck is transported by the means of

transportation.

Warning
 This series truck is installed with electromagnetic brake, rear wheel brake is normally

closed, so the truck cannot be dragged, otherwise it may damage the electromagnetic

brake.

 It’s forbidden to towing truck without power.

56
13. Main technical parameters list

No. Item Unit CQD12-AZ4H CQD14-AZ4H CQD16-AZ4H CQD20-AZ4H

1 Rated capacity kg 1200 1400 1600 2000

2 Load center mm 600 600 600 600

3 Max. lift height mm 12500 12500 12500 12500

4 Free lift height mm 4185 4185 4185 4185

5 Max lift speed (Full Load) km/h 220 220 220 220

Tilting angle
6 (°) 2/4 2/4 2/4 2/4
(Forward/Backward)
Max traveling speed (Full
7 km/h 10.2 10.2 10.2 10.2
load)
8 Max Gradeability (Full load) % 10 10 10 10

9 Min turning radius mm 1725 1725 1725 1800

10 Min ground clearance mm 68.5 68.5 68.5 68.5

Length
mm 1897 1897 1897 1972
dimension

(fork excluded)
Overall

11 Width mm 1270 1270 1270 1270

Height mm 2200 2200 2200 2200

12 Service weight kg 4729 4729 4729 4780

13 Battery Voltage/Capacity V/Ah 48V /460 48V /460 48V /460 48V /600

Traveling kw 6.4 AC 6.4 AC 6.4 AC 6.4 AC

Capacity
Motor

14 Lifting kw 12.8 AC 12.8 AC 12.8 AC 12.8 AC

Steering kw 0.67 AC 0.67 AC 0.67 AC 0.67 AC

Front wheel×2 330×100 330×100 330×100 330×100

Wheel

15
Drive wheel×1 343×140 343×140 343×140 343×140

57
 Mast extended Free lifting height
Lifting Mast Tilting range Load capacity at 600mm
h4 h2
Model
Type

height lowered
h3 h1 Without With Without With Forw Back
1.2t 1.4t 1.6t 2.0t
backrest backrest backrest backrest ard ward
mm mm mm mm mm mm （°） （°） kg kg kg kg kg
1）
5000 2315 5670 5965 1596 1350 2 4 1200 1400 1600 2000 2000
1）
5500 2490 6170 6465 1796 1525 2 4 1200 1400 1600 2000 2000
1）
Three-level fully free wide-view mast

6000 2665 6670 6965 1995 1700 2 4 1200 1400 1600 2000 2000
QA20V (Imported channel steel)

1）
6500 2835 7170 7465 2136 1870 2 4 1200 1400 1600 1900 2000
1）
7000 3020 7670 7965 2350 2055 2 4 1000 1200 1400 1700 1800
1）
7500 3180 8170 8465 2510 2215 2 4 900 1100 1300 1600 1700
1）
8000 3350 8670 8965 2680 2385 2 4 850 1050 1250 1550 1650
1）
8500 3580 9170 9465 2910 2615 2 4 800 1000 1200 1500 1600
1）
9000 3800 9670 9965 3130 2835 2 4 750 950 1150 1450 1550
1）
9500 3970 10170 10465 3300 3005 2 4 700 900 1100 1400 1500
1）
10000 4100 10670 10965 3430 3135 2 4 650 850 1050 1350 1450
1）
10500 4250 11170 11465 3580 3285 2 4 600 800 1000 1300 1400
1）
11000 4450 11670 11965 3780 3485 2 4 550 750 950 1250 1350
1）
11500 4700 12170 12465 4030 3735 2 4 500 700 900 1200 1300
1）
12000 4900 12670 12965 4230 3935 2 4 450 650 850 1150 1250
1）
12500 5150 13170 13465 4480 4185 2 4 400 600 800 1100 1200

1) The corresponding load capacity when configuring 750Ah battery

58
14. Nameplates and warning labels
Stick different nameplates and warning labels at different positions of the truck.

蓄电池平衡重式叉车
许可证号：

型号 规格

整机编号 自重

标准载荷中心距 额定起重量

不带蓄电池自重 允许最大蓄电池重量

1 蓄电池额定电压

无属具
最大起升高度
允许最小蓄电池重量

载荷中心距 最大起升高度起重量

装有属具时，最大起升高度起重量参见属具标牌或载荷曲线标牌

杭叉集团股份有限公司
中国浙江临安经济开发区东环路 号 客服电话：

警 告
6

2 5
警 告

4
3

No. Description
1 Product nameplate：Basic forklift parameter
2 Character label：Manufacturer character
3 Hoisting label：Hoist position indicator.
4 Series label：Product series and tonnage label
5 Danger label：Be careful when lifting the mast
6 Danger label：No climbing
7 Danger label：Loading part is not allowed to carry people. Never stay under the
loading part.

59
Operation procedure label

Slowly! P

WARNING!
WARNING !

60
15. The use, install and safety rules of attachment
HANGCHA will choose attachment that in accordance with International standard ISO2328 Forklift pothook fork and
installation size of carriage, such as sideshifters, fork positioner, rotator, push/pull and clamp etc.

sideshifter fork positioner rotator push/pull coil boom

bar arm clamp paper roll clamp block clamps load stabilizer turnaload
Attachment install
– Untempered technology license of our company, any refit at safety and capability to attachment is strictly
prohibited.
– Actual rating load capacity should be the least of rating load capacity, the load capacity of attachment, combined
load capacity of truck. Generally speaking, the combined load capacity of truck is the least. Attachment load
capacity just a count value of attachment pressure.
– Installation goes to in reason, credibility, safety to avoid the attachment glide around carriage in using.
– After hang attachment, embed the rise catch block to the gap of top beam, let the offset of centre line of
attachment and carriage is less than 50mm.Otherwise, it will affect the landscape orientation stability of forklift.
– To these attachment with rotating function, such as paper roll clamp, bale clamp, muti-purpose clamp, drum clamp,
it needs to weld chock block in the joint of carriage beam and attachment to prevent move from side to side in the
operation.
– Install the attachment of below catch orientation, it need to adjust the clearance between below catch and beam of
carriage.

Attachment use
– Know well the content of nameplate on attachment, read the instruction manual before usage. (Especially the
manual from attachment company) Before operate the attachment, the people should be trained and obtain the
qualification.
– It should be understand the basic capability and operate methods of attachment. Especially the admit load, lift
height, size of cargo and adapt range of attachment.
– Operate the multi-functional attachment, such as with side-shifter, clamp or rotator, it is not allowed that two action
at one time. Operate one functional then do another one.
– Prohibit the cargo at a high position when truck with attachment moves. If the size of cargo is too big, prohibit the
truck move on. Transport the cargo, make sure that the distance of bottom of cargo and ground is less than
300mm and mast incline back.
– The weight of cargo couldn’t exceed the limited value of combination carrying capacity of forklift and attachment. It
is not allowed that partial load at high position. It is a short time work for attachment with side shifter. Partial load is
around 100mm (Above 5 ton (including 5 ton), the side-shifter movable within 300mm.
– In the range of the projection forth 2m of the lower of attachment and cargo, prohibit standing to avoid the
suddenness except the driver position under overhead.
– It is not allowed that an emergency brake in moving. Run slowly with load.
– Prohibit outside force when attachment working;
– It couldn’t be use at malfeasance situation and overstep normal work range.
61
– When the attachment has trouble, prohibit using without check.

Check and maintenance

– Check the clearance of carriage beam and below catch of attachment if meet the attachment manual.
– Check the hook is right on the flute of fork carriage.
– Use the auto general lithium-grease per 500 hours to bearing surface.
– If the tighten firmware become flexible.
– Check the tie-in of hydraulic pressure loop, if tube attaint. Prohibit use after repair.
– Check the drive of attachment or if the rotating elements fray or block, change in time.
– Check if each element and attachment working pressure is normal as well as attachment works normally under
load. If not, check the hydraulic pressure loop, find out the broken part, change sealing element or whole loop
element.

62
16. Battery automatic filling water system(Option)
Makeup of the automatic filling
watering system:
– Automatic Watering Plug
– End Plug
– Floater
– T-piece & L-piece
– Flow Indicator（with filter）
– 6mm, 8mm ,10mm watering pipe
– Male & Female couplings (Kv10 and
KV6, etc.)
– Water Tank

Application specification and installation

During the period of development and long-term practical usage, the leak tightness of FRÖTEK automatic watering
system has received complete recognition. But when you use it, you need to keep the automatic watering system
clean and there can’t be any filth on the surface.
How to properly install the automatic watering system：Our automatic watering system is easy to operate, no need to
finish watering the electrolyte in the storage battery by hand, time saving and labor saving, besides, it can extend the
service life.
How to correctly install the water tank, choose proper floaters, how to confirm the specification & quantity of the
installed accessories according to different types of battery, including correct application rules for automatic watering
plug, watering pipe, T/L-pieces and male/female couplings as well as the cleaning of the flow indicator. We will give
you a brief introduction for the above items as follows:

Watering head Flow 6mm 10mm

Battery T-piece Male/female Water tank
indicator Watering Watering End plug
spec. （6-10-6） K10 Spec.
T-piece （filter） pipe pipe

24V 12 pcs 1 pc 1 pc 3m 5m 2 pcs 1 pc 30L 1 pc

48V 24 pcs 1 pc 1 pc 5m 5m 2 pcs 1 pc 30L 1 pc

63
 80V 40 pcs 1 pc 1 pc 10m 5m 2 pcs 1 pc 60L 1 pc

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

Floater
How to choose proper floaters correctly：
– According to different storage battery, we have five kinds of floaters for you to choose. In order to achieve our
expected standard and completely reflect the effectiveness of the automatic watering system, the most important
thing is to choose proper floaters. At present our company can offer a rule for the client to make judgment and
choose the type of floater. (see diagram)
– The diagram for the installation way of the floaters:

T=T1-(5mm～17mm)

T Length 47 50.5 58 61 72

Float 13 16.5 24 27 38

64
Watering pipe
Our company offers watering pipes of different types and the clients can choose what they need according to the
specification of the battery. The watering pipe must be perfectly sealed with T-piece and L-piece.
Notes during the filling process：
– In order to ensure a safe watering process, we hereby recommend you to use flow indicator (with filter), the flow
indicator with filter can not only timely indicate whether it finishes watering, but also avoid unclean impurities
entering the battery to result interruption.
– You’d better conduct watering within the specified periods, because frequent filling will lead to overflowing for too
much water, which will do great damage to the storage battery.
Note：Filling after finishing charging is the best ideal state, besides, do not filling before charging.
Maintenance（Cleaning）
When you use it, you must pay much attention to keep the automatic watering system clean. No filth remaining on the
surface. The users should regularly clean the watering plug for the plug is a kind of plastic good. Clean the surface
directly with tap water and no need to use other detergent.

open close
Structure Diagram of the Watering Plug
Characteristics of the automatic filling watering system:
– No need to water by hand, labor saving.
– No malfunction factor leading to damage the battery.
– Easy operation, safe.
– Ensure a precise electrolyte level in every battery cell.
– Prevent leakage when watering.
– Effectively avoid the acid liquid to erode the storage battery and the electrolytic bath.
– Extend the service life of the battery.
– Environment protection.
Function Introduction：
– Function of the automatic watering system: the floater of the automatic watering plug can reach correct water level,
when the level rises in the cell, the pressure closes the valves and prevents further water entering the cell.
– When the system finishes watering, the flow indicator will stop running and you can see the water-level indicator
clearly through the top of the watering system.
– Besides, the material of FRÖTEK floater can avoid damage and ineffectiveness.
As for the structure of automatic watering system, there is a terraced step, when the electrolyte gas rises to the
watering plug, the terraced part can prevent the leakage of the electrolyte gas as well as quickly cool the electrolyte
65
gas to make them go back to the storage electrolyte gas as well as quickly cool the electrolyte gas to make them go
back to the storage.

66
17. Related Safety Instruction and Standard（For trucks exporting to Europe or option）
The model by CE certification which according to the following instruction and standard: DIRECTIVE 2006/42/EC OF
THE EUROPEAN PAMENT AND OF THE COUNCIL, DIRECTIVE 2000/14/EC OF THE EUROPEAN PAMENT AND
OF THE COUNCIL, EN1726-1:1998(Engineering Industry truck safety standardize), EN12053:2001, EN1175-1:1998,
EN13059:2002 coordinate standard.
 Main safety elements are in accordance with 2006/42/EC machinery directive as well as EN1726-1:1998,
EN1175-1:1998 standard;
 Noise is calculated according to EN12053:2001, noise from the driver seat is measured by sound pressure level,
less than 74dB(A)
 Vibration data are calculated according to the ISO5349-2:2001, EN13059:2002 and ISO2631-1:1997 standard,
synthetic acceleration from the seat to the operator body is less than 0.80 m/s2

 Electromagnetic compatibility is calculated according to EN12895:2000 and meet 2004/108/EC directive

67
 DECLARATION OF CONFORMITY
EG-KONFORMITÄTSERKLÄRUNG

Business name of the manufacturer: Hangcha Group Co., Ltd.

Firmenbezeichnung des Herstellers:
Full address of the manufacturer: 666 Xiangfu Road, Lin'an District, Hangzhou City, Zhejiang Province
311305, P.R. China
Vollständige Adresse des Herstellers:
Name and address of the person (established in the Community) compiled the technical file:
Name und Adresse der Person (innerhalb der Gemeinschaft), die das technische Datenblatt erstellt hat
Hangcha Europe GmbH
Mariechen-Graulich-Straße 12a,65439 Flörsheim am main Germany
Tel: 0049-61453769188 , Andy Yang(General Manager)

We declare that the machinery

Wir erklären hiermit, dass die Maschine

product name: Electric Forklift Truck

Produktbezeichnung:
commercial name:
Handelsbezeichnung:
function:
Funktion:
model: CQD12/14/16/18/20-AC4, CQD12/14/16/18/20-AD2, CQD12/14/16/20-AZ4H ,
CQD12/14/16/20-AD2H
Modell:
type:
Typ:
serial number: above mentioned products
Seriennummer:
fulfills all the relevant provisions of Directives
entspricht allen relevanten Anforderungen folgender Richtlinien
2006/42/EC
tested in accordance with below standards
wurde gemäß folgender Normen geprüft
EN ISO 3691-1:2015
EN ISO 3691-1:2015/AC:2016
EN 16307-1:2013+A1:2015
EN 1175-1:1998+A1:2010

place and date of the declaration: Hangzhou, 21.07.2020

Ausstellungsort und Datum der Erklärung

signature of the person:

Unterschrift des Ausstellers

68
 Part Two: Structure, principle and maintenance
1. Drive system
Drive system is composed of drive motor, reduction gearbox, electromagnetic brake, steering

motor, steering gear, tyre, fan and wire etc. Power transmission route: drive motor → reduction

gearbox → tyre; tyre steering route: steering motor →pinion → gearwheel → tyre.

4 No. Designation

1 Mounting plate
3
2 Bolt
2 5
3 Drive motor
1
Electromagnetic
4
brake
2
5 Fan
Reduction
10 6
7 6 gearbox
Oil filler plug of
7 reduction
9 gearbox
Drain plug of
8 reduction
8 gearbox
9 Tyre

10 Steering motor

69
Inner reduction gearbox structure refers to the following drawing:
No. Designation
1 1 Brake
10 2 Motor
2
3 Screw
3 11 4 Nut
12
5 5 Screw
4 6 Mounting plate
7 Screw
6 8 Turntable bearing
7 9 Steering gearwheel
10 Steering motor
8 13 11 Screw
14 12 Washer
9 15 13 Steering pinion
14 Washer
15 Screw
16 Wheel
17 17 Assembly
18 Spring washer
19 Wheel nut
19 18 16

4 No. Designation No. Designation

1 5 2 7
1 Drive gear 10 Plug screw
3
8 2 Gear 11 Nameplate
6 9 Protection
10 3 Hex nut 12
cover
17
11 16 Breather
4 13 Plug screw
plug
5 Cap 14 O-ring
14 15
6 Case body 15 Case cover
12 9
13 7 Cover 16 Pin
8 Screw 17 Screw
9 Seal ring

70
 15 No. Designation No. Designation
14
1 Bearing 9 Gear set
1 13 2 Base plate 10 Snap ring
2
12 3 Stud 11 Bearing
4 Gear shaft 12 Gasket
5 Shaft seal 13 Gear shaft
10 11 6 Bearing 14 Bearing
8
7 9 7 Cover 15 Base plate
6
3 4 5 8 Base plate

1.1 Electromagnetic brake

The adopted brake of this truck is spring weighted electromagnetic brake. This brake is one-chip

brake, owns two friction surfaces. It can generate strong braking torque in the power-off position

by pressure spring, and electromagnetic effect releases the brake.

1.Mounting screw

2.Stator component
6

5
3.Braking friction plate

4 4.Axle sleeve
3
5.Friction disk
2
6. Dust cover
1

Working principle
Shaft(9) connects spline housing(4)through flat key; spline housing(4) connects friction disk

assembly(3) through spline. When the stator (11) is off power, spring (10) generated force works

on the armature(8), friction disk assembly(3) drove by the shaft(9) grips between armature(8) and

friction disk(5), thus generates braking torque. For this moment, there will be a gap ―Z‖ between

armature(8) and brake friction plate(3). When need to release the brake, stator(11) connects the

DC, then the generated magnetic field draws the armature(8) move to the stator(11), spring(10) is

compressed when armature(8) moves, at this time, friction disk assembly(3) is loosened, brake is

71
released.

1. Mounting screw
6
3. Braking friction plate

4. Axle sleeve
1 5. Friction disk
7
6. Dust cover
5
7. Hollow screw
3

8 8. Armature

9 9. Motor shaft
4
10.Pressure spring
10
11 11.Stator

Z. Air gap
Z

72
Install the brake
– Put the flat key(12) in the key groove of motor shaft(9), press 13
4 12
the shaft sleeve(4) on the shaft(9), and fix with inner snap
9
spring(13).

– Put friction disk(5) on the motor end face.

– Cover the braking friction plate(3) above the shaft sleeve.

– Assemble stator component(2) and three mounting

screws(1). Note: remove three rubber pads from the stator

component before assembling. 14

Z 15

6
– Screw down there mounting screws(1) with torque

wrench(14), and check braking air gap ―Z‖ with feeler

gauge(15).

73
– Put dust cover（6）.

– Connect brake wire.

Warning
 No wire surface damage to avoid circuit damage.

 Do not process product locating surface or hole voluntarily so as not to affect magnet loop.

 Do not force too much when pressing fitting on the motor shaft, do not damage the friction

surface, remove burrs on the mounting hole and surface, install shaft sleeve on the shaft,

and fix it with axial snap spring.

 Measure the brake connected DC voltage, and compare the voltage with the one stipulated

on the nameplate. 10% deviation is allowable.

 During installation and use of the brake, keep away from oil dirt.

U=x V DC±10%

OIL

Adjust brake air gap

Rated air gap ‖Z‖ will be larger for wear. Make sure the brake get enough brake torque, readjust

air gap before the air gap reaches the largest air gap value. Air gap can be adjusted repeatedly,

when the thickness of friction braking plate reaches the allowable minimum thickness (refer to

specification table), replace the friction disk plate.

When the air gap exceeds maximum air gas value, the brake may be unable to release, friction

braking plate burn out, braking force or retentivity decreases, noises increase, or even cause

severe accident. So check and re-adjust the air gap periodically, and cut off the truck general

power.

74
Specifications
Rated Rated Rated air Max. air Min. rotor Tightening torque of
torque power gap gap thickness mounting screw

16 N.m 30 W 0.2 mm 0.5 mm 8.1mm 9.5 N.m

When the brake is off power, adjust three hollow screws(7), adjust the air gap between armature

and friction brake plate to rated value ―Z‖ with the help of feeler gauge, and ensure that air gap of

each direction is the same. Procedures are as follows:

– Screw off three mounting screws(1).

– Rotate three hollow screws(7) clockwise a little with spanner.

– Screw down three mounting screws(1).

– Use feeler gauge to check if air gap ‖Z‖ meets requirement. Readjust until ‖Z‖ reaches the

rated range.
1

7
Z
-
+
In general working condition, the first air gap adjustment should proceed after brake working for

1500～2000hours, frequency of air gap adjustment is once per 6 months. In severe working

condition, like frequently brake and repeatedly sudden brake etc., the first adjustment can be

shortened and adjust the interval.

Maintenance
– If work in high temperature environment for long time, please prevent rust, it may influence

use if there is rust on the suction surface.

– Do not touch the friction surface with hand, no oil stain, otherwise it cannot reach the

maximum torque.

– General use environment temperature is -10℃～+40℃.

– Please check periodically, and the check item : if the switch motion is normal; if there is noise;

if there is abnormal heating; if any impurity, oil stain mixed into friction part or rotating part; if

clearance of friction part is proper, exciting voltage normal.

Common fault and troubleshooting

75
 Fault Probable cause Corrective action
Power is obstructed 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

Switch installed to AC circuit Install the switch to the DC circuit

after rectifying
Long brake time Improper air gap Adjust air gap

Oil dirt mixed in Clean oil dirt

Unstable operation in previous
Breaking-in for a while
use

Oil dirt mixed in Clean oil dirt

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

High operating frequency Adjust to proper frequency

Over large load Reduce load

Product service environment
Silence design
needs silence

Impurity mixed in. Clear away the impurity

Large noise
Bad mounting Replace mounting surface or shaft

Large rotational inertia or Reduce rotational inertia or

dynamic unbalance value dynamic unbalance value

Dismantle and install the drive system

1. Park the forklift on the stable ground, shut down the forklift, press the red emergency button,
and pull out the battery socket.
2. Jack up the rear end of the forklift, support the frame with whole block or iron, make sure the
block or iron is hard enough to support the forklift and keep stably.

76
 No. Designation
1 Block
2 Drive wheel
3 4 3 Fingertip armrest
4 Seat
6 5 Cover
8 5
6 Cover fixing bolt
7
10 7 Cover fixing bolt
9 8
Base plate rubber
pad
Base plate fixing
9
bolt
1 2 1
10 Base plate

3. Pull out fingertip plug to prevent wire break when taking down the cover.
4. Dismantle cover. Unscrew cover fixing bolt, raise the cover a little vertically, first pull out the
seat OPS(option) plug and fan plug, and then remove the cover.
5. Dismantle the base plate rubber pad and front floor. Before removing the base plate, first pull
out the safety pedal, foot brake pedal and accelerator pedal plugs, in case of wire break.
6. Dismantle all wires and connectors of drive system assembly. Dismantle the drive motor and
steering motor connected wire, pull out the plugs of electromagnetic brake and fan etc.
7. Dismantle drive system assembly. Unscrew mounting plate and truck frame connected bolts,
and hoist the drive system assembly stably.
4
No. Designation

3 1 Mounting plate
2 5
2 Bolt
1
3 Drive motor
2
4 Electromagnetic brake

10 5 Fan
7 6

6 Reduction gearbox
9
Oil filler plug of reduction
7
gearbox
Drain plug of reduction
8 8
gearbox

77
 9 Tyre

10 Steering motor

Caution：
 Before laying aside the drive system assembly, first drain the reduction gearbox oil in case of
the oil leakage in the motor.
8. Drain reduction gearbox oil. Place a container under the reduction gearbox, and unscrew the
drain plug to drain the oil. And then screw down the oil drain plug.

Caution
 The waste oil needs to be dealt with according to local environment requirement, do not dump
at will.
 Replace the reduction gearbox oil every six months.

9. Dismantle the steering motor. Unscrew three bolts on the mounting plate, erect the steering
motor and take it down stably.
10. Dismantle the electromagnetic brake: Dismantle the outer snap ring of the electromagnetic
brake, unscrew bolt, and then erect the brake and take it down stably.
11. Dismantle the steering motor: Unscrew motor fixing bolt, and then erect the steering motor and
take it down stably.
12. Dismantle the reduction gearbox: Dismantle mounting plate, pivotal bearing and gearwheel in
sequence, and then dismantle reduction gearbox.
13. Dismantle the driving wheel: Unscrew wheel nut, pull out the wheel horizontally and then
dismantle.
14. Install the driving system assembly, and the sequence is as follows：
1) Assemble the driving wheel;
2) Assemble the reduction gearbox, big gear, pivotal bearing and bearing seat etc., add gear
oil in the reduction gearbox until oil overflows from the oil filler plug;
3) Install to the truck frame;
4) Install gears on the driving motor shaft and then install the driving motor in the reduction
gearbox;
5) Install pinions on the motor shaft and then install the driving motor in the driving seat;
6) Install the electromagnetic brake and test the air gap of the brake.
7) Connect the electric circuit. Correctly connect motor wire and plugs.
8) Connect plugs of safety pedal, foot brake pedal and accelerator pedal, install front floor
and rubber pad.
9) Connect fan plug, seat sensor and fingertip plugs. And then fix the cover.

78
10) Jack up the rear end of the forklift, and take out the block or iron.
11) Insert the battery plug and start the forklift.

79
2. Front wheel assembly
Front wheel assembly is composed of wheel and electromagnetic brake etc.
The front wheel adopts polyurethane, which is strong and durable.
Electromagnetic brake works with power on, but stops braking with power off. During travelling,
the more the foot brake pedal is depressed, the stronger the front wheel braking force is.
Installation structure of front wheel assembly refers to the following drawing.

No. Designation
1 Wheel
Electromagnetic
2
brake
3 Screw
4 Bearing
5 Circlip for hole
6 End cap
7 Lock washer
8 Screw
9 Screw
10 Screw
11 Washer
12 Front axle
13 Truck front pillar

Disassembly and installment of front wheel

1. Park the forklift on the stable ground, shut down the forklift
2. Jack up the front end of the frame and support with block or iron, make sure the block or iron is
hard enough to support the front end of the forklift.
3. Dismantle the cover plate of front wheel.
4. Unscrew screw 8, dismantle end cap 6, and dismantle snap ring 5.
5. Unscrew screw 9, and knock out tyre assembly.
6. Pull out the electromagnetic brake plug. Unscrew screw 3, and then dismantle the
electromagnetic brake.
7. Unscrew screw 10, and take out front axle.
8. To install, reverse the order of disassembly. When installing bearing, smear lubricating grease.
When installing screw 3, 9 and 10, smear Loctite 270 glue. Torque of screw 9 is 25N.m.

80
 No. Designation
9 Screw
14 Bushing
15 Spacer bush
16 Spring

Caution：
 Front wheel brake adjusts the space automatically, torque of screw 9 is 25N.m, please refer to
the above drawing for details.

Common failures and troubleshooting measures

Condition Cause and Analysis Correction

Thread damage Replace tyre

Unstable wheel running
Bearing wear Replace bearing
Electromagnetic brake failed to Check and repair
stop the wheel rotation electromagnetic brake
Wheel does not rotate Bearing damage and seizure Replace bearing
Front axle distortion Replace
Electromagnetic brake Electromagnetic brake
Repair brake or replace
malfunctions malfunction or no braking force

81
3. Steering device
This series forklift is electric powering steering, which can realize 180°or 360°turn on the ground
by turning the steering wheel. Steering device is mainly composed of steering wheel, housing and
guide rail, as shown in the drawing below.
Steering wheel position is adjustable. Adjusting steps: turn the knob 4 in counterclockwise, release
housing and move it to a proper position, and then tighten the knob 4 in clockwise.

No. Designation

Steering
1
wheel

3 2 Housing

3 Guide rail
4
1 2 4 Knob

Fault diagnoses and corrections

Condition Cause and Analysis Correction
Steering wheel cannot Nuts on the steering wheel are Adjust the tightness of nuts on
be turned or too loose screwed too tight or loose. the steering wheel.
Steering motor damage or failure Inspect
Steering electronic control system
No steering Inspect
failure or line failure
action Gears of reduction gearbox failure or
Inspect or replace
wear
Pivotal bearing wear Replace
Dry engagement of big gear wheel and Smear lubricating grease or
pinion or gear damage replace gear
Noise Pivotal bearing wear Replace
Main reduction gearbox insufficient Add lubricating grease or
gear lubrication or gear damage replace gear
Turn the steering Check the wiring or debug the
wheel, the instrument Wiring fault or controller fault
controller
angle does not display
steering angle Instrument damage Replace

82
4. Hydraulic system
Hydraulic system is mainly composed of oil tank assembly, mutiway valve, cylinder and tube. Step
on the safety pedal with left foot, operate the fingertip with right hand, and the cylinder proceeds
the corresponding movement. Hydraulic schematic diagram is as follows.

83
Mutiway valve
Mutiway valve is integrated type, below is the drawing and schematic diagram of model 11170478
P2.
E1 E2 J
A M
15 15 16 17
13

11

3B 9
18 F1 19
12
D5 7 N
18 F2 14 19
10 1H K 7
3
T
10 6 8 D1
7 C1
2 4 6 D2
7 7
G C2
3
5 6
L C3 D4 D3
S

CART CODE ITEM PART NO. PART NAME QTY

H 1 11032702 CP208-1-B-0-E-C-260 1
2 11170480 BODY 1
B,S,T 3 130037 CP100-3-B-0-005 3
G 4 131504 CP701-1-B-0-150 1
L 5 131643 CP308-1-B-0-0.1 1
C1-C3 6 133851 CP124-1-B-0 3
D1-D5 7 133853 CP104-2-B-0 5
8 321211 PLUG, SAE#4 TAPERED BUNA-N 9
9 321212 PLUG, SAE#6 TAPERED BUNA-N 7
10 545020140+463200060 PLUG-M10×1 2
11 545020190+463150530 PLUG-M20×1.5 4
N 12 805315819+171149919 SVP10-NOR-24D-FL-B-00 1
J 13 83011831 PSVP12-NCR-24D-FL-B-00 1
K 14 83022514 CP200-7-B-0-E-C-230 1
E1,E2 15 850168819+171149919 PSV10-34-02-24D-FL-22-B-00 2
A 16 850168919+171149919 PSV10-34-05-24D-FL-22-B-00 1
M 17 850255919+171187619 PSV12-NC-80-24D-FL-B-00 1
F1,F2 18 860106519 CB10 HV-2-B-1-E-150-B-00 2
19 Z8242005 PLUG, EXPANDER (8MM) 24

84
Multiway valve pipeline connection
4 5 6 No. Connection
7 1 Connect oil pump port
3 2 Connect oil tank port
Connect lifting cylinder
8 3
port
Connect mast tilting oil
4
line port
Connect mast tilting oil
5
line port
Connect mast side
9 6
shift oil line port
Connect mast side
7
shift oil line port
Connect forward
8
2 1 cylinder front end port
Connect forward
9
cylinder rear end port

85
Main valve group function of multiway valve
2

Valve body 1 can lower the mast manually. First unscrew the hex nuts in counterclockwise, and
then screw slowly in clockwise with hex wrench, thus hydraulic oil in the mast lifting cylinder flows
into the oil tank through the multiway valve body, and the mast lowers. It is prohibited to stand
under forks when lowering the mast manually.
Valve body 2 can adjust system oil pressure. First unscrew the hex nuts in counterclockwise, and
then turn slowly in clockwise or counterclockwise with hex wrench to adjust system pressure.
Laypeople are not allowed to adjust system pressure.
Tonnage(t) 1.2 1.4 1.6 1.8 2.0
Safety pressure valve
22 22
（MPa）

Adjustment to the safety valve value of the hydraulic system

The pressure has been adjusted before leaving factory. Generally the user cannot adjust at will.
Take a rated capacity of 2000 kg as an example to state the adjusting procedures.
(1) Place 125% of rated load on the forks stably, that is 2500kg.
(2) Depress the accelerator pedal to the end, operate lifting and lowering control lever, if the forks
can be lifted to 0～300mm, the main relief valve pressure is right, otherwise follow step below.
(3) If the forks cannot be lifted (off the ground), increase the main relief valve pressure by
removing the base plate and loosening the locking nut of main relief valve and screwing the
adjusting bolt in clockwise; if the lifting height of forks is over 300mm, screw the adjusting bolt
in counterclockwise to reduce safety valve pressure accordingly.
(4) Depress the accelerator pedal to the end; lift the forks to a range from 0 to 300mm. otherwise
repeat the step 3 to meet the requirement.

Warning
 Goods must be placed stably;
 Once the pressure is set, please do not adjust casually.

86
 Fault diagnoses and corrections
Fault Probable reason Corrective action
Oil pressure is too low Check and turn up the safety valve value
Oil intermingle in the
Replace the seal ring on the piston rod
inner cylinder cavity
Cylinder extends Oil leakage Check the connection and oil tube
powerless Oil intermingle or
damage in the inner Replace the seal ring or replace multiway valve
multiway valve cavity
Oil pump leakage Replace the seal ring, replace damaged part
Oil lacks and oil pump
Add the hydraulic oil to the dipstick scale
cannot absorb oil.
Filter blockage Replace the hydraulic oil and clean filter.
No pressure oil in oil
Oil leakage Check the oil line
system
Oil pump malfunction Repair the oil pump or replace
Damage in the inner
Repair or replace
multiway valve cavity
Oil pump gear damage Replace the gear
Oil pump bearing
Abnormal noise Replace
damage
Air in the oil pump Check the reason for the bubble and eliminate.
Do not step on the Step on the safety pedal with left foot, operate
safety pedal the fingertip with right hand.
Operate fingertip but Line fault Check if the line is correctly connected.
cylinder does not Controller software
Debugging
work failure
Check if the oil line connects correctly or leaks,
Oil line breakdown
check oil pump, multiway valve and oil cylinder
Mast one-way governor
Replace
valve
Oil leaks in lifting
Mast lowers Replace the seal ring
cylinder piston
automatically
Multiway valve damage Repair or replace
Oil leak from the
Replace the connector seal ring
connector

87
5. Mast system
The lifting system is mast, reach device, load bracket, fork carriage, forks, lifting cylinder, tilting
cylinder, forward cylinder and pipeline etc. There are three types for the fitted mast: duplex wide
view mast, duplex full free lift mast and triplex full free lift mast.
There are many mast choices for this series forklift, mast structure and pipeline connection may be
different for different mast heights. Due to the continuous updating and improvement of the masts,
there may be minor discrepancies between your forklift mast and this manual.

8
9

5
4

88
Trouble shooting and corrective action
Fault Probable cause Corrective action
Tilting cylinder and seal ring abraded Replace piston seal ring or
Fork carriage excessively tilting cylinder.
tilts
automatically Fingertip does not reset automatically in place Adjust or replace
or malfunctions

Mast reaches, Piston jamming or piston rod bends Replace the damage parts.
lifts and tilts
sluggishly. Too much dirt is accumulated in the cylinder. Clear
Improper adjustment between rollers and Adjust clearance between roller
channel steel and channel steel
Fork carriage Dirt in the mast channel steel or damage Remove dirt or repair
is lifted or
lowered Apply grease on contact
unsmoothly Insufficient mast channel steel lubrication surfaces of sliding parts
Reach device
moves
unsmoothly Mast deflection or fork carriage bent Repair or replace

Channel deflection or reach device bend Repair or replace

Fork carriage is Improper adjustment of lifting chains Adjust lifting chains on both
lifted unevenly sides to the same tightness
Rollers deformation or damage Replace
Lifting roller Improperly adjustment of lifting roller. Adjust.
cannot rotate
Rollers get stuck by dirt Clean and lubricate the rollers.

Too much Insufficient lubrication. Lubricate.

noise on the Side rollers on fork carriage adjust improperly. It
mast strikes the mast channel steel, when the Adjust the rollers and side
rolling adjusting gaskets
extended mast lowering.
Oil line pressure is too low Adjust safety valve value

Oil intermingle in the inner cylinder cavity Replace cylinder seal ring
Insufficient Check, repair or replace seal
lifting power or Oil line leaks or connector leaks ring
unable to lift
Fingertip line fault Repair

Overloaded Load in the regulated range

Outer mast tilts Outer mast is not vertical, but tilts Adjust connecting rod and bolt
Mast disassembly and installation
1. Disassemble the fork. Lower the mast 15~20cm off the ground, unscrew the bolts in the middle
of the fork carriage, pull up the fork stopper and rotate it 90°, push the forks to the middle of the
fork carriage and aim at the gap. Tilt the fork carriage forward, slowly back up the truck,
meanwhile the mast lowers and the forks fall off.
2. Move the mast forward to the end and lower it.

89
3. Press down parking brake button and shut down the forklift.
4. Dismantle the hydraulic block connected multiway valve rubber pipe, and plug the coupling to
prevent oil outflow.
5. Dismantle mast connecting wires to prevent wire breakage when removing the mast.
6. Rope or wire rope hangs to the lifting device through the inner mast beam, fasten firmly to
avoid dropping. Notice that the lifting rope cannot extrude the oil pipe to avoid damage.
7. Dismantle the bottom connection of outer mast and reach device. Dismantle mast and reach
device, left and right connecting bolts, as well as intermediate connecting rod.
8. Dismantle the upper connection of the outer mast and reach device. Unscrew the pedestal
cover bolts, and then hoist the mast slowly with the lifting device. Knock out the eccentric
bushing, to prevent from being lost or damage during transport or laydown. Never stand
around or under the mast when the mast is hoisted or transported.

No. Designation/Remark

1 Bolt

2 Pedestal cover

3 Eccentric bushing

4 Reach device

5 Mast
9. Dismantle the reach device. 1. First dismantle two front blocks; 2. Dismantle forward cylinder
connecting oil pipe, and plug the connector. Dismantle reach device connecting forward
cylinder end. 3. Dismantle multiway valve connecting oil return pipe and pressure pipe. Pull
out the multiway valve and controller connecting wire plug so as not to break the wire when
removing the reach device. 4. Tie the steel wire or rope to the reach device beam, pull out
horizontally and hoist.
10. To install, reverse the order of disassembly. Smear lubricating grease to the channel steels
when installing. Smear lubricating grease to the rotary parts. After installment, adjust the
clearance between rollers and steel channels, and adjust the outer mast verticality. Correctly
connect each line and each oil pipe connection.

Caution：
 According to Provisions on the Administration of Highway Management for Over Limit
Transport Vehicles by Ministry of Communications, overall height of loaded truck for
heavy/medium truck and semi-trailer is calculated from the ground, with 4M high limit;
container truck with 4.2M high limit. If the outer mast is too high, dismantle it to transport.
Reassemble by professionals after reaching the destination. Non-professionals are not
allowed to dismantle or assemble the mast.
 It's prohibited to stand under or near the mast when disassembling and assembling the mast,

90
 as it is very high and heavy.
 For different high masts, mast, oil line and circuit of this manual may not be exactly the same
as the forklift you own.

Inner structure of lifting cylinder

5 6 7 8 9 13

1 2 3
4 10 11 12

1.Plunger 2.LBH Dust 3. Check 4.IDI seal 5. Guide 6. Cylinder 7.O-ring

lever ring ring ring sleeve body
8.Sealing 9.Plug screw 10. 11.Valve 12. 13. Nipple
gasket Support sleeve Check component
ring ring

91
Inner structure of forward cylinder
7 8 14 15
45 6 9 10 13 11 12 13 16
1 2 3 2 3

1. Piston rod 2. Circlip for hole 3.Bearing 4.Guide 5.A1 dust ring 6.B3 seal ring
sleeve
7.O-ring 8.FR guide ring 9.Cylinder 10.Piston 11.O-ring 12.KR-ring
body
13.FR guide 14.Washer 15.Nut 16.Pin
ring

Inner structure of tilting cylinder

7
8
2 34 5 6 9

1. Piston group of 2.Dust ring 3.O-ring 4.U-ring 5.Guide sleeve

piston rod
6.O-ring 7.GLYD ring 8.Support ring 9.Cylinder tube

Caution
 Forward cylinder, lifting cylinder and tiling cylinder relate to the mast height. For different high
masts, their cylinders maybe different.

92
6. Electrical system
6.1Motor
AC motor
AC motor does not have commutator and brush. No maintenance. But it needs regular inspection
and dusty clearing.

Rated Rated Rated Max. Rated

Insulation Frequency Duty Temperature
Type power voltage current current speed
class Hz min ℃
kW V A A r/min

00000021 0.67 28 2170 IP20 78 S2-60

00000019 6.4 32 1755 IP20 60 S2-60

HPB12.8-4HC3 12.8 34 1700 H 61.1 40

Motor maintenance
1. Motor must be maintained well so as to guarantee safety work and extend service life.
2. Motor installation and each fastener should be reliable.
3. Power cable should be correctly and firmly connected, no protrusion, no oil stain on the
insulation part, and keep dry.
4. Idle motion should be quick.
5. If there is any abnormal phenomenon, stop immediately, such as overheating or abnormal
noise. Operate until malfunction is corrected.
6. Do not disassemble the motor arbitrarily, follow the rules of CAUTION OF MOTOR
DISASSEMBLING.
7. Clean the surface of motor regularly, replace the grease of the motor bearing annually(working
temperature of grease is -40℃~+200℃).
8. Washing the motor case with high pressure liquid is strictly prohibited, in case of case
deformation.
9. To protect the shaft extension, do not remove the motor by putting ropes on motor shift, during
the disassembling and assembling process.
Caution of motor disassembling：
1. Be careful of the outer coder, no strike and protect the connectors of both signal wire. Do not
knock against coder gear when disassembling and inspecting the coder. Clear the gear before
assembling.
2. Clear rust and other stain fully before assembling.

93
3. No any part damages during the assembling.
4. Wire connection should be correct and secure. No cutting-edge protrusion, no stain on
insulation, and keep dry.
5. The motor rotor can rotate easily by hands.

Common fault and corrections

Trouble Probable cause Corrective action

Inspect the voltage of battery, switch, wire line, contact
Power failure terminal, motor connect terminal. Find out the causes and
correct
Check for the reason of fuse burnout and correct. Reinstall
Fuse burnout
a new fuse according to the motor capacity
Check for the connection of control circuit according to
Faulty connection of control circuit
electric schematic. find out the causes and correct
Inspect the coil by using multimeter, tramegger or indicator
Stator or rotor coil open circuit lights. If there is an open circuit, find out the open place
and reconnect.
Check for equilibrium of motor there phases, Check for
Motor fail Short circuit or earth connection of
earth connection of coil, find out the disorder place and
to start stator coil phases
correct
Recalculate the load, select the proper motor or lighten the
Overloaded or mechanical part gets
load, check if mechanical transmission mechanism gets
stuck
stuck and correct
Improper thermorelay or thermorelay
Select proper thermorelay and readjust according to motor
is adjusted small, or overflow relay is
rated electric current
adjusted small
Faulty connection of motor, causing
Reconnect the motor according to the motor nameplate
the motor fail to start on heavy load
Recheck the head or tail port of stator coil, connect
Faulty connection of stator coil
correctly
Inspect the power line, motor connect terminal, fuse,
Starts on single phase switch, contact terminal. Find out the disconnection and
correct
The sectional area of fuse is too
Fuse was Rematch and replace a new fuse.
small
burned
A coil phase is shorten to the ground Disassemble and repair the motor coil
out, when
motor Overloaded or mechanical part gets Adjust the load to the rate value, and eliminate the
starts stuck mechanical failure
Shorten circuit of connecting wires
Repair after finding out the shorten place
between battery and motor
The starting resistance of motor with Eliminate the shorted circuit or increase the starting
coils rotor is too small or shorted. resistance
Check for the voltage of power, ask power supply
Lower voltage of power
department for helps
Inspect the voltage of power, contactor, switch, one phase
Motor fails Phase lack of power
disconnection ,find out the causes and correct
to start The head or tail port of motor is Power DC to the stator coil inspects the polarity of the coil.
and gives misconnected or inner connection of Check the correct connection of the head or tail port of
out coil connects contrary coil, and reconnect.
buzzing
Misconnect △to Y connection Change Y to △connection
noise after
power on Find out the open circuit place and repair, Check the
contact condition of brush of coil rotor and collecting ring.
Coil of stator or rotor is shorted
Check open circuit of the staring resistance or big
resistance

94
 Trouble Probable cause Corrective action
Overloaded or mechanical part got Release the load, eliminate the mechanical failure or
stuck replace the motor
Tight installation or hard grease Reinstall, and replace the grease
When polarity changing and
Select proper coil type and pitch. Lathe the rotor diameter
rewinding, the match of wedge and
improperly, Recalculate the parameters of coil
groove select improperly
Misconnection of power wire and
Eliminate the fault connection, motor shell should connect
ground wire. Badly earth connection
to the protective ground wire securely
of the motor
Charged
Wet coil and insulation aging Dry the coil and replace the insulation aged coil
motor
shell Lead wire and terminal box interfere
Pack up or replace the extension line
with the ground
Top end of the coil is connected to Find out the grounded place, pack up, insulate and paint,
the ground and add insulator into the end cover
When the Cage rotor broken bar or break
Check broken bar or break welding place, and repair
motor runs welding
with or One phase brush of cage rotor is Adjust the stress of brush, increase the contact surface of
without poor contacted brush and collecting ring
load, the Collecting ring short circuiting device
current of cage rotor type motor contact Inspect and maintain or replace short circuiting device
keep poorly
unsteadily One phase open circuit of coiled
Find out the open place and correct
rotor

6.2 Controller fault code

ace2_par
MDI CAN
ALARM Description Corrective action
CODE CODE
94 0 NONE None
Fault in the area of memory in which the adjustment
parameters are stored: the truck stops automatically
after this fault occurred. If the defect persists when
the key is switch OFF and ON again, replace the
71 13 EEPROM KO EEPROM damage
logic card. If the alarm disappears, remember that
the parameters stored previously have been
cancelled and replaced by the default values, set
again.
LOGIC Failure in current protection of logic card. Replace
17 17 Logic card failure 3
FAILURE #3 the controller.
Fault in the hardware section of the logic card which
LOGIC
55 18 Logic card failure 2 manages the phase's voltage feedback. Replace the
FAILURE #2
controller
This alarm signals that the undervoltage/overvoltage
protection interrupt has been triggers. In 24V system,
controller detected voltage is over 45V or below 9V;
In 48V system, controller detected voltage is over
65V or below 11V
Possible causes：
1. If short in the circuit system, like DC-DC,
restraining coil, or if the controller input power
LOGIC contacts well.
54 19 Logic card failure 1
FAILURE #1 2. A real undervoltage/overvoltage situation
happened.
3. Check if wires on the B+, B and main contactor
are firm.
4. If the controller voltage calibration parameter
accord with the actual voltage.
5. Fault in the hardware section of the logic card
which manages the overvoltage protection, Replace
the controller.

95
 MDI CAN
ALARM Description Corrective action
CODE CODE
Reason: When power on, MOS high-end voltage is
lower than 66% of capacitor voltage or the voltage
during motor running is smaller than request value
Possible causes：
72 30 VMN LOW VMN is low 1. Problem with the motor connector or the motor
power circuit; check if the 3 phases are correctly
connected; if motor is grounded or motor coil open.
2. If the main contactor is closed firmly; any wear on
the contact.
3. Replace the controller.
Reason: When power on, MOS low-end voltage is
higher than 10% of normal battery voltage or phase
voltage higher than 1/2 battery voltage.
Possible causes：
0 31 VMN HIGH VMN is high
1. Problem with the motor connector or the motor
power circuit; check if the 3 phases are correctly
connected; if motor is grounded or motor coil open.
2. Replace the controller.
Before closing the main contactor coil, the controller
checks if the main contactor contact is stuck. Try to
discharge the capacitor, failure may occur if the
CONTACTOR
75 37 Contactor closed capacitor voltage reduces 20% of the battery
CLOSED
voltage.
1. It is suggested to check the contactor contact, if it
is stuck, or replace the controller.
The main contactor coil has been driven by the logic
card, but the contactor does not close. Possible
causes:
CONTACTOR
77 38 Contactor open 1. Mechanical failure or seizure of the contactor.
OPEN
2. Contactor contact is not well connected.
3. The contactor is not properly working. Replace the
controller.
Check if the motor current is zero when the truck is in
standby condition. If failure occurs when the current
is not zero, stop the truck immediately. Possible
causes:
Standby current is
53 53 STBY I HIGH 1. Terminal -SH directly connects other loads but not
high
the drive motor, such as lift motor.
2. Current sensor or logic card damage. First replace
the logic card, if the defect persists, replace the
power unit.
When the key is switched ON, the controller tries to
charge the capacitor through a power resistance,
and check if the capacitor is charged within a
timeout. If they do not charge fully, capacitor voltage
is still less than 20% of the battery voltage, an alarm
is signaled; the main contactor is not closed.
CAPACITOR Wrong capacitor
60 60 Possible causes：
CHARGE charge
1. Auxiliary equipment, like DC-DC, motor or other
equipment interfere the charging, please eliminate
these equipment generated interference.
2. The charging resistance is opened, the charging
circuit has a failure or there is a problem in the power
section, please replace the controller.
If the default persists after dropping the controller
TH. Controller thermal temperature below 85°, it maybe the temperature
62 62
PROTECTION protection sensor failure or controller logic card failure. Then
replace the controller.
1. This warning is signaled if motor temperature
switch ON or the analog signals overtakes the cut off
MOTOR Motor temperature level.
65 65
TEMPERAT. is high 2. This warning is signaled when the motor
temperature reaches 120℃, the truck can still travel,
but the maximum current is cut down, and the truck

96
 MDI CAN
ALARM Description Corrective action
CODE CODE
performance is reduced. When the motor
temperature reaches 125℃, the motor stops. Try to
cool the motor at this time.
3. If it happens when the motor is cold, check the
wiring. If all is ok, replace the controller.
If the ―BATTERY CHECK‖ parameter is not 0, this
warning is signaled when the battery capacity is
lower than 15% and no bars on the instrument, and
0 66 BATTERY LOW Battery is low the lifting function is locked. Charge in time. If the
battery still has power, check if the parameter value
of ― ADJUST BATTERY‖ accords with the battery
voltage.
When the electric lock is switched OFF, the controller
will detect if the main contactor driver is shorted, it
DRIVER
74 74 Driver shorted will alarm if shorted; check the positive of the main
SHORTED
contactor coil is shorted to A16 or power negative. If
auxiliary equipment is normal, replace the controller.
The above faults occur when the main contactor
malfunctions. Possible causes：
CONTACTOR Contactor driver 1. The contactor coil is shorted, open or not
75 75
DRIVER failure connected.
2. The contactor coil driver is shorted.
3. Contactor plug-in failure or logic card failure.
The test is made in standby. This alarm indicates that
the accelerator voltage is 1V greater than the
minimum value programmed by the PROGRAM
VACC function.
Possible causes：
78 78 VACC NOT OK Accelerator fault 1. Upper and lower limit values of the accelerator
voltage are not gathered, enter PROGRAM VACC
and gather again.
2. Accelerator failure, accelerator pedal does not
return or inner failure in the accelerator.
3. Controller fault
This alarm signals an incorrect start sequence.
Possible causes：
1. Direction switch is off before starting up.
INCORRECT Incorrect start
79 79 2. Error in sequence made by the operator
START sequence
3. Incorrect wiring;
4. If the defect persists after checking, replace the
controller.
The test is carried out continuously. An alarm is
signaled when a double running request is made
Forward and
simultaneously. Possible causes:
backward signals
80 80 FORW + BACK 1. defective wiring;
coexist(direction
2. direction switch failure;
switch get stuck)
3. incorrect operation
4. If the defect persists, replace the controller.
Controller detects that two continuous speed
readings on the encode differs a lot: as the system
encoder cannot change speed a lot in a short time,
so it maybe the encoder error (one or two encoder
lines damage or break), check the encoder
mechanical and circuit function; or the
electromagnetic interference on sensor bearing
ENCODER
82 82 Encode error causes the alarm; if not the above reasons, please
ERROR
replace the controller.
Please notice that human operation can also cause
this failure, such as the following condition:
1.The truck bumped into barrier accidentally and
cannot travel;
2. Depress the brake suddenly when the truck in high
speed.
0 200 WRONG Wrong Check if the configuration of controller software is

97
 MDI CAN
ALARM Description Corrective action
CODE CODE
CONFIG configuration correct.
1. Incorrect sensor installation
TILT POS Tilt position sensor
0 201 2. Incorrect sensor wiring.
SENSOR failure
3. Controller failure.
CTB STOP Cut speed 1. Incorrect cut speed wiring.
0 202
MISM. mismatch 2. Cut speed switch corresponding type error.
SAFETY
0 203 Safety input error Safety input open or wrong parameter adjustment.
MISMATCH
A13 INPUT Hand brake signal is incorrect, or the hand brake
89 204 A13 input mismatch
MISM. wiring is wrong.
POT. 4
88 205 POT.4 failure Analog 4 failure, fingertip 4 failure
FAILURE
POT. 3
87 206 POT.3 failure Analog 3 failure, fingertip 3 failure
FAILURE
POT. 2
86 207 POT.2 failure Analog 2 failure, fingertip 2 failure
FAILURE
POT. 1
85 208 POT.1 failure Analog 1 failure, fingertip 1 failure
FAILURE
Wrong operation sequence, possible causes:
1. Accelerator has input before starting up
VACC NOT OK Side shift analog
89 209 2. Analog input before switching value.
S failure
3. Wrong wire connecting.
4. If the defect persists, replace the controller.
The test is made in standby. This alarm indicates that
the analog voltage is 1V greater than the minimum
value programmed by the analog signal.
Possible causes：
VACC OUT Side shift analog is
90 210 1. Upper and lower limit values of the analog are not
RNG S out of range.
gathered, enter Adjustments and gather again.
2. Analog failure, fingertip does not return or inner
failure in the fingertip.
3. Controller failure.
Wrong operation sequence, possible causes:
1. Accelerator has input before starting up
VACC NOT OK
87 211 Tilt analog failure 2. Analog input before switching value.
T
3. Wrong wire connecting.
4. If the defect persists, replace the controller.
The test is made in standby. This alarm indicates that
the analog voltage is 1V greater than the minimum
value programmed by the analog signal.
Possible causes：
VACC OUT Tilt analog is out of
88 212 1. Upper and lower limit values of the analog are not
RNG T range.
gathered, enter Adjustments and gather again.
2. Analog failure, fingertip does not return or inner
failure in the fingertip.
3. Controller failure.
Wrong operation sequence, possible causes:
Forward and 1. Accelerator has input before starting up.
VACC NOT OK
85 213 backward analog 2. Analog input before switching value.
R
failure 3. Wrong wire connecting.
4. If the defect persists, replace the controller.
The test is made in standby. This alarm indicates that
the analog voltage is 1V greater than the minimum
value programmed by the analog signal.
Forward and Possible causes：
VACC OUT
86 214 backward is out of 1. Upper and lower limit values of the analog are not
RNG R
range. gathered, enter Adjustments and gather again.
2. Analog failure, fingertip does not return or inner
failure in the fingertip.
3. Controller failure.
Wrong operation sequence, possible causes:
VACC NOT OK Lift and low analog 1. Accelerator has input before starting up
83 215
P failure 2. Analog input before switching value.
3. Wrong wire connecting.

98
 MDI CAN
ALARM Description Corrective action
CODE CODE
4. If the defect persists, replace the controller.
The test is made in standby. This alarm indicates that
the analog voltage is 1V greater than the minimum
value programmed by the analog signal.
Possible causes：
VACC OUT Lift and low analog
84 216 1. Upper and lower limit values of the analog are not
RNG P is out of range.
gathered, enter Adjustments and gather again.
2. Analog failure, fingertip does not return or inner
failure in the fingertip.
3. Controller failure.
1. Check if VCM controller communication circuit is
NO CAN MSG. No CAN message
0 218 virtually connected or interfered.
VMC of VCM controller
2. VCM controller communication module damage.
WARNING VCM controller
0 219 Replace the controller
VMC alarm
The test is made in standby. This alarm indicates that
the accelerator voltage is 1V greater than the
minimum value programmed by the PROGRAM
VACC function.
Possible causes：
PROG VACC
78 220 Accelerator failure 1. Upper and lower limit values of the accelerator
NOT OK
voltage are not gathered, enter PROGRAM VACC
and gather again.
2. Accelerator failure, accelerator pedal does not
return or inner failure in the accelerator.
3. Controller fault
DEADMAN Safety switch
0 221 Incorrect safety switch wiring
MISMATCH mismatch
In the CAN communication network, certain
controller accepts the signal that another controller is
unable to communicate, so this controller keeps
WAITING FOR
0 222 Waiting for node waiting until all CAN communication network is
NODE
normal. Check the module wirings that cannot
communicate, check the software version or if the
parameter setting is right.
Watchdog activates before startup. Watchdog signal
(warning) is invalid in standby or running.
8 223 WATCHDOG#1 Watchdog failure#1 Fault analysis: Watchdog hardware circuit or
microcontroller output is damaged. Both conditions
are irrelevant to external part, replace the controller.
Drive circuit of electromagnetic braking or solenoid
valve lowering short.
AUX COIL Check if A18 is shorted to A17 or low impedance
68 224 Auxiliary drive short
SHORT lowers the output.
Logic card actuator circuit fault, please replace the
controller.
In the CAN communication network, certain
controller accepts the signal that another controller is
unable to communicate, so this controller keeps
WAITING FOR Waiting for traction
84 225 waiting until all CAN communication network is
TRAC motor signal
normal. Check the module wiring that cannot
communicate, check the software version or if the
parameter setting is right.
The test is made in standby. This alarm indicates that
the accelerator voltage is 1V greater than the
minimum value programmed by the PROGRAM
VACC function.
Possible causes：
VACC OUT Accelerator signal
85 226 1. Upper and lower limit values of the accelerator
RANGE is out of range
voltage are not gathered, enter PROGRAM VACC
and gather again.
2. Accelerator failure, accelerator pedal does not
return or inner failure in the accelerator.
3. Controller fault

99
 MDI CAN
ALARM Description Corrective action
CODE CODE
Watchdog activates before startup. Watchdog signal
(warning) is invalid in standby or running.
8 227 WATCHDOG#2 Watchdog failure #2 Fault analysis: Watchdog hardware circuit or
microcontroller output is damaged. Both conditions
are irrelevant to external part, or replace controller.
When the equipment exceeds the set idle time
without any operation, the instrument will display
0 228 IDLE TIME Idle time
IDLE TIME. Adjust IDLE TIME parameter or switch
on the key again.
86 229 SAFETY INPUT Safety input error Safety input open or wrong parameter adjustment
Contactor drive circuit short
Check if A16 is shorted to A17 or low impedance
MC COIL Contactor drive
76 230 lowers the output.
SHORT short
Logic card actuator circuit fault, please replace the
controller.
COIL SHORT Hardware loop This type of fault is irrelevant to external part, please
76 231
HW KO short replace the controller logic card.
1. Key switch input terminal voltage is lowered by
external loading, like DC converter, coil or contactor
switch motion.
KEY OFF 2. Check if battery power line is connected right, if
76 232 Key switch short
SHORT loose or virtually connected.
3. Check if the controller and contactor terminal are
firmly connected.
4. Controller damage.
Before the main contactor is closed, power bridge is
checked by the software: turn to MOS low end
POWER MOS power, phase voltage value drop to –BATT(raise to
89 233 Power MOS short
SHORT +BATT), if the phase voltage value changes do not
accord with the command, this fault is signaled.
Replace the controller.
The test is made in standby. This alarm indicates that
the accelerator voltage is 1V greater than the
minimum value programmed by the PROGRAM
Brake VACC function.
BRAKE/QI RUN potentiometer Possible causes：
0 234
OUT signal is out of 1. Upper and lower limit values of the brake are not
range gathered, enter Adjustments and gather again.
2. Brake failure, brake pedal does not return or inner
failure in the brake.
3. Controller fault
Handbrake is
0 235 HANDBRAKE Hand brake switch is engaged all the time
engaged
Maximum current gain parameter is factory default. It
indicates the maximum current adjustment
CURRENT
92 236 Current gain failure parameter program has not yet operated.
GAIN
Solution：ZAPI technician will set the current gain
parameter correctly.
This warning is signaled when all analog signals
input A/D change to a fixed value, time delay over
ANALOG Analog signal input 400 milliseconds. This function is used to detect the
96 237
INPUT failure A/D converter fault or analog signal conversion.
Fault analysis：If the defect persists, replace the
controller.
VMN high-end voltage feedback value is not about
2.5V when starting up. Controller circuit is damaged.
Fault analysis： It is suggested to check the following
items.
WRONG 0
53 238 Wrong zero voltage Motor internal connection
VOLTAGE
Motor power cable connection
Drain current between motor and truck frame.
If the motor connection is good, then the problem is
from the controller, replace the controller.
0 239 SAFETY Safety output Safety output open or parameter adjustment error.

100
 MDI CAN
ALARM Description Corrective action
CODE CODE
OUTPUT wrong
Under the controller self-check, Mosfets drive/
HARDWARE contactor drive/auxiliary drive cannot be closed
0 240 Hardware fault
FAULT normally, even restart the key switch, please replace
the controller.
Software check program failed to restore the
FLASH Flash checksum contents in the flash. The solution is to download the
71 241
CHECKSUM wrong software again, if the defect persists, replace the
controller.
Controller detects that two continuous speed
readings on the encoder differs a lot: as the system
encoder cannot change speed a lot in a short time,
so it maybe the encoder error(one or two encoder
lines damage or break), check the encoder
mechanical and circuit function; or electromagnetic
interference on the sensor bearing causes the alarm;
ENCODER
82 242 Encoder failure if not the above reasons, please replace the
LOCKED
controller.
Please notice that human operation can also cause
this failure, such as the following condition:
1.The truck bumped into barrier accidentally and
cannot travel;
2. Depress the brake suddenly when the truck in high
speed.
1. Wrong setting of motor temperature sensor type
SENS MOT Motor temperature 2. Motor temperature sensor is out of range.
65 243
TEMP KO sensor fault 3. Motor temperature sensor wiring error.
4. Controller damage.
SOFTWARE
0 244 Software failure Software error
ERROR
WRONG RAM Wrong RAM After restarting the key, if the defect persists, replace
71 245
MEMORY memory the controller.
Auxiliary coil drive circuit cannot drive the loads. The
AUX Auxiliary output
0 246 device or drive coil is damaged. Replace the
DRIV.OPEN drive fault
controller.
DATA Data acquisition Once this fault is signaled, please wait until the data
0 247
ACQUISITION fault is acquired.
CAN communication fault between the instrument
67 248 NO CAN MSG. No CAN message and controller. Test the CAN wiring, software setting
and version information.
PEDAL BRK Brake pedal is signaled all the time or cannot cutoff
90 249 Brake pedal fault
STUCK the signal normally
Temperature
THERMIC Check if the temperature senor is correctly
61 250 sensor connection
SENS. KO connected.
fault
The controller detects the battery voltage and check
if it is within the nominal voltage when starting.
1. Check if the BATTERY VOLTAGE parameter in
WRONG SET Wrong battery the TESTER menu is the same as the one displayed
0 251
BAT. setting. on the voltmeter. If not match, use ADJUST
BATTERY to change the battery voltage to the
measured value.
2. Replace the battery
TIMEOUT Timeout lockout
83 252
LOCKOUT fault
SLIP PROFILE parameter selection is wrong.
99 253 SLIP_PROFILE Slip fault
Check the SLIP value in the hardware set parameter
Drive circuit of electromagnetic braking or auxiliary
electric braking short.
AUX Check if A18 is shorted to A17 or low impedance
0 254 Auxiliary drive short
DRIV.SHRT. lowers the output.
Logic card actuator circuit fault, please replace the
controller.

101
vcmm_par
MDI CAN
ALARM Description Corrective action
CODE CODE
0 244 CHECK UP Maintenance time it's time to repair
0 0 NONE None
Watchdog activates before startup.
Watchdog signal (warning) is invalid in
standby or running.
8 8 WATCHDOG Watchdog failure Fault analysis: Watchdog hardware circuit or
microcontroller output is damaged. Both
conditions are irrelevant to external part, or
replace controller.
The above faults occur when the proportional
valve coil or external wiring has problem.
Possible causes
1. The proportional valve coil is shorted,
54 19 OVERLOAD Overload failure
open or not connected.
2. The proportional valve driver is shorted.
3. The controller plug-in failure or logic card
failure.
WRONG
0 200 Parameter is wrong Valve type parameter setting is wrong.
PARAMETER
WRONG SLAVE Slave software version is
13 201 Update the slave software
VER. wrong
Traction controller and
0 202 HM MISMATCH VCM controller hourmeter Check hourmeter parameter setting
mismatch
TILLER CAN TILLER configuration Check if the CAN TILLER parameter setting
0 203
MISMATCH is wrong or software version is right.
If the ―BATTERY CHECK‖ parameter is not 0,
this warning is signaled when the battery
capacity is lower than 15% and no bars on
the instrument, and the lifting function is
0 206 BATTERY OUT Battery power is low
locked. Charge in time. If the battery still has
power, check if the parameter value of
― ADJUST BATTERY‖ accords with the
battery voltage.
Fault in the area of memory in which the
adjustment parameters are stored: the truck
stops automatically after this fault occurred. If
the defect persists when the key is switch
13 208 EEPROM KO EEPROM damage OFF and ON again, replace the logic card. If
the alarm disappears, remember that the
parameters stored previously have been
cancelled and replaced by the default values,
set again.
PARAM If the defect persists after switching on the
13 209 Parameter restore failure
RESTORE key again, replace the logic card.
WRONG RAM If the defect persists after switching on the
71 210 RAM memory is wrong
MEM. key again, replace the logic card.
Controller detects that two continuous speed
readings on the encoder differs a lot: as the
system encoder cannot change speed a lot
in a short time, so it maybe the encoder
error(one or two encoder lines damage or
break), check the encoder mechanical and
circuit function; or the electromagnetic
ENCODER interference on the sensor bearing causes
82 213 Encoder 1 fault
LOCKED 1 the alarm; if not the above reasons, please
replace the controller.
Please notice that human operation can also
cause this failure, such as the following
condition:
1.The truck bumped into barrier accidentally
and cannot travel;
2. Depress the brake suddenly when the

102
 MDI CAN
ALARM Description Corrective action
CODE CODE
truck in high speed.
Controller detects that two continuous speed
readings on the encoder differs a lot: as the
system encoder cannot change speed a lot
in a short time, so it maybe the encoder
error(one or two encoder lines damage or
break), check the encoder mechanical and
circuit function; or the electromagnetic
interference on the sensor bearing causes
ENCODER
82 214 Encoder 2 fault the alarm; if not the above reasons, please
LOCKED 2
replace the controller.
Please notice that human operation can also
cause this failure, such as the following
condition:
1.The truck bumped into barrier accidentally
and cannot travel;
2. Depress the brake suddenly when the
truck in high speed.
OUT PORT Hardware configuration If the defect persists after switching on the
29 215
PULL-UP fault key again, replace the controller.
If the defect persists after switching on the
96 217 ANALOG INPUT Analog input fault
key again, replace the controller.
RESET Check if 3A8 DIG INPUT#1 and 3A9 DIG
82 218 Encoder reset is wrong
ENCODER KO INPUT#2 signals are normal.
1. Check main control and slave software
0 219 VALVE ENABLE Valve enable fault 2. If the defect persists after switching on the
key again, replace the controller.
LIFT/LOW
0 222 Lift or low lever fault Check if the lift and low lever is normal
LEVER
1. Check communication line.
CAN communication is
67 223 NO CAN MSG. 5 2. If the defect persists after switching on the
overtime
key again, replace the controller.
In the CAN communication network, certain
controller accepts the signal that another
controller is unable to communicate, so this
WAITING FOR controller keeps waiting until all CAN
0 224 Waiting for node signal
NODE communication network is normal. Check the
module wirings that cannot communicate,
check the software version or if the
parameter setting is right.
CONTROLLER Controller customer code Replace the controller software or replace
12 225
MISM. is wrong the controller.
PUMP IN Pump controller issues the Check the fault condition of the pump
0 226
ALARM fault controller.
1. Check if the pump controller
NO CAN MSG. Pump controller communication line is correct.
67 227
14 communication fault 2. If the defect persists after switching on the
key again, replace the pump controller.
1. Check if the handle or operating terminal
Handle or operating communication line is correct.
67 228 NO CAN MSG. A terminal communication 2. If the defect persists after switching on the
fault key again, replace the handle or operating
terminal.
1. Check if the VCM or traction controller
communication line is correct.
VCM or traction pump
67 229 SDO TRAC. 2. If the defect persists after switching on the
communication failed
key again, replace the VCM or traction
controller.
INTERLOCK
99 230
FORK
CARRIAGE
0 231
LEVER
0 232 TILT LEVER
0 233 SIDE SHIFT

103
 MDI CAN
ALARM Description Corrective action
CODE CODE
LEVER
0 234 WAITING PCF
WRONG Check if the controller software configuration
0 235 Configuration is wrong
CONFIG is correct.
NO CONFIG
0 236
BACKUP
NO CONFIG
0 237
MASTER
0 238 PCF TIMEOUT
REACH SENS
0 239
OUT R
REACH ACQ.
0 240
SENS.
Main control and slave
control parameters are 1. Check parameters of parameter node 1.0
M/S PAR CHK different(implement and 1.1, and revise to the same value.
13 241
MISM according to the default 2. If the defect persists after switching on the
parameter, no bound key again, replace the VCM controller.
action)
1. Check parameters of parameter node 1.0
Main control and slave
PARAM and 1.1, and revise to the same value.
13 242 control parameters are
TRANSFER 2. If the defect persists after switching on the
different
key again, replace the VCM controller.
0 243 PRESELECTOR
1. Check if the traction controller
communication line is correct.
Traction controller
67 246 NO CAN MSG. C 2. If the defect persists after switching on the
communication is wrong.
key again, replace the VCM or traction
controller.
1. Check if the steering controller
Steering controller communication line is correct.
67 247 NO CAN MSG. 6
communication failed 2. If the defect persists after switching on the
key again, replace the steering controller.
1. Check if the instrument communication
NO CAN MSG. Instrument communication line is correct.
67 248
10 failed 2. If the defect persists after switching on the
key again, replace the instrument.
CAN BUS
67 249 Key switch relay open Replace the key switch relay.
DISPLAY
RESET Check if 3A8 DIG INPUT#1 and 3A9 DIG
82 205 Reset encoder fault
ENCODER INPUT#2 signals are normal.
The above faults occur when the proportional
valve coil or external wiring has problem.
Possible causes:
1. The proportional valve coil is shorted,
0 199 OVERLOAD Overload fault
open or not connected.
2. The proportional valve driver is shorted.
3. The controller plug-in failure or logic card
failure.
0 245 SEAT
If the ―BATTERY CHECK‖ parameter is not 0,
this warning is signaled when the battery
capacity is lower than 15% and no bars on
the instrument, and the lifting function is
0 204 BATTERY LOW Battery power is low
locked. Charge in time. If the battery still has
power, check if the parameter value of
― ADJUST BATTERY‖ accords with the
battery voltage.
This alarm signals an incorrect starting
sequence. Possible causes：
PUMP INC. Pump startup sequence 1. Fingertip signal is input before starting up.
0 211
START fault 2. Error in sequence made by the operator
3. Incorrect wiring.
4. If the defect persists after checking,

104
 MDI CAN
ALARM Description Corrective action
CODE CODE
replace the controller.

vcms_par
MDI CAN
ALARM Description Corrective action
CODE CODE
Watchdog activates before startup. Watchdog signal
(warning) is invalid in standby or running.
8 8 WATCHDOG Watchdog fault Fault analysis: Watchdog hardware circuit or
microcontroller output is damaged. Both conditions are
irrelevant to external part, or replace the controller.
This alarm signals that the undervoltage/overvoltage
protection interrupt has been triggers. In 24V system,
controller detected voltage is over 45V or below 9V; In
48V system, controller detected voltage is over 65V or
below 11V
Possible causes：
1. If short in the electrical system, like DC-DC,
restraining coil, or if the controller input power contacts
LOGIC Logic card failure
54 19 well.
FAILURE #1 1
2. A real undervoltage/overvoltage situation happened.
3. Check if wires on the B+, B and main contactor are
firm.
4. If the controller voltage calibration parameter accord
with the actual voltage.
5. Fault in the hardware section of the logic card which
manages the overvoltage protection, replace the
controller.
Drive circuit of EVP1/EVP2 coil short.
Check if A13 is shorted to A24/A25 or low impedance
OUT1/2 COIL EVP1/EVP2 coil
0 199 lowers the output.
SH. short
Logic card actuator circuit fault, please replace the
controller.
Drive circuit of EVP3/EVP4 coil short.
Check if A14 is shorted to A2/A3 or low impedance
OUT3/4 COIL EVP3/EVP4 coil
0 200 lowers the output.
SH. short
Logic card actuator circuit fault, please replace the
controller.
Drive circuit of EVP5/EVP6 coil short.
Check if A15 is shorted to A26/A27 or low impedance
OUT5/6 COIL EVP5/EVP6 coil
0 201 lowers the output.
SH. short
Logic card actuator circuit fault, please replace the
controller.
Drive circuit of EVP7/EVP8 coil short.
Check if A16 is shorted to A4/A5 or low impedance
OUT7/8 COIL EVP7/EVP8 coil
0 202 lowers the output.
SH. short
Logic card actuator circuit fault, please replace the
controller.
Drive circuit of EV3 coil short.
Check if B8 is shorted to B15 or low impedance lowers
LASER COIL
0 203 EV3 coil short the output.
SH.
Logic card actuator circuit fault, please replace the
controller.
BAT OUT
0 204
COIL SH.
LOAD BRK
0 205
COIL SH
ALARM COIL
0 206
SH.
Watchdog activates before startup. Watchdog signal
(warning) is invalid in standby or running.
WATCH DOG Main control
0 207 Fault analysis: Watchdog hardware circuit or
MASTER watchdog fault
microcontroller output is damaged. Both conditions are
irrelevant to external part, or replace the controller.

105
 MDI CAN
ALARM Description Corrective action
CODE CODE
Fault in the area of memory in which the adjustment
parameters are stored: the truck stops automatically after
this fault occurred. If the defect persists when the key is
EMPROM
13 208 EEPROM KO switch OFF and ON again, replace the logic card. If the
damage
alarm disappears, remember that the parameters stored
previously have been cancelled and replaced by the
default values.
PARAM Parameter If the defect persists after switching on the key again,
13 209
RESTORE restore failure replace the controller.
WRONG RAM memory is If the defect persists after switching on the key again,
71 210
RAM MEM. wrong replace the controller.
PEVP1 drive circuit open
PEV DRV. PEVP1 drive
75 211 Check if A13 is open to A24/A25.
OPEN open
If the logic card driver circuit failed, replace the controller
PEVP1 drive circuit open
PEV DRV. PEVP1 drive Check if A13 is shorted to B- or low impedance lowers
74 212
SHORT. short the output.
If the logic card driver circuit failed, replace the controller.
Main control and
1. Check parameters of parameter node 1.0 and 1.1, and
slave control
VALVE MISM. revise to the same value.
0 213 internal
OUT 2. If the defect persists after switching on the key again,
calculation
replace the VCM controller.
mismatch
OUT PORT Hardware If the defect persists after switching on the key again,
29 215
PULL-UP configuration fault replace the VCM controller.
ANALOG If the defect persists after switching on the key again,
96 217 Analog input fault
INPUT replace the controller.
Main control and
slave control read
8 218 IN. MISM. D Contact ZAPI engineer or replace the VCM controller.
switch conditions
mismatch
Main control and
slave control read
8 219 IN. MISM. A/E encoder Contact ZAPI engineer or replace the VCM controller.
conditions
mismatch

epsm_par
MDI CAN
ALARM Description Corrective action
CODE CODE
SERIAL ERROR Controller slave chip did not receive master chip
6 39 Serial error
#1 message, replace the controller.
Possible causes：
1. EEPROM address read-write error;
2. Hourmeter gets over three hour records.
13 8 EEPROM KO Memory damage
3. It occurs also when the busy bit of the
EEPROM does not rise within 12 msec.
Solution: replace the controller
LOGIC FAILURE W and V voltage amplifier output exceed 0.25V
16 15 Logic failure#4
#4 drifting, replace the controller
LOGIC FAILURE W and U voltage amplifier output exceed 0.25V
17 14 Logic failure #3
#3 drifting, replace the controller
LOGIC FAILURE Voltage of W and V is inconsistent with demand
18 13 Logic failure #2
#2 voltage, replace the controller.
LOGIC FAILURE Voltage of W and U is inconsistent with demand
19 12 Logic failure #1
#1 voltage, replace the controller.
This warning is signaled if the detected motor
32 9 VMN NOT OK VMN fault voltage amplifier output is not between 2.2V and
2.8V when startup. Please replace the controller.
This warning is signaled when the steering
MAIN CONT. controller did not receive contactor closing
48 20 Main contactor open
OPEN message within 1.5 second. Check the main
contactor break reasons from the travelling.
53 5 STBY I HIGH Current is too high in Possible causes：

106
 MDI CAN
ALARM Description Corrective action
CODE CODE
standby 1. After switching on, the current amplifier is
detected not within 2.2-2.8V during initialization.
2. Current amplifier output exceeds 0.15V drifting
after initialization. Solution: replace the controller.
This warning is signaled once the controller
HIGH Controller temperature
61 10 temperature exceeds 78°C, use after heat
TEMPERATURE is too high
dissipation or temperature drops.
This warning is signaled when the motor
temperature exceeds the controller inner setting
MOTOR Motor temperature is alarm value. Check if the temperature sensor is
65 48
TEMPERAT. too high correctly connected, temperature sensor
resistance is normal, or use after the motor
cools.
This warning is signaled if the current of the
limiting current hardware circuit is too high when
70 1 HIGH CURRENT Current is too high switching on the key or during travelling. Check if
the motor power matches with controller, if so,
replace the controller.
When the motor receives the travelling
command, the motor V phase current is 0.
1. Check if the controller fuse is normal;
POWER
71 4 Power failure#3 2. Check if the power line and controller is firmly
FAILURE #3
connected;
3. Check if controller V phase is well connected;
4. Replace the controller.
When the motor receives the travelling
command, the motor U phase current is 0.
1. Check if the controller fuse is normal;
POWER
72 3 Power failure #2 2.Check if the power line and controller is firmly
FAILURE #2
connected;
3. Check if controller U phase is well connected;
4. Replace the controller.
When the motor receives the travelling
command, the motor W phase current is 0.
1. Check if the controller fuse is normal;
POWER
73 2 Power failure #1 2.Check if the power line and controller is firmly
FAILURE #1
connected;
3. Check if controller W phase is well connected;
4. Replace the controller.
BAD ENCODER Encoder phase
83 26 Interchange encoder A and B phases.
SIGN sequence is wrong
STEER Double potentiometer
84 45 Replace the double potentiometer
SENSOR KO fault
1. Decrease the steering angle and restart the
STEER Steering angle is too key.
85 0
HAZARD much 2. Change steering controller inner angle
parameter setting,
MICRO SLAVE
217 51
#3
CLOCK PAL
218 44 Clock fault Replace the controller
NOT OK
Stepper motor Q and
STEPPER MOT D line frequency do
219 50 Replace the controller
MISM not match with the
voltage value.
This warning is signaled when 90% time of the
MOTOR
220 49 Steering motor stalling steering motor continuous maximum current
LOCKED
exceeds 1s. Check if mechanical seizure.
Steering motor current
MICRO SLAVE
221 40 is opposite to the Replace the controller.
#4
command direction
This warning is signaled when steering motor is
FB SENS Feedback encoder
222 47 commanded to run with 40% of maximum
LOCKED failed
steering speed and the steering motor encoder is

107
 MDI CAN
ALARM Description Corrective action
CODE CODE
locked. Check if the encoder lines are right, or
parameter DEBUG OUTPUT set as LEVEL 11.
Corner potentiometer
223 46 JERKING FB voltage changes too Replace the corner potentiometer;
much
DIR. NOT
224 55
CONIFIG
Maximum current gain parameter is factory
default. It indicates that the maximum current
adjustment parameter program has not yet
225 43 CURRENT GAIN Current gain fault
operated.
Solution：ZAPI technician will set the current gain
parameter correctly.
226 42 NO SYNC Out of sync fault Replace the controller;
Main contactor does
SLAVE COM.
227 41 not receive messages Replace the controller;
ERROR
from slave contactor
1. Check if the steering motor encoder A and B
POSITION phases connection loosens;
228 38 Position error
ERROR 2. Check if A and B phases connection is
interfered.
LOOK. FOR
229 31
PATH
230 32 PATH OUT
231 33 LATERAL OUT
232 34 ANGLE
233 35 LOSING PATH
LOSING
234 36
STRAIGHT
WRONG ANT.
235 30
RECEP
236 29 ANT. MISSING
1. Check if CAN BUS communication lines are
well connected;
237 0 WAITING DATA Wait for data
2. Check if the communication baudrate is
consistent.
1. Check if zero proximity switch is correctly
installed;
EPS NOT 2. Check if zero proximity switch selection is
238 0 Zero is not found
ALIGNED correct;
3. Check if zero proximity switch output data is
correct;
1.Check if CAN BUS communication lines are
well connected;
WAITING FOR Wait for traction
239 0 2. Check if the interlock switch wires are correct;
TRAC controller
3. TILLER SEITCH should be set as HANDLE if
the interlock switch is controlled by handle;

This warning is signaled when low logic level

signal is detected by the control during
initialization phase. Fault analysis：It may be
caused by too low voltage, and is suggested to
check the following items:
-Key switch is based on external loading(like
DC-DC converter activates, relay or contactor
240 0 KEYOFF Key switch short switch input signal is lower than starting voltage)
- Check the connection of power cable with
battery positive and negative electrode as well as
main contactor and controller –BATT and +BATT.
Connect with screw and the torque range is
13NM÷15NM.
- If the pressure drop is not detected on the
power supply line, this warning is signaled once
the key switch is ON. The fault may occur on the

108
 MDI CAN
ALARM Description Corrective action
CODE CODE
controller hardware, so it's necessary to replace
the controller.
Controller detects that two continuous speed
readings on the encoder differs a lot: as the
system encoder cannot change speed a lot in a
short time, so it maybe the encoder error(one or
two encoder lines damage or break), check the
encoder mechanical and circuit function; or the
electromagnetic interference on the sensor
ENCODER bearing causes the alarm; if not the above
241 25 Encoder error
ERROR reasons, please replace the controller.
Please notice that human operation can also
cause this failure, such as the following
condition:
1.The truck bumped into barrier accidentally and
cannot travel;
2. Depress the brake suddenly when the truck in
high speed.
1. Check if stepper motor connecting line is well;
Q LINE Stepper motor Q LINE
242 7 2. Resistance between Q line and B- is too
SENSOR KO voltage is invalid
small(approach 30Ω)
1. Check if stepper motor connecting line is well;
D LINE SENSOR Stepper motor D LINE
243 6 2. Resistance between D line and B- is too
KO voltage is invalid
small(approach 30Ω)
EEPROM memory
GAIN EEPROM
244 27 current value is Replace the controller.
KO
different
DATA Once this fault is signaled, please wait until the
245 11 Data acquisition
ACQUISITION data is acquired.
1. The detected stepper motor directions from
main microprocessor and slave microprocessor
are different when using the stepper motor;
Main and slave 2. In the closed-loop control system, main
MICRO SLAVE
246 24 microprocessors contactor detected stepper motor direction is
KO
mismatch wrong, and also is different from the one
detected from the main contactor.
3. Steering limit is not detected by main
contactor, but by the slave contactor.
1. Check if CAN BUS communication lines are
well connected;
2. Check if the communication baudrate is
CAN BUS
247 28 CAN BUS KO consistent.
communication fault
3. Check if the CAN communication is open.
4. Check if the CAN communication loop
resistance is 60Ω.
This warning is signaled if CPOC1 end exceeds
0.8V-4.2V of the range for single potentiometer
S.P OUT OF Corner potentiometer or the sum of two sliding ends（CPOC1+CPOC2）
248 22
RANGE is out of range exceeds 4.4V-5.5V of the range for double
potentiometer. Check the potentiometer
connection.
This warning is signaled when the feedback
Steering motor potentiometer（CNB#6 connected CPOT） failed
F.B OUT OF
249 23 encoder feedback is or CPOT exceeds 0.3V-4.7V of the range. Check
RANGE
out of range if the steering motor encoder is correctly
connected or open circuit.
BUS messages of
main microprocessor
and slave
250 21 MICRO SLAVE Replace the controller;
microprocessor
conditions are frozen
to OXFF value
The safety contactor of ；The safety contactor of the main contactor is
251 19 KM OPEN
the main contactor is detected not closed in time by the slave

109
 MDI CAN
ALARM Description Corrective action
CODE CODE
not closed in time contactor, please replace the controller.
The safety contactor of The safety contactor of the slave contactor is
252 18 KS OPEN the slave contactor is detected not closed in time by the main
not closed in time contactor, please replace the controller.
The safety contactor of The safety contactor of the main contactor is
253 17 KM CLOSED the main contactor is detected closed ahead of time by the slave
closed ahead of time contactor, please replace the controller.
The safety contactor of The safety contactor of the slave contactor is
254 16 KS CLOSED the slave contactor is detected closed ahead of time by the main
closed ahead of time contactor, please replace the controller.

epss_par
MDI CAN
ALARM Description Corrective action
CODE CODE
Controller slave chip did not receive
SERIAL
6 6 Serial error master chip message, replace the
ERROR #1
controller.
8 241 NO SYNC Out of sync fault Replace the controller;
The safety contactor of the main
The safety contactor of the
contactor is detected closed ahead of
77 242 KM CLOSED main contactor is closed
time by the slave contactor, please
ahead of time
replace the controller.
The safety contactor of the main
The safety contactor of the
contactor is detected not closed in time
74 243 KM OPEN main contactor is not closed in
by the slave contactor, please replace
time
the controller.
Steering motor current is
MICRO SLAVE
5 244 opposite to the command Replace the controller.
#4
direction
CLOCK PAL
76 245 Clock fault Replace the controller.
NOT OK
ANTENNA
53 246
MISSING
Switch OFF the interlock switch again
49 247 EMERGENCY Emergency reverse after emergency reverse finished, and
then this fault disappears.
0 248 LATERAL OUT
0 249 ANGLE
MICRO SLAVE
0 250
#3
Main microprocessor encoder
MICRO SLAVE
0 251 is different from slave Replace the controller.
#8
microprocessor encoder
AUTOM
0 252
MISMATCH

110
disp_grph_ci_par
CAN
ALARM Description Corrective action
CODE
Watchdog activates before startup. Watchdog signal (warning) is
invalid in standby or running.
8 WATCHDOG Watchdog fault Fault analysis: Watchdog hardware circuit or microcontroller
output is damaged. Both conditions are irrelevant to external part,
or replace the controller
Fault in the area of memory in which the adjustment parameters
are stored: the truck stops automatically after this fault occurred.
EEPROM If the defect persists when the key is switch OFF and ON again,
13 EEPROM damage
KO replace the logic card. If the alarm disappears, remember that the
parameters stored previously have been cancelled and replaced
by the default values, set again.
LEFT STBY I
54
HIGH
CNB#1 connected auxiliary drive short. Solution：
1. Check if the line connection between instrument circuit board
COIL
76 Coil is shorted and loads is correct;
SHORTED
2. Instrument overload protecting circuit is damaged, please
replace the instrument.
Controller detects that two continuous speed readings on the
encoder differs a lot: as the system encoder cannot change
speed a lot in a short time, so it maybe the encoder error(one or
two encoder lines damage or break), check the encoder
mechanical and circuit function; or the electromagnetic
ENCODER
82 Encoder error interference on the sensor bearing causes the alarm; if not the
ERROR
above reasons, please replace the controller.
Please notice that human operation can also cause this failure,
such as the following condition:
1.The truck bumped into barrier accidentally and cannot travel;
2. Depress the brake suddenly when the truck in high speed.
CLEAN HYD.
240
OIL
D5 D6 INP.
241
STUCK
Possible causes：
FREE LFT Free lift senor 1. Check the sensor mounting and wiring,
242
SENS KO open 2. Check if the sensor works normally;
3. If the above are normal, replace the circuit board.
Possible causes：
SENSOR 0 Zero lift sensor 1. Check the sensor mounting and wiring,
243
KO open 2. Check if the sensor works normally;
3. If the above are normal, replace the circuit board.
Instrument does not receive pump controller CAN messages. If
only the instrument displays this fault and together with other
Oil pump
CAN BUS KO faults, this fault may happen on the CAN interface of the display,
244 communication
PUMP it’s suggested to check instrument CAN wiring. If other controller
fault
also displays this fault, check the pump controller CAN wiring and
parameter setting.
AUX Auxiliary drive coil Check if the coil wiring is correct, replace the controller if the
245
DRIV.OPEN open circuit board is damaged.
AUX Auxiliary drive coil Check if the coil wiring is correct, or resistance lowered between
246
DRIV.SHRT. short open B- and CNB#1. If the circuit board is damaged, replace it.
247 CAN BUS KO CAN BUS open Check if CAN BUS is well connected or open.
HARDWARE
248 Hardware fault Replace the circuit board.
FAULT
SERVICE
249 Need to service It's time for maintenance.
REQUIRED
Instrument does not receive VMC controller CAN messages. If
only the instrument displays this fault and together with other
VMC
CAN BUS KO faults, this fault may happen on the CAN interface of the display,
250 communication
VMC it’s suggested to check instrument CAN wiring. If other controller
fault
also displays this fault, check the VMC controller CAN wiring and
parameter setting.
251 HM SYNC. Hourmeter system When switching ON, the controller need to send hourmeter to the

111
 CAN
ALARM Description Corrective action
CODE
FAILED failed instrument, and this warning is signaled when the controller
cannot send hourmeter.
。Within two minutes of this warning being signaled, hourage
HM Hourmeter received from the traction controller is different from the hourage
252
MISMATCH mismatch of the instrument in 5 hours. Reset according to "LOAD HM
TYPE" after two minutes.
This warning is signaled when zero lift sensor and free limit
sensor trigger at the same time. Possible causes：
LIFT SENS Lift sensor
253 1. Check the sensor mounting and wiring,
MISM. mismatch
2. Check if the sensor works normally;
3. If the above are normal, replace the circuit board.

This warning is signaled when forward limit sensor and reverse

Forward and limit sensor trigger at the same time.
REACH
254 reverse limit Possible causes：
SENS MISM.
sensor mismatch 1. Check the sensor mounting and wiring,
2. Check if the sensor works normally;
3. If the above are normal, replace the circuit board.

112
 F3-10A
2Y 10
48VDC-24VDC
1R
DC-DC C0
K1 S2
MC Emergency switch 300W
急停
3RW 102 102

钥匙开关 S1
60 R
4RG

1F 2F 3F
300A 300A F F60 35A
10A 10A F4
10A

F 10A
F40-15A
F30-15A

5RU 50
40
W
U

Proximity switch

2Y1
CONSOLE RU 3A28 KEY 2 1
- 3A24 LIFTING (OPTION #1--> proportional valve)
2B1 RW 2Y2 (OPTION #2--> ON/OFF valve) KEY
3A1 +BATT 4A7
2B2 2 1 RU
RU 3B7 +BATT - 3A25 LOWERING(proportional valve) +B
2B3 KEY 2A1 RU
2B4 KEY 5C6
RU B
KEY 1A1 2B5 3B20 -BATT + 3A13 -B
Y 5C5 HEATER Drive Enable
2B6 OPT 5B4 B+ DIG1 5D2
S12 势能回收开关 2Y3 U B1
工作灯开关

CONSOLE FLASH 3B19 GND 2 1

S10警示灯开关

2A4 SLIDE ENTER(OPTION #1--> proportional valve)

S11

- 3A2 Speed cutback switch （暂不接）

1B1 PROGRAMMING ECODER 3B18 B 2Y4 (OPTION #2--> ON/OFF valve) ELECTRICAL
2B7 DIG2 5D3
1B2 K2 2 1 STEERING UB S7 51
OPT HEIGHT 3B17 A - 3A3 SLIDE EXIT(OPTION #1--> proportional valve) 41
1B3 +24V 2B8 4M1 EPS AC0 180/360 degree steering WU
1B4 SAFETY OUT 1A19 (OPTION #2--> ON/OFF valve) UW
B2 BRAKE POT
3A33 +12V Stepper motor A4 U mode switch
1B5 P switch relay（用来做指示灯） B+ + 3A14 4B5
与Parking brake一起工作
DIG1 5D4 G
1B6 PPOT 2A2 RBDL S8
4A9 48V/45A
6.3 Electric schematic diagram

H2 警示灯

GU 2Y5 V 3M1 GRAPHIC OPT

2A19SAFETY OUT CPOT 2A3 URQL G
H3 工作灯

SAFETY IN 1A11 OPT 2 1 4A8 Steering motor DIG1 5D1

FLASH 2A6 SEAT B - 3A26 TILT UP(OPTION #1--> proportional valve) W GND
SMART 油压开关
PUMP MODE 2A10 FORK FREE HEIGHT 2Y6 (OPTION #2--> ON/OFF valve) 4A10 DISPLAY S13
PROGRAMMING 2B6 Seat switch （常开）
W RU
1B7 B 2 1 B GND D
RY -BATT 2A9 - 3A27
倒车继电器 HORN RELAY

A5
K2

SEAT 1A6 2B1 TILT DOWN(OPTION #1--> proportional valve) 4A11

Parking brake (OPTION #2--> ON/OFF valve)
1B8 YW SAFETY IN 2A11 B 3A8 DIG INPUT#1 31
HB 1A13 + 3A15 YB NPN（低电平有效） S
2W ZERO SENSOR 4A2 Proximity switch
RW B1 ACC. POT W P1 KEY 6B3
B+ PPOT 1A2 PLC/PEB 2A17 2B2 2Y7 90 degree
G B+ 2M1 2 1
CPOT 1A3 2V 3A9 DIG INPUT#2 - 3A4 SIDE SHIFT RIGHT(OPTION #1--> proportional valve) B+ 6A14
B-
PUMP V 2Y8 (OPTION #2--> ON/OFF valve) 40 (+24v)
motor ACE 2 2 1
UB
1W B U - 3A5 GND 4A12 B+ 6B5
-BATT 1A9 2U SIDE SHIFT LEFT(OPTION #1--> proportional valve)
PUMP S4 Safety pedal switch
1M1 (OPTION #2--> ON/OFF valve) NPOT 6C3
G1 A2
H4 倒车蜂鸣器

Traction 1V TRAC MODE 1A10 2A5 + 3A16 Lift/lowering fingertip

Battery B- 48V/450A VCM 4A3
motor PLC/PEB 1A17 S

2
24V

1
1U BW A3 4B2 PPOT 6A9
NLC 1A16 K3 Auto centering 2R1
K1 MC 2A17 - 3A6 6C2
B- BR Horn relay（喇叭继电器） request swtich 1 （暂不接）
NEB 1A18 4B6
Y1 EB （ON-OFF TYPE） 24V 24V Reach out/in fingertip
P GY S5 CAN TILLER
GR CAN L 1A20 WR NLC 2A16 Y3
1A22 PTHERM Temp. 2A22 PTHERM - 3A7 4A7 GU A6
Temp. GB N WB
Sensor 1A23 NTHERM CAN H 1A21 Sensor 2A23 NTHERM 势能回收电磁阀（不带比例） Auto centering
GR 4B3 PTHERM 2R2
门架前后移速度可控 当S12闭合时，此线圈作用 Temp. request swtich 2 （暂不接） 6A10
CAN T 1A12 GB 4A1
UR UB NPN（低电平有效） Sensor 4A13 NTHERM S6
1A14 ENC B 2A14 ENC B G Tilt up/down fingertip
+ 3A17
W 1A7 ENC A WG 2A7 ENC A R VCC
1A19

2B3 4B4
Encoder B Encoder BY 3A10 DIG 4B8 UR CHA
1A15 ENC GND 2A15 ENC GND W CHB Encoder 2R3
R RB 4B7 6A11
1A8 PENC 2A8 PENC 前小轮比例制动器（2个） 4A1 B GND
起升切断 选项

113
SPEED1 2A13 BRAKE（Porportional Type） option
NPN（低电平有效） - 3B23 4A5 SAFETY Side shift left/right fingertip
CAN L 2A20 P 1A6
2B4 B 6A16 B-
ACE 2 CAN H 2A21 N Y2
3A20 DIG INPUT#6 B 6A13 2R4
TRACTION CANL 6B2 B-
A1 CAN T 2A12 下降切断 4A6
NPN（低电平有效） + 3B8 NPOT 6A12
48V/450A CANH 4A4
2B5 4A14 B
3A21 DIG INPUT#7 5C1 -B 6B1 CAN_L
B 6A15
5B3 -B
6B4 CAN_H

P Y S3 Direction switch（车辆前进/后退信号）
5C4 CAN_L FWD /Back6A4
N 5C3 CAN_H
UY
N Horn 6A3
5C2 CAN_T H1 喇叭按钮
当喇叭按钮按下时， K3得电（24V）

3A30 CAN L2
3A31 CAN H2
GU 3A11 CAN L1
GU 3A12 CAN H1

CQD12/14/16/20-AZ4H Electric schematic diagram

代号 名称 英文名称 代号 名称 英文名称 代号 名称 英文名称 代号 名称 英文名称
G1 蓄电池 Battery A5 仪表 dispaly 2R1 起升/下降拇指开关 Lift/lowering fingertip P1 接近开关0度 Proxmity switch zero position
K1 主接触器 Main contactor 1M1 行走电机 Traction motor 2R2 前移/后移拇指开关 Reach out/in fingertip P3 高度编码器 Height encoder
K2 倒车继电器 Backward relay 2M1 起升电机 Pump motor 2R3 前倾/后倾拇指开关 Tilt forward/backward fingertip H1 喇叭 Horn
K3 喇叭继电器 Horn relay 3M1 转向电机 Steering motor 2R4 左移/右移拇指开关 Side shift left/right fingertip H2 警示灯 Caution light
1F 行走控制器熔断器 Fuse drive controller 4M1 步进电机 Stepper motor 2Y1 起升电磁阀 Lifting valve H3 工作灯 Headlight
2F 起升控制器熔断器 Fuse pump controller S1 钥匙开关 Key switch 2Y2 下降电磁阀 Prop. lowering valve H4 倒车蜂鸣器 Backward buzzer
3F 转向控制器熔断器 Fuse EPS controller S2 紧急断电开关 Emergency switch 2Y3 后移电磁阀 Reach in valve 2B1 起升高度开始开关 Lift switch starting
F3 DC-DC熔断器 Fuse DC-DC S3 方向开关 Direction switch 2Y4 前移电磁阀 Reach out valve 2B2 货叉零位开关 Zero forklift switch
F4 控制器回路熔断器 Fuse control circuit S4 脚踏安全开关 Safety pedal switch 2Y5 前倾电磁阀 Tilt forward valve 2B3 门架前后移开关 Forklift switch up/back
F10 喇叭熔断器 Fuse horn S5 自动对中开关1 Autocentering request swtich 1 2Y6 后倾电磁阀 Tilt backward valve 2B4 起升切断开关 LIMIT SWITCH lifting
F30 工作灯熔断器 Fuse head light S6 自动对中开关2 Autocentering request swtich 2 2Y7 右移电磁阀 Sideshift right valve 2B5 下降切断开关 LIMIT SWITCH lowering
F40 警示灯熔断器 Fuse caution light S7 龟爬开关 Speed reduction switch 2Y8 左移电磁阀 Sideshift left valve 2B6 座椅开关 Seat switch
F60 阀控熔断器 Fuse myhio falsh controller S8 180/360度转向模式切换开关 180/360 steering mode switch Y1 电磁制动器 Electric magnetic brake
A1 牵引控制器 Taction controller S9 喇叭开关 Horn switch Y2 前小轮左右比例制动器 BRAKE（Porportional Type）
A2 起升控制器 Pump controller S10 警示灯开关 Caution light switch Y3 势能回收电磁阀 Potential energy recovery valve
A3 阀控制器 Mhyio flash controller S11 工作灯开关 Headlight switch B1 踏板加速器 Accelerator
A4 转向控制器 Electric steering controller S12 势能回收开关 Potential energy recovery switch B2 踏板制动器 Brake potetionmeter
S13 油压开关 Oil pressure switch G2 DC-DC转换器48V/12V DC-DC converter 48V/12V
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 杭叉集团股份有限公司
HANGCHA GROUP CO., LTD.

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