Service Manual

EPT20-20RAS
EPT25-RAS
Electric Pallet Truck
Service Manual
EPT20-20RAS
EPT25-RAS
Electric Pallet Truck
Release Date Version No. Changes (Serial number)
2016-05-13 SM-1221 05.16 New Version

*    If there are any changes, revised version will be published once every 12 months;
if there is no change, please follow the most recent version.
*   Please refer to the corresponding version of the service manual against the purchase time
of your vehicle.
*  If you need the latest versions of the manual, please contact our service department or
dealer to obtain.

This manual applies to:

Model Specifications
EPT20-20RAS 2,000 kg Capacity, Standing
EPT25-RAS 2,500 kg Capacity, Standing
Some sections of the manual only involve certain model, please refer to the manual
according to the actual configuration of the vehicle.
 FOREWORD
　
This Service Manual can help readers learn more about the truck system components,
maintenance and troubleshooting, and other related information. The operation and
maintenance personnel must read this Manual carefully before using the product. And when
vehicle is in use, be sure to follow the complete operation and maintenance information in
this Manual for vehicle maintenance.

Before using, please check if the pages of the Manual are clear and complete, so as not
to affect your normal use because of incomplete information. If the contents of the Manual
have been illegible or damaged, which may affect reading, please contact our company or
dealer for replacement.

With the constant update and improvement of our products, the equipment you are using
may be slightly different from what has been described in this Manual, therefore, we must
reserve the right to modify the appearance, configuration and technical specifications. If you
have any questions, please contact our sales department or dealer.

Safety signs and instructions:

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

Please pay attention to the important safety instructions.

i Instructions.

Copyright

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

EP Equipment Co., Ltd.

EP Industrial Park, Xiaquan Village,

Dipu Town, Anji County, Zhejiang Province

www.ep-zl.com

REV. SM-1221 05.16

 TABLE OF CONTENTS

TABLE OF CONTENTS

SECTION PAGE
1. INFORMATION & SPECIFICATIONS .............................. 1
1.1 After-sales Service Platform ......................................... 3
1.2 Introduction ................................................................... 4
1.3 Common Tools.............................................................. 5
1.4 General Tightening Torques ......................................... 6

2. MAINTENANCE ............................................................... 9
2.1 Overview..................................................................... 11
2.2 Maintenance ............................................................... 12
2.2.1 Cleaning ........................................................................12
2.2.2 Inspection ......................................................................12
2.2.3 Lubrication .....................................................................16

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

3.1 Structure & Functions ................................................. 21
3.1.1 Travel Switch .................................................................21
3.1.2 Lifting/Lowering Switch ..................................................21
3.1.3 Emergency Reverse Switch ..........................................21
3.1.4 Horn Switch ...................................................................21
3.1.5 Key Switch .....................................................................22
3.1.6 Emergency Stop Switch ................................................22
3.1.7 Charge Gauge ...............................................................22
3.1.8 Horn ...............................................................................22
3.1.9 Fuse 1...........................................................................23
3.1.10 Fuse 2..........................................................................23
3.1.11 AC0 Controller (Traction Controller).............................23
3.1.12 EPS-DC0 Controller ...................................................23
3.1.13 Lifting Limit Switch .......................................................24
3.1.14 Interlock Switch ...........................................................24
3.1.15 Pump Motor .................................................................24
3.1.16 Gear Pump ..................................................................24
3.1.17 Pump Contactor...........................................................25
3.1.18 Solenoid Valve .............................................................25
3.1.19 Main Contactor ............................................................25
3.1.20 Potentiometer ..............................................................25

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

4.1 Load Wheel ................................................................ 29
4.1.1 Removal and Installation ...............................................29
4.1.2 Faults and Causes.........................................................30

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TABLE OF CONTENTS

SECTION PAGE
4.2 Cover .......................................................................... 30
4.2.1 Removal and Installation ...............................................30
4.3 Caster ......................................................................... 31
4.3.1 Removal and Installation ...............................................31
4.4 Safety Gate................................................................. 32
4.4.1 Removal and Installation ...............................................32
4.5 Lifting Mechanism....................................................... 33
4.5.1 Fork Inspection ..............................................................33
4.5.2 Connecting Rod Adjustment ..........................................33
4.5.3 Removal and Installation ...............................................34

5. DRIVE SYSTEM ............................................................. 35

5.1 Drive Wheel ................................................................ 38
5.1.1 Removal and Installation ...............................................38
5.1.2 Faults and Causes.........................................................38
5.2 Electromagnetic Brakes.............................................. 39
5.2.1 Removal and Installation ...............................................39
5.2.2 Faults and Causes.........................................................40
5.2.3 Checking and Testing ....................................................40
5.2.4 Control Circuit Troubleshooting .....................................41
5.3 Drive Motor ................................................................. 42
5.3.1 Removal and Installation ...............................................42
5.3.2 Faults and Causes.........................................................42
5.3.3 Checking and Testing ....................................................43
5.3.4 Control Circuit Troubleshooting .....................................44
5.4 Gearbox ...................................................................... 45
5.4.1 Removal and Installation ...............................................45
5.4.2 Faults and Causes.........................................................46
5.5 Proximity Switch ......................................................... 46
5.5.1 Removal and Installation ...............................................46
5.5.2 Faults and Causes.........................................................47
5.5.3 Checking and Testing ....................................................47
5.5.4 Control Circuit Troubleshooting .....................................48
5.6 Steering Motor ............................................................ 49
5.6.1 Removal and Installation ...............................................49
5.6.2 Faults and Causes.........................................................50
5.6.3 Checking and Testing ....................................................50
5.6.4 Control Circuit Troubleshooting .....................................50
5.7 Speed Encoder ........................................................... 51
5.7.1 Removal and Installation ...............................................51
5.7.2 Faults and Causes.........................................................51

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SECTION PAGE
5.7.3 Checking and Testing ....................................................51
5.7.4 Control Circuit Troubleshooting .....................................51

6. OPERATING SYSTEM................................................... 53
6.1 Control Lever .............................................................. 55
6.2 Button Switch.............................................................. 55
6.2.1 Removal and Installation ...............................................55
6.2.2 Faults and Causes.........................................................56
6.2.3 Checking and Testing ....................................................56
6.2.4 Control Circuit Troubleshooting .....................................57
6.3 Travel Switch .............................................................. 59
6.3.1 Removal and Installation ...............................................59
6.3.2 Faults and Causes.........................................................59
6.3.3 Checking and Testing ....................................................59
6.3.4 Control Circuit Troubleshooting .....................................60
6.4 Potentiometer ............................................................. 61
6.4.1 Removal and Installation ...............................................61
6.4.2 Faults and Causes.........................................................62
6.4.3 Checking and Testing ....................................................62
6.4.4 Control Circuit Troubleshooting .....................................62
6.5 Speed Mode Switch.................................................... 63
6.5.1 Removal and Installation ...............................................63
6.5.2 Connection Mode ..........................................................63
6.5.3 Faults and Causes.........................................................63
6.5.4 Checking and Testing ....................................................64
6.5.5 Control Circuit Troubleshooting .....................................64

7. HYDRAULIC SYSTEM................................................... 65
7.1 Overview..................................................................... 67
7.1.1 Hydraulic Schematic Diagram ......................................68
7.2 Pump and Motor Assembly......................................... 69
7.2.1 Removal and Installation ...............................................69
7.2.2 Component ....................................................................69
7.3 Pump Motor ................................................................ 70
7.3.1 Removal and Installation ...............................................70
7.3.2 Faults and Causes.........................................................70
7.3.3 Checking and Testing ....................................................71
7.4 Pump Contactor.......................................................... 72
7.4.1 Faults and Causes.........................................................72
7.4.2 Checking and Testing ....................................................72
7.4.3 Control Circuit Troubleshooting .....................................73

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TABLE OF CONTENTS

TABLE OF CONTENTS

SECTION PAGE
7.5 Solenoid Valve ........................................................... 74
7.5.1 Faults and Causes.........................................................74
7.5.2 Checking and Testing ....................................................74
7.5.3 Control Circuit Troubleshooting .....................................75
7.6 Reach Cylinder ........................................................... 76
7.6.1 Cylinder Removal Precautions ......................................76
7.6.2 Cylinder Installation Precautions ...................................77
7.6.3 Removal and Installation ...............................................78
7.7 Hydraulic Troubleshooting .......................................... 80
7.8 Hydraulic Symbol........................................................ 81

8. ELECTRICAL SYSTEM ................................................. 83

8.1 Controller .................................................................... 85
8.1.1 Removal and Installation ...............................................85
8.1.2 Controller Interface Function .........................................86
8.2 Fuse............................................................................ 90
8.2.1 Location of Fuses ..........................................................90
8.2.2 Checking and Testing ....................................................91
8.3 Main Contactor ........................................................... 92
8.3.1 Removal and Installation ...............................................92
8.3.2 Faults and Causes.........................................................92
8.3.3 Checking and Testing ....................................................93
8.3.4 Control Circuit Troubleshooting .....................................93
8.4 Lifting Limit Switch ...................................................... 94
8.4.1 Connection Mode ..........................................................94
8.4.2 Faults and Causes.........................................................94
8.4.3 Checking and Testing ....................................................94
8.4.4 Control Circuit Troubleshooting .....................................94
8.5 Key Switch .................................................................. 96
8.5.1 Removal and Installation ...............................................96
8.5.2 Faults and Causes.........................................................96
8.5.3 Checking and Testing ....................................................96
8.5.4 Control Circuit Troubleshooting .....................................96
8.6 Charge Gauge ............................................................ 97
8.6.1 Removal and Installation ...............................................97
8.6.2 Faults and Causes.........................................................97
8.6.3 Checking and Testing ....................................................97
8.6.4 Control Circuit Troubleshooting .....................................97
8.7 Interlock Switch .......................................................... 98
8.7.1 Removal and Installation ...............................................98
8.7.2 Faults and Causes.........................................................98

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SECTION PAGE
8.7.3 Checking and Testing ....................................................98
8.7.4 Control Circuit Troubleshooting .....................................98
8.8 Handheld Unit (Optional) ............................................ 99
8.8.1 Handheld Unit Connection.............................................99
8.8.2 Handheld Unit Menu Options ........................................99
8.8.3 TESTER Menu ............................................................101
8.9 Controller Error Message ......................................... 103
8.9.1 Traction Controller .......................................................103
8.9.2 Steering Controller (EPS-ACO) ...................................108
8.10 Cable Wiring Diagrams........................................... 117
8.11 Electrical Schematic Diagrams ............................... 118
8.12 Wiring Harness and Connectors............................. 120

9. TROUBLESHOOTING ................................................. 121

9.1 Preparation Before Troubleshooting ......................... 123
9.1.1 Check the Voltage of Battery .......................................123
9.2 Troubleshooting Solutions of Common Faults .......... 124

APPENDIX .................................................................. 127

B SERVICE MANUAL - BATTERY ................................. 129

B1 Lead-acid Battery ...................................................... 131

B1-1 Safety and Warnings .............................................. 131
B1-2 Use of Battery ........................................................ 131
B1-2.1 Pre-use Checks ........................................................131
B1-2.2 Discharging ...............................................................131
B1-2.3 Charging ...................................................................132
B1-2.4 Temperature ..............................................................132
B1-3 Maintenance & Care ............................................. 132
B1-3.1 Daily Maintenance ....................................................132
B1-3.2 Weekly Maintenance.................................................132
B1-3.3 Monthly Maintenance ................................................133
B1-3.4 Care ..........................................................................133
B1-4 Storage .................................................................. 134
B1-5 Troubleshooting ..................................................... 134

B2 Maintenance-free Battery ......................................... 137

B2-1 Safety and Warnings .............................................. 137
B2-2 Use of Battery ........................................................ 137

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SECTION PAGE
B2-2.1 Pre-use Checks ........................................................137
B2-2.2 Discharging ...............................................................137
B2-2.3 Charging ...................................................................138
B2-3 Maintenance & Care .............................................. 138

C SCHEDULE ................................................................. 139

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 SAFETY WARNING

For your own safety and that of others, please observe the following safety instructions:

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

1
NOTE:

2
 INFORMATION & SPECIFICATIONS

1.1 After-sales Service Platform

Claims/Replacement Parts Service Platform: After-sales Maintenance Service Platform:
1
Customer Customer

Claim Form Claim Form

nxsp@ep-zl.com nxsp@ep-zl.com

Customer service to input Customer service to input

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

Maintenance service Within two business

specialist will provide days after the mainten-
Components on-site service at the ance, customer service
Warehouse appointed time. will call back and close
the claim.
Shipped within
24 hours

Customer Customer

i NOTE
In order to provide you with a fast and efficient
after-sales service, when you claim / order spare
parts or after-sales service upon maintenance,
please provide accurate truck model, vehicle
body serial number and part number.

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 INFORMATION & SPECIFICATIONS

1.2 Introduction
WARNING
This series are electric pallet trucks. Its import-
1
- Please refer to the nameplate for rated load
ant structure is as shown in Figure 20001. capacity of the vehicle.
- The vehicle can only be used on the level gro-
und indoors, never use it on mezzanine or
balcony area.

No. Name No. Name

1 Charge Gauge 7 Chassis
2 Covers 8 Caster Wheel
3 Control Lever 9 Drive Wheel
4 Battery Cover 10 Standing Platform
5 Emergency Stop Switch 11 Safety Gate
6 Load Lifting Device

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 INFORMATION & SPECIFICATIONS

The truck is driven forward or backward by AC

motor.
The Electric Power Steering has greatly met the
demand for high mobility of the truck. 1
Only when the safety gates are fully closed, can
the truck run at full speed, which ensures the
safety of drivers.
The truck is equipped with interlock switch at
handle joint, only by pressing the switch can the
truck be operated, which has greatly reduced
the possibility of misuse by the operator.

WARNING
Truck can only be operated by single operator;
other personnel is forbidden from riding.

1.3 Common Tools

No. Name Remark

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

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 INFORMATION & SPECIFICATIONS

1.4 General Tightening Torques

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

Table 1.4.1 Screws/Bolts Performance Levels

Performance Level Material Specification (mm)

5.8 5.8 grade Low carbon steel M6 ~ M48

Quenched and tempered medium

8.8 8.8 grade M6 ~ M48
carbon steel

Quenched and tempered medium

10.9 10.9 grade M6 ~ M48
carbon alloy steel

Quenched and tempered medium

12.9 12.9 grade M6 ~ M48
carbon alloy steel

CAUTION
- The performance levels of screws or bolts are
marked on the heads of the screws or bolts.
- If you find the screws or bolts used on certain
position are not marked with performance
level, please select spare parts with perform-
ance level of at least 8.8 grade or higher level
forreplacement.

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 INFORMATION & SPECIFICATIONS

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

Nominal Diameter 5.8

Performance Level
8.8 10.9 12.9
1
(mm) Proof Stress (MPa)
380 600 830 970
M6 7~8 10~12 14~17 17~20
M8 16~18 25~30 34~41 41~48
M8×1 17~20 27~32 37~43 43~52
M10 31~36 49~59 68~81 81~96
M10×1 35~41 55~66 76~90 90~106
M12 55~64 86~103 119~141 141~167
M12×1.5 57~67 90~108 124~147 147~174
M14 87~103 137~164 189~224 224~265
M14×1.5 144~170 149~179 206~243 243~289
M16 136~160 214~256 295~350 350~414
M16×1.5 144~170 228~273 314~372 372~441
M18 186~219 294~353 406~481 481~570
M18×1.5 210~247 331~397 457~541 541~641
M20 264~312 417~500 576~683 683~808
M20×1.5 294~345 463~555 640~758 758~897
M22 360~431 568~680 786~941 918~1099
M22×1.5 395~473 624~747 803~1034 1009~1208
M24 457~547 722~864 998~1195 1167~1397
M24×2 497~595 785~940 1086~1300 1269~1520
M27 669~801 1056~1264 1461~1749 1707~2044
M27×2 723~865 1141~1366 1578~1890 1845~2208
M30 908~1087 1437~1717 1984~2375 2318~2775
M30×2 1005~1203 1587~1900 2196~2629 2566~3072
M36 1587~1900 2506~3000 3466~4150 4051~4850
M36×3 1680~2011 2653~3176 3670~4394 4289~5135
M42 2538~3039 4088~4798 5544~6637 6479~7757
M42×3 2731~3269 4312~5162 5965~7141 6921~8345
M48 3813~4564 6020~7207 8327~9969 9732~11651
M48×3 4152~4970 6556~7848 9069~10857 10598~12688

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 INFORMATION & SPECIFICATIONS

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2. MAINTENANCE

9
NOTE:

10
 MAINTENANCE

2.1 Overview
i NOTE
Only by performing regular vehicle maintenance - Under harsh working conditions: such as, the
and repair, can ensure the continuous and external temperature is too high or too low,
reliable use of the truck. dusty, or implementing multiple shifts per day,
Only specially trained and qualified personnel the maintenance and care interval should be
are capable of maintenance and repair opera- shortened.
tions of the equipment. If you want to perform
the maintenance and repair on your own, it is
- Prior to lubrications, replacement of filters or
operating the hydraulic system, please clean
2
recommended that on-site training should be the external parts carefully and use a clean
conducted to your maintenance personnel by container.
the service representative of the vendor.
- Only compliant lubricants can be used See
Table 2.2 Lubricants.
Working conditions:
- Truck must be parked on the level ground
reserved for maintenance (such area needs
to be clean and with less dust), block the
wheels with wooden wedges, disconnect
the key switch and disconnect the battery
connections.
- When lifting the truck, the lifting tools can
only be installed on the fixed positions as
specified.
- When jacking up the truck, appropriate tools,
such as wedge blocks, wooden blocks, and
so on, must be used to secure the truck to pr-
event the occurrence of accidental rolling or
tipping over.

WARNING
When lifting load components or during the
operations under the cabin, sufficiently strong
chains or safety device must be used to secure
the vehicle.

CAUTION
Without the supplier's consent, it is strictly
forbidden to make modifications to truck, espe-
cially to the safety devices. It is strictly forbidden
to change the various working speeds of the
truck.

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 MAINTENANCE

2.2 Maintenance Regular inspection and maintenance under

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

truck is powered by battery, battery plug must

be pulled out.
- When cleaning electrical and electronic com-
ponents, you should use low-intensity suction
gas or compressed dry air. Meanwhile, clean
the dust on the surface of components with
non-conductive and antistatic brush.
- Do not use vapor steam to clean the equipm-
ent.

2.2.2 Inspection
Regular inspection and maintenance under
normal conditions of use:

Operating
Requirements
Hours (h)
50 At least once per 7 days
250 At least once per 60 days
500 At least once per 90 days
1000 At least once every 6 months
2000 At least once per year

CAUTION
When the truck is at running-in phase (after
approximately 100 hours of operation), the
equipment user must check the fastening of
wheel nuts and bolts and re-tighten them if
necessary.

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 MAINTENANCE

Table 2.1 Inspection & Maintenance List

Interval in days/months/years 7d 60 d 90 d 6m 1y
Interval in hours 50 250 500 1000 2000
Functions and Control
Check the functions of the operation switches and
display
A 2
Check alarm system functions A
Check interlock switch functions A
Check speed mode switch functions A
Check the emergency switch functions A
Check the cables for damage and if the terminals are
A
secure
Check the lifting limit switch functions A
Check and tighten the controllers and contactors A
Check fault information records and operating hours A
Power Supply & Drive System
Check the battery cables for damage and replace if
A
necessary
Check the battery charge connector A
Check if the cable connections between battery mon-
omers are secure, apply some grease to electrodes if A
necessary
Check and tighten motor mounting bolts A
Check the connections of motor connectors A
Check the position of various bearings for noise A
Check transmission oil level A
Replace after 100 hours of early operation.
Clean or replace the gear oil
Then replace once every 2000 hours
Check the gearbox for abnormal noise or leaks A
A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the
vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.

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 MAINTENANCE

Table 2.1 Inspection & Maintenance List (Continued)

Interval in days/months/years 7d 60 d 90 d 6m 1y
Interval in hours 50 250 500 1000 2000
Power Supply & Drive System

2 Check and lubricate the bearings between drive motor

and gearbox
A/L

Check and lubricate steering large ring gear A/L

Check the drive wheel and load wheel for worn or
A
damage
Check the drive mounting base and fixation A
Check the wheel bearings and fixation A
Check the travel speed A
Hydraulic System
Check the functions of hydraulic system A
Check if the hoses, pipes and interfaces are fastened
A
or sealed securely, and check if there is damage
Check the cylinders for leaks A
Check the cylinders for damages and check the fixation A
Check the oil tank fixation and check for leaks A
Check the hydraulic oil level A
Replace after 100 hours of early operation.
Clean or replace the hydraulic oil
Then replace once every 2000 hours
Check the function of emergency pressure relief
A
valve
Check and clean oil tank air filter A
Replace the oil tank air filter and filter A
Check the relief pressure A
A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the
vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.

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 MAINTENANCE

Table 2.1 Inspection & Maintenance List (Continued)

Interval in days/months/years 7d 60 d 90 d 6m 1y
Interval in hours 50 250 500 1000 2000
Breking System
Check the braking functions of electromagnetic brake
Check the air gap of electromagnetic brake
A
A
2
Check the installation and connection of electromagn-
A
etic brake
Check the braking distance of electromagnetic brake A
Lifting Mechanism
Check the connecting rod mechanism for wear or
A
damage
Check whether the pin shaft is fixed securely A
Check and lubricate the moving parts of connecting
A/L
rod mechanism
Check the lifting and lowering speed A
Other
Check if the signs are clear and complete A
Check the chassis for cracks or damages A
Check the connections of bolts and nuts A
Checking covering parts for damages A
Check if the optional features are functioning properly A

A = Check / Adjust
Please refer to Inspection & Maintenance List
for regular inspection and maintenance of the
vehicles.
L = Lubrication
Under harsh conditions, the lubrication intervals
should be shortened by half.

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 MAINTENANCE

2.2.3 Lubrication Please see Table 2.2 for the lubricants used in
this truck.
Lubricant
CAUTION
- Improper operations may constitute hazards
to the operator's health and life, as well as to The use and disposal of lubricants must be
the surrounding environment. carried out in strict accordance with the manufa-

2 - When storing or adding lubricant, use clean

containers. It is strictly forbidden to mix
cturer's regulations.

different types and specifications of lubricants

with each other (except for those can be
mixed under clear statement).

Sliding surface

Hydraulic oil injection nozzle

Gear oil injection nozzle

Gear oil discharge nozzle

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 MAINTENANCE

Table 2.2 Lubricants

Code Type Specification Amount Position

Anti-wear hydraulic oil L-HM46

Hydraulic
A Low temperature anti-wear 0.55 L
L-HV32 System

B
hydraulic oil (cold storage)

Multi-purpose grease Polylub GA352P Appropriate amount

Sliding surface 2
(See Table 2.3)
C Grease (MoS2) 80W-90 GL-5 1.38L (Align with oiling port) Gearbox

Table 2.3 Sliding Surface

Lubrication Table
Code Position
L1 Steering Gear
L2 Caster Wheel
Short Pin Shaft of Lower
L3
Contecting rod
Long Pin Shaft of Lower
L4
Contecting rod
L5 Load Wheel
L6 Wheel Bracket
L7 Upper Contecting rod
L8 Steering Bearing

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 MAINTENANCE

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3. STRUCTURE & FUNCTIONS

19
NOTE:

20
 STRUCTURE & FUNCTIONS

3.1 Structure & Functions

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

Lifting/Lowering Switch

3.1.3 Emergency Reverse Switch Emergency Reverse Switch

Location: control lever;
Function: press the switch, the vehicle will
travel in reverse direction;
Description: reverse switch is normally-open.
When pressing, the reverse switch is on; after
release, the switch will automatically reset;
Note: Unserviceable.

3.1.4 Horn Switch

Location: control lever;
Function: to press the horn;
Description: the horn switch is normally-open.
When pressing, the horn switch is on; after re-
lease, the switch will automatically reset;
Note: Unserviceable.

Horn Switch

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 STRUCTURE & FUNCTIONS

3.1.5 Key Switch

Location: upper cover;
Function: for operator to switch on or off the
truck;
Description: remove the key to prevent opera-
tions to the truck by unauthorized operator;
Note: Unserviceable.
Key Switch

3 3.1.6 Emergency Stop Switch

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

3.1.7 Charge Gauge

Location: upper cover;
Function: display battery power, working hours
(this function is available on the component with
timer function);
Description: 24V operating voltage;
Note: Unserviceable.
Charge Gauge

3.1.8 Horn
Location: behind the electrical mounting plate;
Function: can provide sound alarm through the
operation to horn switch operation;
Description: 24V operating voltage;
Note: Unserviceable.

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 STRUCTURE & FUNCTIONS

3.1.9 Fuse 1
Location: electrical mounting plate;
Function: overcurrent protection;
Description: fusing current is 200A; Fuse 1
Note: Unserviceable.

3.1.10 Fuse 2 3
Location: electrical mounting plate;
Function: overcurrent protection;
Description: fusing current is 200A;
Fuse 2
Note: Unserviceable.

3.1.11 AC0 Controller (Traction Controller)

Location: electrical mounting plate;
Function: to control the speed of drive motor
through the signal input by the accelerator;
Description: 24V operating voltage, to control
the drive motor circuit;
Note: Unserviceable.

AC0 Traction Controller

3.1.12 EPS-DC0 Controller

Location: electrical mounting plate;
Function: to control the rotating direction of
steering motor through signal input by potentio-
meter;
Description: 24V operating voltage, to control
the steering motor;
Note: Unserviceable.
EPS-DC0 Controller

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 STRUCTURE & FUNCTIONS

3.1.13 Lifting Limit Switch

Location:top side of pump and motor assembly;
Function: limit the lifting height of the fork;
Description: lifting limit switch is normally
closed. When the fork is lifted in higher position
(that is to trigger the limit switch to disconnect),
lifting will be limited;
Note: Unserviceable.
Lifting Limit Switch

3
3.1.14 Interlock Switch
Location: at handle joint;
Function: the truck cannot be operated if the
interlock switch is not closed;
Description: to prevent misuse of truck;
Note: Unserviceable.

Interlock Switch

3.1.15 Pump Motor

Location: left side of drive assembly;
Function: to provide power for gear pump for
lifting the loading rack;
Description: upon receiving the signal input by
control switch, traction controller to control the
power transmission of pump motor;
Pump Motor
Note: Unserviceable.

3.1.16 Gear Pump

Location: below the valve body;
Function: to provide pressure for hydraulic sys-
tem of the entire vehicle;
Description: N/A;
Gear Pump
Note: Unserviceable.

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 STRUCTURE & FUNCTIONS

3.1.17 Pump Contactor

Location: outside of the pump motor;
Function: to connect and disconnect circuit of
pump motor, and to control the power trans-
mission of pump motor;
Description: the signal obtained by drive
controller from lifting switch controls the ON/ Pump
OFF of pump contactor; Contactor

Note: Unserviceable.
Solenoid 3
3.1.18 Solenoid Valve Valve

Location: on valve body at pump and motor as-

sembly;
Function: to realize the lowering of fork, con-
troller gets signal from the lowering switch to
control the absorption of solenoid valve, forming
a hydraulic circuit;
Description: 24V operating voltage;
Note: Unserviceable.

3.1.19 Main Contactor

Location: electrical mounting plate;
Function: to connect and disconnect circuit and
to control the power transmission of drive motor;
Description: to provide power loads through Main
controller under the circumstances that the con- Contactor
troller is failure-free;
Note: Unserviceable.

3.1.20 Potentiometer
Location: below the handle joint;
Function: to provide steering input signals to
the steering controller;
Description: 5V operating voltage; Potentiometer
Note: Unserviceable.

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 STRUCTURE & FUNCTIONS

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4. CHASSIS SYSTEM

27
NOTE:

28
 CHASSIS SYSTEM

4.1 Load Wheel

4.1.1 Removal and Installation
Removal
- Lift the vehicle carefully with lifting equipment
through the lifting holes at back;

WARNING
Make sure the lifting equipment is solid and
secure, and the load capacity should be greater
than the total weight of the vehicle.

Single Wheel (see Figure 20103)

- Remove the elastic cylindrical pin (1) within
the wheel bracket (2) with an ejector pin;
4
- Knock out the wheel pin shaft (3) from side
and remove load wheel and bearing assem-
bly;
- Remove the bearing (5) of load wheel (4) with
hammer and jacking equipment.

- Place a wooden wedge under the chassis

near load wheel, make the load wheel off the
ground;

WARNING
When replacing wheels, be sure that the truck
won't tilt.

Double Wheels (see Figure 20102)

- Turn the wheel bridge (1) to vertical direc-
tion, remove the screws (2) and nuts (3), and
remove the load wheel and bearing assem-
bly; Installation and Commissioning
- Remove the shafts (6) and bearings (5) of - Install according to the reverse order of rem-
load wheel (4) with hammer and jacking equi- oval;
pment. - Run the truck to see if the load wheel is fun-
ctioning properly. If there is blocking or noise,
please install again.

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 CHASSIS SYSTEM

4.2 Cover
CAUTION
When installing, please apply appropriate 4.2.1 Removal and Installation
amount of grease on the axle first.
(See Section 2.2.3 for specifications)
Removal
Quality of tyres directly affects the stability and - Unscrew the three screws (1), and loosen the
driving performance of the device. rotation cover (2);
If you need to replace the factory-fitted tyres, - Unscrew the two screws (3) with a wrench
please use original spare parts provided by the and remove the middle cover (4) ;
equipment manufacturer to reach the original - Unscrew the four screws (5) with a wrench
design performance of the truck.
and remove the lower cover (6) .

4.1.2 Faults and Causes

4 1
Fault Bearing noise or jammed
Cause Bearing fatigue damage or foreign
Abnormal tyre wear, cracking or
Fault
2 degumming
Cause Improper use

CAUTION
The covers are all made of plastic materials,
even force must be applied when pulling, be
sure not to concentrate the force on one spot to
prevent the covers from being damaged.

Installation
- Install according to the reverse order of rem-
oval.

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 CHASSIS SYSTEM

4.3 Caster
CAUTION
4.3.1 Removal and Installation After long time of use, the drive wheel will wear
and tear to certain level, at this time, adjust
Removal the height of drive wheel through adjusting the
- Remove the lower cover;(See Section 4.2.1) adjusting nut to make the two casters and drive
wheel to be in close contact with the ground.
- Lift the vehicle carefully with lifting equipment
through the lifting holes at at front and back; CAUTION
Tyre wear can affect the stability of the truck,
WARNING adjust the caster with minor wear on a regular
Make sure the lifting equipment is solid and basis, or replace the caster with heavy wear.
secure, and the load capacity should be greater Quality of tyres directly affects the stability and
than the total weight of the vehicle.Lifting height driving performance of the device. If you need

4
of not more than 300mm, to prevent the hazards to replace the factory-fitted tyres, please use
to the maintenance personnel working under original spare parts provided by the equipment
the vehicle for caster removal and installation. manufacturer to reach the original design
performance of the truck.

Upon maintenance or replacement for parts

of the caster, please refer to Figure 30106 for
removal and installation.

- Unscrew four screws (1), then remove the

caster (3) and adjustment shim (2).

Installation
- Install according to the reverse order of rem-
oval.

Adjustment
- Park the truck with replacement completed
on level ground to see if the casters and drive
wheel can both be in contact with the ground;
- When the truck is running, check if the three
wheels are functioning properly.

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 CHASSIS SYSTEM

4.4 Safety Gate

4.4.1 Removal and Installation
Removal
- Remove the cover ;(See Section 4.2.1)
- Disconnect the connection between speed
mode switch (14) and main wiring harness;
- Unscrew the two screws (3) with a wrench
and remove the mounting plate (4) from the
bracket (8);

- Unscrew the screws (20) and nuts (21) ,

remove the right sheath (18) or the left sheath
(19) ;
- Unscrew the four screws (11) with a wrench
and remove the safety gate from the chassis.

Installation
- Install according to the reverse order of rem-
oval.

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 CHASSIS SYSTEM

4.5 Lifting Mechanism

4.5.1 Fork Inspection
Lower the forks completely down: Lift the forks completely:
The truck is equipped with batteries, the height The truck is equipped with batteries, the height
from fork surface at center of load wheel to the from fork surface at center of load wheel to the
ground (h1): ground (h2):
- Single Wheel : 82 mm ~ 88 mm - Single Wheel : 207 mm ~ 213 mm
- Double Wheels : 82 mm ~ 88 mm - Double Wheels : 207 mm ~ 213 mm

4.5.2 Connecting Rod Adjustment

- Fully lower the forks and switch off the power
supply; WARNING
- Lift the vehicle carefully with lifting equipment Make sure the lifting equipment is solid and
through the lifting holes at at front and back; secure, and the load capacity should be greater
than the total weight of the vehicle.Lifting height
of not more than 400mm, to prevent the hazards
Stop Blocks to the maintenance personnel working under
Connector the vehicle for connecting rod adjustment.
Retaining Nut
- Loosen the retaining nut, adjust the relative
distance between long rod and connector;
- Adjust the fork surface distance to standard
value, tighten the retaining nut.

Long Rod

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 CHASSIS SYSTEM

4.5.3 Removal and Installation - Unscrew the two screws (10) and tap the pin
shaft (8) out from the side to separate the
Removal connecting rod (6) from the lower connecting
rod (11);
- Remove battery and lift the vehicle carefully
with lifting equipment through the lifting holes - Unscrew the screw (3), tap the pin shaft (4)
at at front and back; out from the side, and remove the wheel
bracket assembly (5).
WARNING
Make sure the lifting equipment is solid and CAUTION
secure, and the load capacity should be greater When replacing the long connecting rod, the
than the total weight of the vehicle.Lifting connecting rod must be adjusted so that the fork
height of not more than 400mm, to prevent the surface height can reach the specified value.
hazards to the maintenance personnel working
under the vehicle for connecting rod removal
and installation. Installation
4 - Install according to the reverse order of rem-
oval.

CAUTION
Before going on with the next step, please fix
the wheel bracket first. Be sure to avoid the
falling of wheel bracket during removal, resulting
in personal injury.

- unscrew the screw (1) and tap the axle (2)

out from the side to separate the wheel brac-
ket from the front chassis;
- Remove the shaft (7) to separate the lower
connecting rod (11) from the front chassis;

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5. DRIVE SYSTEM

35
NOTE:

36
 DRIVE SYSTEM

Drive System

No. Name No. Name

1 Drive Wheel 7 Steering Motor
2 Electromagnetic Brakes 8 Motor Gear
3 Drive Motor 9 Pinion Gear
4 Large Steering Bearing 10 Proximity Switch
5 Large Ring Gear 11 Speed Encoder
6 Gearbox

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 DRIVE SYSTEM

5.1 Drive Wheel

5.1.1 Removal and Installation
Removal
- Lift the vehicle carefully with lifting equipment
through the lifting holes at at front and back;

WARNING
Make sure the lifting equipment is solid and
secure, and the load capacity should be greater
than the total weight of the vehicle.Lifting height
of not more than 300mm, to prevent the hazards
to the maintenance personnel working under
the vehicle for caster removal and installation. CAUTION
Tyre wear can affect the stability of the truck,
adjust the caster with minor wear on a regular
basis, or replace the caster with heavy wear.
5 Quality of tyres directly affects the stability and
driving performance of the device. If you need
to replace the factory-fitted tyres, please use
original spare parts provided by the equipment
manufacturer to reach the original design
performance of the truck.

5.1.2 Faults and Causes

- Rotate the drive assembly to the right. Fault Drive wheel slipping or jumping
1
- Loosen the five flange nuts (1) with wrench or Cause Wear
socket wrench, and then unscrew the flange Drive wheel cracking or degumm-
nuts and spherical washer by order. Fault
2 ing
- Remove the drive wheel (2) from the gearbox
Cause Improper use
(3).
Fault Vehicle sways while running
3
Installation Cause Drive wheel lock nut loosening

- Install according to the reverse order of rem-

oval.

CAUTION
- Screw the five nuts as shown in Figure
50204.
- Tighten the nuts by order and mark with the
torque: 140 N • m.

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 DRIVE SYSTEM

5.2 Electromagnetic Brakes 5.2.1 Removal and Installation

Removal
The truck is braked through electromagnetic
brake. When the truck is powered off, the The brake is installed on the drive motor. See
electromagnetic coil (6) doesn't absorb the Figure 20203
pressure plate (8), the friction force generated
between brake pads (2), pressure plate and
friction plates (5) will prevent the drive motor
from rotating, thus to brake the vehicle.

- Switch off the truck power connections and

No. Name pull out the brake connectors;
1 Mounting screw - Remove the lower cover;(see Section 4.2)
2 Brake pads - Remove the three mounting screws (1) with
3 Brake gear wrench. Remove the electromagnetic coil (2)
and dust cover (3);
4 Dust cover
- Remove the brake pads (4) and friction plates
5 Friction plate (5) by order;
6 Electromagnetic coil - Remove the circlip (6) on the shaft with circlip
7 Spring pliers and remove the brake gear (7).

8 Pressure plate
Installation
9 Adjusting screw
- Install according to the reverse order of rem-
oval.

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 DRIVE SYSTEM

After the coil is powered off, the

CAUTION Fault
2 pressure plate won't release
When installing the brake gear (7), make sure
the flat key is installed on the shaft of drive Cause Foreign body blocking
motor . Fault Abnormal noise after absorption

Adjustment 3 a. Fully absorbed, but plate not

Cause flat.
- Switch off the truck power connection; b. Mechanical resistance
- Remove the lower cover;(see Section 4.2)
Fault Brake temperature is too high
- Loosen the mounting screws (9);
- Adjust the three adjusting screws (1) with 4 Pressure plate does not fully
wrench to make the air gap between electro- Cause absorb, overcurrent of the coil, or
magnetic coils and pressure plate be 0.2mm energized too frequently
~ 0.3 mm
- Turn on the power and press the handle.
5.2.3 Checking and Testing
Slowly turn the accelerator button:
If the brake is absorbed (with the sound of Electromagnetic Coil Checks
absorption), it is working properly;

5 If the brake does not absorb, it needs to be

re-adjusted.
- Switch off the truck power connections and
pull out the brake connectors;
Air gap Standard value Maximum value - Check the resistance of the coil with a multi-
meter: measurement method is as shown in
s 0.2 mm 0.4 mm Figure 50209;

CAUTION
When the air gap s exceeds 0.4mm, replace the - Identify if the electromagnetic coil is normal
brake pads (2, Figure 20202) according to the readings of resistance on the
multimeter.
5.2.2 Faults and Causes As shown in the following table:
Resistance
Judgment
After the coil is energized, the Measurement
Fault
pressure plate does not absorb Approx. 30 Ω Normal
a. Mechanical part failure; Coil shorting
1 b. Foreign body blocking; 0Ω
(replace the brake)
Cause c. Coil failure;
d. Coil supply voltage less than Coil breaking
∞Ω
24V (replace the brake)

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 DRIVE SYSTEM

Air Gap Checks Check if there is foreign body in the air gap that
may affect the absorption or bouncing off of the
- Switch off the truck power connections and pressure plates.
pull out the brake connectors;
- Check the air gap between electromagnetic
coil and pressure plate with feeler gauge: Spring Checks
measurement method is as shown in Figure Deformation or foreign bodies stuck in the
50208; spring may affect the normal absorption of
- Determine if the air gap is normal according pressure plates.
to the gauge measurements. Check if the distribution of the springs on the
As shown in the following table: electromagnetic coil is correct, and check if
there is foreign body in the spring hole.
Air gap distance Judgment

0.2~0.4mm Normal i NOTE

The air gap is too large After a period of time of use, the springs may
> 0.4mm be deformed due to the effect of radial force,
(replace brake pads)
such case may result in abnormal air gap of the
brake, and the spring must be replaced.
i NOTE
After a period of use, brake pads of the electr-
omagnetic brake will wear. After being worn 5.2.4 Control Circuit Troubleshooting
5
too much, the air gap between electromagnetic
coil and pressure plate may exceed the Brake Control Circuit (Figure 20205)
predetermined maximum value, which may Check if the circuit is broken by using a multi-
cause electromagnetic absorption failure. meter:
- Set the multimeter to ON-OFF;
Foreign Body Checks - Check if #9 circuit (circuit between brake and
Foreign bodies stuck in the brake may affect the controller) is conducted;
normal absorption of pressure plates. - Check if #14 circuit (circuit between brake
and controller) is conducted;

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 DRIVE SYSTEM

5.3 Drive Motor Speed Encoder

This truck obtains drive force through AC motor. Removal

Temperature
Sensor

Speed
Encoder

- Switch off the truck power connections;

- Unplug the AMP connector on the speed
5.3.1 Removal and Installation encoder(2, Figure 20207) ;
Drive Motor - Unscrew the screw (1) from the drive motor

5 Removal
and remove the speed encoder (2).

Drive motor (3, Figure 20201) is mounted on Installation

the large steering bearing (4).
- Install according to the reverse order of rem-
- Switch off the truck power connections and oval.
remove the brake;
- Unplug the AMP connector on the drive
motor, and remove the U, V and W cables co- 5.3.2 Faults and Causes
nnected between drive motor and controller;
- Unscrew the six screws from the drive motor Fault Motor does not rotate
and remove the drive motor.
a. Cable U, V, or W is broken;
b. Loosening connections to cable
Installation 1 U, V or W ;
Cause c. Stator coil open circuit;
- Install according to the reverse order of rem- d. Motor bearing damage;
oval. e. Speed encoder or its circuit
failure.
CAUTION
Motor is rotating in slow speed and
Fault
- When installing the motor gear of gearbox 2 reverse
onto the shaft of the motor, make sure that
Cause Cable connection error
the woodruff key on the motor shaft is fully
seated on the motor gear; Motor with abnormal noise or
Fault
- Motor gear should fully engage with the gear vibration
within the gearbox, rotate the gearbox without a. Uneven clearance between
blocking, and then fix it with six screws; 3 stator and rotor;
- Requirements on tightening torque of fixing Cause b. Bearing failures;
screws: 140 N • m. c. Loosening fixing screws on
motor housing.

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 DRIVE SYSTEM

Motor temperature too high, - Identify if there is leakage current through

Fault measuring the resistance between U, V, W
controller failure
and motor housing respectively.
a. Stator winding short circuit; as shown in the following table:
b. Motor U, V and W terminals with
surface ; Resistance
5 Measurement
Judgment
c. Bearing failure, resulting in
Cause Leakage current
severe heating; 0Ω
d. Motor cooling duct blockage (replace the motor)
with foreign body; ∞Ω Normal *
e. Overload.
* For normal motor, U, V and W terminals are
On load, motor speed is turning insulated from motor housing.
Fault
slow
a. Insufficient voltage of battery; Temperature Sensor
6 b. Overload;
c. U, V, W terminals with abnormal Temperature sensor is used to monitor motor
Cause temperature.
voltage input;
d. Speed encoder or its circuit
failure.
5
5.3.3 Checking and Testing
U, V, W Terminals
- Identify if the motor windings are normal
through measuring the resistance of U-V, V-W,
and U-W respectively, if there is short circuit
or breakage;
as shown in the following table:
Measure the resistance between pin connector
CAUTION (20#) and (24#) with a multimeter to identify if
Due to the small size of windings, when measu- the temperature sensor is normal.
ring with a multimeter, put it on a low resistance As shown in the following table:
range. Resistance
Judgment
Resistance Measurement
Judgment
Measurement With readings Normal
With readings,
Normal * Sensor short circuit
but very low 0Ω
(replace the motor)
Winding internal short circuit
0Ω Sensor open circuit
(replace the motor) ∞Ω
(replace the motor)
Winding internal open circuit
∞Ω
(replace the motor)
Speed Encoder
* The difference between the resistance values
measured at U-V, V-W and U-W shall not be Speed encoder is used to detect the speed
greater than 2%. of the motor and covert the speed into fixed
signals.

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 DRIVE SYSTEM

Checking
- Check if the motor encoder and the appear- - The vehicle is powered on, measure the
ance of cables are in good condition, and if voltage between pin connector (15#) and
the plug connection is secure. (19#) with a multimeter, normally should be
- Remove the speed encoder and check its 12V;
sensing surface for wear. - Check if the connection between 16# and 17#
is reversed. (If the two circuits are connected
Testing reversely, the controller won't report for
failure, but the travel speed of the vehicle
may slow down)
- Check the “ENCODER” readings on TESTER
Menu. Operate the truck, if the display is
always “0”: (see Section 8.8)
speed encoder failure;
motor encoder disc failure;

5.3.4 Control Circuit Troubleshooting

5 Motor Control Circuit (Figure 20210)
Check if the circuit is broken by using a multi-
meter:
- Set the multimeter to ON-OFF;
- Check if #15/#16/#17/#19 circuit (circuit
between motor encoder and controller) is
conducted;
- Check if #20/#24 circuit (circuit between
motor temperature sensor and controller) is
conducted.

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 DRIVE SYSTEM

5.4 Gearbox Seals Replacement

5.4.1 Removal and Installation - Loosen the oil drain plug (2), drain the gear
oil within the gearbox;
Removal - Unscrew the four screws (6) and remove the
The gearbox is installed under the drive mount- upper cover (20) and the O-ring (19) from box
ing base. - (1);
- Remove the drive motor (see Section 5.3.1) Unscrew the eight screws (6) and remove the
side cover (4) and the O-ring (3) from box (1);
- Unscrew the six bolts (1) on the drive mount-
ing base and remove the gearbox; Unscrew the three bolts (13) and remove the
- Unscrew the eight bolts on the steering bear- locking tab (12) and washer (11) from gear
shaft (24);
ing, remove the large steering bearing, large
ring gear and gearbox . Knock out the gear shaft (24) from box(1)
and remove the oil seal (23);
Replace the new seals : O-ring (3), O-ring (19)
and oil seal (23);
Install according to the reverse order of rem-
oval.

Installation
5
- Install according to the reverse order of rem-
oval.

CAUTION
- Before installing the new gearbox, please add
gear oil (see Section 2.2.3 for specification
and filling amount);
- Before installing gearbox, remove the proxi-
mity switch first; after the installation is
completed, then adjust the proximity switch.
(see Section 5.5)
CAUTION
- Carry out the maintenance work in a clean Check the gear oil level
environment to prevent impurities from enter-
ing into gearbox, causing gearbox damage. - Loosen the oiling port plug and observe the
oil level;
- During the installation, hydraulic oil of
the same specifications must be used for - If oil level is aligning with lower level of oiling
cleaning or lubrication. port, it indicates that the oil level is normal;
- If the oil level is below the lower level of oiling
port, it is necessary to add gear oil.

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 DRIVE SYSTEM

Add / Replace Gear Oil 5.5 Proximity Switch

- Loosen the oil drain plug, drain the gear oil
5.5.1 Removal and Installation
within the tank;
- Remount the oil drain plug, and add the gear Removal
oil of same specification with tubing through Proximity switch is installed on the drive mount-
oiling port: ing base.
gear oil specification: 80W-90 GL-5
Gear oil filling amount: 1.38 L - Pull out the AMP connector on proximity swit-
ch;
- Loosen Nut (1) and unscrew the proximity
5.4.2 Faults and Causes switch.

Fault Gearbox Abnormal Noise

1 a. Supporting bearing wear;

Cause b. Gear wear, the gap is too big;
c. Foreign objects in gear oil.
Fault Gearbox Oil Leaks
2
5 Cause Oil seal wear or aged
Fault Gearbox Stuck
a. Gear fastening screws or nuts
3 loosening;
Cause
b. Support bearing damage
c. Foreign objects in gear oil.
Installation and Commissioning
- Adjust the position of big ring gear to align
the mounting holes of proximity switch to the
convex of the big ring gear;
- Screw the proximity switch into the mounting
hole on driver's seat. Make sure that Lock
Washer (2,Figure 20211) has been mounted;

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46
 DRIVE SYSTEM

- Adjust the height of Proximity Switch (3,Figure 5.5.3 Checking and Testing
20212) to make the spacing between proxi-
mity switch end face and upper surface of big
ring gear to be between 1~2 mm; Brown
- Turn the key switch on and pull the emergen- Blue Black
cy stop switch, the system will carry out self-
test (positioning) to the position of drive
wheel;
- The truck starts properly, instrument displays
are normal, and the proximity switch is
installed properly, tighten Nut (1).

i NOTE
Installation Failure:
Steering positioning failed, drive wheel keeps
rotating with system error. - The truck adopts NO (normally open) proxi-
mity switches: When no signal is triggered,
Carry out the debugging again until the system
the output wire (44# Black Wire) is dangling,
can start normally .
that is, 44# line is not connected with positive
power supply input wire (1# Brown Wire).
- LED Indicator (1): when energized and the
5
5.5.2 Faults and Causes inductive surface is facing convex of big ring
gear, proximity switch will trigger signal, and
Drive wheel fails to position and 44# wire will be connected with 1# wire, LED
keeps rotating; will be lit.
(the controller reports for error,
Fault - Inductive Surface (2): induction of iron or
and fault information is displayed
steel objects (upper surface of big ring gear
on the handheld unit: EPS NOT
for the truck) with inductive distance of 1~2
ALIGNED)
mm.
a. Between the proximity switch
1 and the ring gear convex, there Checking
are impurities attached, such as
- Check if the proximity switch and the appear-
iron scrap;
ance of wiring harness are in good condition,
Cause b. Proximity switch with too large
and if the plug connection is secure;
inductive clearance;
c. Proximity switch failure; - Check if the inductive distance is normal, if
d. Proximity switch control circuit exceeding inductive range, please re-adjust
malfunction. (see 5.5.2).

Testing
- Start the vehicle;
- Align the inductive surface of proximity switch
(2, Figure 20213) to concave of big ring gear,
so that it does not sense. Measure if there is
24V voltage between Pin (45#) and Pin (1#)
with multimeter. If there is no voltage, check
if the circuit is connected; if there is voltage,
move on to the next step.

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 DRIVE SYSTEM

- Measure the voltage between Pin (44#) and

Pin (1#). If there is 24V voltage (or the switch
is energized under non-induction state, LED
is lit), the switch has been damaged, please
replace; if there is no voltage, move on to the
next step.
- Touch the inductive surface with an iron sheet
to make it trigger signals. If there is still no
voltage between Pin (44#) and Pin (1#), the
switch has been damaged, please replace.

5.5.4 Control Circuit Troubleshooting

Control Circuit (Figure 20214)
Check if the circuit is broken by using a multi-
meter:
- Set the multimeter to ON-OFF;

5 - Check if #1/#44/#45 circuit (circuit between

proximity switch and controller) is conducted.

Key Switch

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 DRIVE SYSTEM

5.6 Steering Motor - Switch off the truck power connections;

- Remove the lower cover; (see Section 4.2)
This truck is driven by DC steering motor to the
large ring gear, thus achieving the function of - Unplug the AMP connector on the steering
steering. motor, and remove the cables connected
between steering motor and controller;
- Unscrew the screw (1) with a wrench and
remove the pinion gear (2) from the steering
motor (5);
- Unscrew the three mounting screws (3) with
hex wrench and remove the speed encoder
(4) from the steering motor (5);
- Unscrew one copper screw (9) with a wrench
and remove the magnet (10) and copper
stopper (11);
- Unscrew the four screws (6) with a wrench
and remove the steering motor (5) from the
drive mounting base .
5.6.1 Removal and Installation
Steering Motor Carbon Brush
- Unscrew the four screws (7) and remove the
5
Removal motor end cover;
Steering motor (5, Figure 20216) is mounted on - Then the carbon brush (8) can be replaced.
the drive mounting base .

Installation
- Install according to the reverse order of rem-
oval.

CAUTION
- During installation, fasten the bottom surface
of steering motor into the groove of motor
mounting base, and then tighten the four
mounting screws.

WARNING
Due to magnetic force, the rotor and the stator
may pull each other, therefore, when disman-
tling motor rotor, do not hold your hand between
the rotor and the stator to avoid pinch hazard!

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 DRIVE SYSTEM

Adjustment Motor with abnormal noise or

Fault
- After replacing the steering motor or carbon vibration
brush, conduction test must be carried out to
a. Uneven clearance between
the motor (see Section 5.6.3). 4 stator and rotor;
- After replacing carbon brush, running opera- Cause b. Bearing failures;
tion must be carried out to the carbon brush: c. Loosening fixing screws on
By running the motor with repeated steering, motor housing.
letting the carbon brush to be fully running,
making its surface smooth to fit the rotor. Fault Motor smoking or burning smell
5 Stator winding short circuit, motor
Cause
burnt
5.6.2 Faults and Causes
Fault Excessive temperature rise
Fault Motor does not rotate a. Stator winding short circuit;
a. Negative electrode cable b. Motor positive and negative
broken; 6 electrodes with surface
b. Motor positive and negative Cause oxidation, resistance increases
electrode with loose terminals; and results in heating;
1 c. Armature winding with broken c. Bearing failure, resulting in
5 Cause
circuits;
d. Motor bearing damaged and
severe heating.

blocked;
e. Serious wearing of carbon 5.6.3 Checking and Testing
brush.
Checking
Fault Motor speed is turning slow
- Check if the motor and appearance of
a. Insufficient voltage of battery; cables are in good condition, and if the plug
b. Carbon brush worn or carbon connection is secure;
brush spring pressure - Check if the circuit is connected.
2 decreases;
Cause c. Bearing wear or lack of Testing
lubricating oil; - Carry out ON/OFF test to motor positive and
d. Armature winding has short negative electrodes with a multimeter:
circuit elements; If connected, the motor is normal;
e. Carbon brush winding grounded. If not connected:
1) Broken circuits in rotor coils (replace the
Motor sometimes can start, motor);
Fault
sometimes cannot 2) Carbon brush wearing, move on to the
a. Motor positive and negative next step.
3 electrode with loose terminals - Replace the carbon brush (See Section
and poor connection; 5.6.1).
Cause
b. Carbon brush wear and tear;
c. Armature winding has circuit CAUTION
broken unit.
When replacing the carbon brush, replace the
complete set of carbon brushes.

5.6.4 Control Circuit Troubleshooting

See Section 5.7.4 .

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 DRIVE SYSTEM

5.7 Speed Encoder

Speed encoder is used to detect the speed
of the motor and covert the speed into fixed
signals.

Speed Encoder

Copper Screw
Magnet
Copper Stopper Testing
- The vehicle is powered on, measure the volt-
age between pin connector (40#) and (43#)
5.7.1 Removal and Installation with a multimeter, normally should be 5V;
- Check if the connection between 41# and 42#
See Section 5.6.1 .
is reversed. (If the two circuits are connected
reversely, the controller will report for failure,
5.7.2 Faults and Causes and the handheld unit will display fault code:

1
Fault Motor does not rotate
83 BAD ENCODER SIGN)
- Check “ENC SPEED” readings on TESTER 5
Cause Speed encoder or its circuit failure Menu (EPS-DC0).(see Section 8.8)
On load, motor speed is turning Operate the forklift, if the display is always “0”:
Fault Speed encoder failure, replace the encoder.
2 slow
Cause Speed encoder or its circuit failure
5.7.4 Control Circuit Troubleshooting
5.7.3 Checking and Testing Control Circuit (Figure 20219)

Checking Check if the circuit is broken by using a multi-

meter:
- Check if the speed encoder and the appear-
ance of cables are in good condition, and if - Set the multimeter to ON-OFF;
the plug connection is secure; - Check if #40/#41/#42/#43 circuit (circuit
between speed encoder and controller) is
- Remove the speed encoder and check if conducted.
its sensing surface is parallel to the round
section of magnet.

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 DRIVE SYSTEM

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6. OPERATING SYSTEM

53
NOTE:

54
 OPERATING SYSTEM

6.1 Control Lever 6.2 Button Switch

Control lever is used to control the travel, lifting, Push button switch is the switch that makes
lowering, horn and emergency reverse of the the dynamic and static contacts ON or OFF to
vehicle. achieve the switching of circuits through push-
button drive mechanism. In the electrical control
Removal circuits of this truck, the push button switch is
used for manual emitting of control signals to
Control lever is mounted on control arm (5, Fig- control the vehicle lifting, lowering, horn and
ure 30301). emergency reverse.
- Unscrew four screws (1) and remove the cap
By function:
assembly (2) and the bottom cover (6);
- Lifting Button Switch
- Disconnect control lever wiring harness from - Lowering Button Switch
wiring harness; - Horn Button Switch
- Unscrew two screws (4), remove the control - Emergency Reverse Switch
lever (3).
6.2.1 Removal and Installation
Lifting/Lowering/Horn Switch
(See Figure 30302)
- Remove pin (6&18) securing switches (16) ;
- Unscrew three screws (11), remove the wire
clamps (12) and remove the lifting-lowering-
horn switch wiring harness (15).
- Install according to the reverse order of rem-
6
oval.

Lifting-Lowering Button

Lifting-Lowering Button

Installation
- Install according to the reverse order of rem-
oval.
Horn Button
CAUTION Lifting Switch
Lowering Switch
When removing or installing, please pay attent-
ion to protect the cables from being damaged.

Horn Switch

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 OPERATING SYSTEM

Lifting/Lowering Button 6.2.2 Faults and Causes

(See Figure 30302)
Operate the push button switch,
- Remove switch assembly (5 or 9) form cap Fault but the vehicle responds with no
(1); action
- Remove pin (6) securing buttons and remove 1
a. Push button switch failure;
the lifting button (2 or 7) , the lowering button Cause b. Push button switch circuit not
(3 or 8) and springs (4). conducted.
- Install according to the reverse order of rem-
Push button switch not operated,
oval.
Fault but the vehicle responds with
2 action
Horn Button
Cause Pushbutton switch failure
(See Figure 30302)
- Unscrew three screws (11) and remove bra-
cket (20) and springs (19) and horn button 6.2.3 Checking and Testing
(17).
Checking
- Install according to the reverse order of rem-
oval. - Check if the pushbutton switch and the
appearance of cables are in good condition,
and if the plug connection is secure.
Emergency Reverse Switch
(See Figure 20302) Testing

6 - Remove pin (5) securing button and remove

the emergency reverse button (1) and springs
- Check if the push button switch circuit is
connected;
(2) from bracket (4). - Carry out ON/OFF test to the push button
- Remove pin (3) and remove the emergency switch with a multimeter:
reverse switch (6).
- Install according to the reverse order of rem-
oval. Emergency Reverse
Button

Emergency Reverse
Switch

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 OPERATING SYSTEM

Lifting Switch Horn Switch

(See Figure 30304) (See Figure 30304)
- Carry out ON/OFF test to the circuit between - Carry out ON/OFF test to the circuit between
#1 and #2 with a multimeter: #1 and #4 with a multimeter:
push button switch at original position, broken push button switch at original position, broken
circuit; circuit;
press the button , the circuit is conducted. press the button , the circuit is conducted.

Lowering Switch Emergency Reverse Switch

(See Figure 30304) (See Figure 20303)
- Carry out ON/OFF test to the circuit between - Carry out ON/OFF test to the circuit between
#1 and #3 with a multimeter: #1 and #6 with a multimeter:
push button switch at original position, broken push button switch at original position, broken
circuit; circuit;
press the button , the circuit is conducted. press the button , the circuit is conducted.

6.2.4 Control Circuit Troubleshooting

Lifting Switch Control Circuit

6
(Figure 20304)
Check if the circuit is broken by using a multi-
meter:
- Set the multimeter to ON-OFF;
- Check if #1 circuit (circuit between lifting
switch and key switch) is conducted;
- Check if #2 circuit (circuit between lifting
switch and controller) is conducted.

Key Switch

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 OPERATING SYSTEM

Lowering Switch Control Circuit

(Figure 20305)
Check if the circuit is broken by using a multi-
meter:
- Set the multimeter to ON-OFF;
- Check if #1 circuit (circuit between lowering
switch and key switch) is conducted;
- Check if #3 circuit (circuit between lowering
switch and controller) is conducted.

Key Switch

6 Horn Switch Control Circuit

(Figure 20306)
Check if the circuit is broken by using a multi-
meter:
- Set the multimeter to ON-OFF;
- Check if #1 circuit (circuit between horn swit- Horn Checks
ch and key switch) is conducted; Energize the horn with a voltage of 24V:
Horn sounds, it is working properly;
- Check if #4 circuit (circuit between horn swit- Horn does not sound, it failure, needs to be
ch and horn) is conducted. replaced.

Horn

Key Switch

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 OPERATING SYSTEM

6.3 Travel Switch 6.3.2 Faults and Causes

Travel switch provides forward or backward in- Operate travel switch, the vehicle
put signals for the vehicle. Fault
cannot go forward or backward
1 a. Travel switch failure;
6.3.1 Removal and Installation Cause b. Travel switch circuit not
conducted.
Removal
Travel switch not operated, the
(See Figure 30309) Fault vehicle goes forward or backward
- Remove four screws (1), lift up cap assem- 2 automatically
bly (2);
Cause Travel switch failure;
- Remove the emergency reverse button;(See
Section 6.2.1)
- Unscrew the screw(4 & 5) and remove the 6.3.3 Checking and Testing
travel switch (9).
Checking
- Check if the appearance of travel switch and
its wiring harness are in good condition, and
if the connectors are connected securely.

Testing
- Enter TESTER Menu to check the status of

6
the switch:
"FORWARD SWITCH" / "BACKWARD SWIT-
CH", toggle the switch forward / back-ward, if
the display does not change, then it indicates
the travel switch or its circuit failure;
- Turn off the vehicle to check the travel swit-
ch and its wiring harness. (See Figure 30310)
- Energize the travel switch with a voltage of
24V and check the voltage of each port with
a multimeter;

Installation
- Install according to the reverse order of rem-
oval.

CAUTION
When removing or installing, please pay attent-
ion to protect the cables from being damaged.

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 OPERATING SYSTEM

- Place the travel switch at Middle position.

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

6 6.3.4 Control Circuit Troubleshooting

Travel Switch Control Circuit
(Figure 20307)
Check if the circuit is broken by using a multi-
meter:
- Set the multimeter to ON-OFF;
- Check if #1/#10/#11/#12/#18 circuit (circuit
between travel switch and controller) is con-
ducted.

Key Switch

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 OPERATING SYSTEM

6.4 Potentiometer Adjustment

Potentiometer provides the vehicle with steering STER 1:
input signals.
Connect the handheld unit with EPS controller.

6.4.1 Removal and Installation STER 2:

Go into "Adjustment" menu.

Removal
(See Figure 20308) STER 3:

Find "ZERO SP POT" and enter

STER 4:
Turn the handle you will find the value of
"ZERO SP POT" is changing.and put the
handle in straight way,then save the value
(usually around 2.1-2.5)
STER 5:

restart the truck,and check if the wheel is

straight when the handle is straight (zero
position).
Straight,please go to SETP 9;
Not straight,please go to SETP 6. (usually it
should be straight, SETP 6-SETP 8 is just for
special case)
6
STER 6:

Go into "Adjustment" menu

STER 7:

Find "SET STEER 0-POS." and enter

- Disconnect the connection between potentio-
meter and main wiring harness; STER 8:
- Unscrew the two screws (1) with a wrench,
Increase or decrease the value to make the
and remove the mounting plate (3) from the
zero position go right or left.Then try turn
joint holder (2);
around the handle and make it straight again
- Unscrew the two screws (5), and remove the
to make sure the wheel is correct,then save.
potentiometer (6) and the rocker (4) from the
mounting plate (3). STER 9:

Installation Turn the handle to the max position (both

side),and check if the wheel can reach the 90
- Install according to the reverse order of rem- deg in both side
oval.

CAUTION
When removing or installing, please pay attent-
ion to protect the cables from being damaged.

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 OPERATING SYSTEM

STER 10: Testing

- Enter TESTER Menu (EPSDC0) to check the
If the wheel can not match the handle max stepper motor voltage:
position,please go into "Parameter Change"
menu.
Green White
STER 11:
Red Black
Find the "1ST ANGLE COARSE","1ST
ANGLE FINE","2ND ANGLE COARSE","2ND
ANGLE FINE",1ST is for the left max position:
Increase 1 level of "1ST ANGLE COARSE"
can increase 10deg;
Increase 1 level of "1ST ANGLE FINE" can
increase 1deg (same for 2ND,right side).
Each time change the level,please turn back
the handle then turn to the max position,check
the wheel position again.
“STEPPER MOTOR”, turn the handle, if the
STER 12: voltage display is always "0", it indicates that
the potentiometer has no signal output (see
Save the parameter and key off. Section 8.8):
- mechanical loosening between potentiome-
ter and rocker;

6 6.4.2 Faults and Causes

Operate the handle, the vehicle
- potentiometer failure or its circuit not cond-
ucted.
- Check if the circuit from controller to potentio-
does not respond to the steering meter is conducted.
Fault signal;
If the circuits are conducted, but the fault still
the handheld unit displays fault
1 exists, then replace the potentiometer .
code: STEER SENSOR KO
a. Potentiometer failure;
Cause b. Potentiometer circuit not
6.4.4 Control Circuit Troubleshooting
conducted.
Potentiometer Control Circuit
(Figure 20310)
6.4.3 Checking and Testing Check if the circuit is broken by using a multi-
meter:
Checking
- Set the multimeter to ON-OFF;
- Check if the appearance of the potentiometer
- Check if #28/#29/#30/#31 circuit (circuit
and its wiring harness are in good condition,
and if the connectors are connected securely; between potentiometer and controller) is con-
ducted.
- Check if the mechanical connection between
potentiometer and rocker is secure and if
there is loosening.

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 OPERATING SYSTEM

6.5 Speed Mode Switch

Normally-closed (NC):
Terminal (1) and Terminal (3) for connection of
wiring harness connector to switch base

6.5.3 Faults and Causes

6.5.1 Removal and Installation When put down the safety gate,
Fault
but travel speed is not reduced
See Section 4.4.1 .
1 a. Speed mode switch failure;
Cause b. Speed mode switch with broken
6.5.2 Connection Mode circuit.
Speed mode switch has 3 terminals. When open the safety gate, the
Fault
The switch can be switched between open and speed is reduced
close by toggling the roller lever to achieve the 2 a. Speed mode switch failure;
control of connection and disconnection of the Cause b. Speed mode switch shorted
circuit. (short circuit).

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 OPERATING SYSTEM

6.5.4 Checking and Testing

Checking
- Check the switch for damage and check the
roller for deformation;
- Check if the handwheel is working smoothly
and if there is foreign body blockage.

Testing
- Enter TESTER Menu to check the status of
the switch; (see Section 8.8)
- Turn the key switch to "OFF", remove key.
And switch off the power supply.
- Check the ON/OFF normally-opened (NO)
terminal with a multimeter: with handwheel
at natural position, Terminal (2) and (3) not
conducted; toggle the handwheel, Terminal (2)
and (3) conducted.
- Check the ON/OFF normally closed (NC)
terminal with a multimeter: with handwheel
at natural position, Terminal (1) and (3) con-
ducted; toggle the handwheel, Terminal (1)
and (3) not conducted.
6
6.5.5 Control Circuit Troubleshooting
Speed Mode Switch Control Circuit
(Figure 20313)
Check if the circuit is broken by using a multi-
meter:
- Set the multimeter to ON-OFF;
- Check if #7/#25 circuit (circuit between switch
and controller) is conducted.

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7. HYDRAULIC SYSTEM

65
NOTE:

66
 HYDRAULIC SYSTEM

The system pressure of the entire hydraulic Hydraulic Oil

system pressure is provided by hydraulic power
unit system, which is used for lifting. While the Hydraulic oil for truck:
hydraulic power unit is equipped with a relief Specifications: Anti-wear Hydraulic Oil L-HM46.
valve to ensure that the entire system pressure * For cold storage: Low Temperature Anti-wear
is always within the safety limits that can lift the Hydraulic Oil L-HV32.
maximum load capacity.
Solenoid valve on the valve body is used for the
control of lowering. Throttle valve is used for the Hydraulic Seals
control of lowering speed. Inlet is equipped with The seals installed within the cylinder are made
a filter to prevent the impurities in the hydraulic of rigid polyurethane. The deformation during
oil from entering into the pump. assembly due to compression will not cause a
Hydraulic Schematic Diagram is as shown in permanent deformation.
Figure 20401; When assembling, pay attention to prevent the
See Section 7.8 for hydraulic symbol descripti- seals from being broken, rolled and undercut.
ons.

Assembly Instructions
7.1 Overview The tools used to install the seals must be made
of soft metal or suitable plastic, without burrs
- Lower the fork to the bottom, remove the air and sharp edges on surfaces. It is prohibited
filter on cylinder, observe the oil level with the to use the tools that can easily damage the
oil dipstick. When adding hydraulic oil, please surface of seals, such as, screwdriver or other
use hydraulic oil of the same specifications. similar tools with hard front edges.
- When the fork occasionally jitters, that may Where the hydraulic seals to be installed should
be leaks in the cylinder, or there could be be free of burrs, sharp edges and cracks. If the
leaks on the valve body. Dismantle and clean
7
installation of seals needs to cross sharp edges,
(to clean with hydraulic oil of the same spe- grooves or cuts, protective devices must be
cifications) the valve on the valve body, disch- used for protection. Before installing, lubrication
arge the foreign bodies within the valve body should be performed to the seals and the
through repeatedly lifting and lowering of the mounting positions first.
fork.
- If hydraulic oil is becoming less, please tho- CAUTION
roughly check the hydraulic system for leaks. The lubricant used during assembly must be of
- Disassembly of cylinder needs to be perfor- the same specifications with the hydraulic oil
med in a clean environment. Before removing used in the vehicle.
the cylinder, the stains on the cylinder must
be removed first. Carefully remove the piston
rod to prevent the cylinder wall from being
scratched by its end surface or damaged
part. Every time when replacing the cylinder,
also replace the cylinder seals.

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 HYDRAULIC SYSTEM

7.1.1 Hydraulic Schematic Diagram

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 HYDRAULIC SYSTEM

7.2 Pump and Motor Assembly 7.2.2 Component

7.2.1 Removal and Installation

Removal

- Remove the lower cover; (see Section 4.2)

- Remove the positive and negative electrode
cables (1) from the pump contactor and the
wires from the solenoid valve (4) (see Figure
20402);
- Unscrew the articulated joint between tub-
ing and pump and motor assembly with a
wrench, and remove the tubing (2);
- Unscrew the two bolts (3) on mounting plate
No.
1 Pump Motor
Name
7
with a wrench, and remove the pump and 2 Carbon Brush
motor assembly. 3 Pump Contactor
4 Solenoid Valve
Installation
5 Valve Body
- Install according to the reverse order of rem- 6 Gear Pump
oval.
7 Filter
8 Hoop
CAUTION
9 Tank
When removing the tubing and pump and
motor assembly, the system will lose some
hydraulic oil, please refer to Section 2.2.3 for
supplementary adding of hydraulic oil.

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 HYDRAULIC SYSTEM

7.3 Pump Motor Adjustment

7.3.1 Removal and Installation - After replacing the steering motor or carbon
brush, conduction test must be carried out to
Removal the motor (see Section 7.3.3).
- After replacing carbon brush, running opera-
tion must be carried out to the carbon brush:
By running the motor with repeated lifting,
letting the carbon brush to be fully running,
making its surface smooth to fit the rotor.

7.3.2 Faults and Causes

Fault Motor does not rotate

a. Negative electrode cable
broken;
b. Motor positive and negative
electrode with loose terminals;
- Remove the pump and motor assembly; 1 c. Armature winding with broken
Cause
- Remove the 2 long screws (1) on the motor circuits;
end cover, and remove the pump motor (2) d. Motor bearing damaged and
from the valve block (3); blocked;
- If you need to replace carbon brush (4). Re- e. Serious wearing of carbon
brush.
move motor end cover, replace the carbon
brush on the holder. Fault Motor speed is turning slow

7 CAUTION a. Insufficient voltage of battery;

b. Carbon brush worn or carbon
When replacing the carbon brush, replace the brush spring pressure
complete set of carbon brushes. 2 decreases;
Cause c. Bearing wear or lack of
Installation lubricating oil;
d. Armature winding has short
- Install according to the reverse order of rem-
circuit elements;
oval.
e. Carbon brush winding grounded.
CAUTION Motor sometimes can start,
Fault
When installing the pump motor, make sure the sometimes cannot
shaft and the coupling on motor rotor are mated a. Motor positive and negative
in place. (Rotate the motor around to make the electrode with loose terminals
3
end surface of motor be in full contact with valve and poor connection;
block). Cause
b. Carbon brush wear and tear;
c. Armature winding has circuit
WARNING broken unit.
Due to magnetic force, the rotor and the stator
may pull each other, therefore, when disman-
tling motor rotor, do not hold your hand between
the rotor and the stator to avoid pinch hazard!

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 HYDRAULIC SYSTEM

Motor with abnormal noise or Circuit between pump motor and pump
Fault contactor
vibration
a. Uneven clearance between Positive
4 stator and rotor;
Cause b. Bearing failures;
c. Loosening fixing screws on
motor housing. Negative
Fault Motor smoking or burning smell
5 Stator winding short circuit, motor
Cause
burnt
Fault Excessive temperature rise

a. Stator winding short circuit;

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

7.3.3 Checking and Testing

Checking
- Check if the pump motor and appearance of
cables are in good condition, and if the plug
connection is secure;
- Check if the circuit is connected.
7
Testing
- Remove the cables on the pump motor;
- Carry out ON/OFF test to motor positive and
negative electrodes with a multimeter:
If connected, the motor is normal;
If not connected:
1) Broken circuits in rotor coils (replace the
motor);
2) Carbon brush wearing, move on to the
next step.
- Replace the carbon brush (See Section
7.3.1).

CAUTION
When replacing the carbon brush, replace the
complete set of carbon brushes.

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7.4 Pump Contactor 7.4.2 Checking and Testing

This truck is using DC contactor with normally- Checking
open contacts. And the ON/OFF of the - Check if the pump contactor and appearance
contactors is controlled through controller, thus of cables are in good condition, and if the
to achieve the control of ON/OFF of the vehicle. plug connection is secure;
When the contactor coil (Between A and B) is
energized, the coil current will create a magnetic Testing
field, making the static stator core produce a - Switch off the power supply of the vehicle;
steady magnetic force to absorb the core and
drive the contactor actions: normally-opened - Carry out ON/OFF test to contacts of pump
contact (C and D) connected, so the circuit is contactor with a multimeter:
disconnected. If connected, but with contactor adhesion,
replace the contactor;
When the contactor coil is powered off, the If not connected, move on to the next step;
magnetic force disappears, the pressure plate
is released along with the release of spring,
and the contact recovers: normally-opened con-
tact (C and D) disconnected, so the circuit is
disconnected.

7 - Measure the resistance between pump

contactor coil end point A and B to identify if
the coil is normal;
7.4.1 Faults and Causes As shown in the following table:

Fault Contact adhesion or slow release Resistance

Judgment
Measurement
a. Contact fusion welding; Approx. 22 Ω Normal
b. Contact spring pressure is too
1 low; Coil shorting
Cause 0Ω
c. Mechanical moving parts (replace the contactor)
blocked, shaft rusted or crooked; Coil breaking
d. Anti-force spring damaged. ∞Ω
(replace the contactor)
Contact not absorbed or not fully If the coil is normal, move on to the next step.
Fault
absorbed
a. Insufficient voltage of battery;
2 b. Main contactor coil open circuit;
Cause c. Mechanical moving parts
blocked, shaft rusted or crooked;
d. Control contact poor contact.

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- Energize the contactor coil between end point

A and B (24V):
If the contact is not absorbed (without the
sound of absorption), the contactor is having
mechanical failure with its contact, replace
the contactor;
If the contact is absorbed (with the sound
of absorption), and contact C and D are
conducted, then the contactor is working pro-
perly.

7.4.3 Control Circuit Troubleshooting

Pump Contactor Control Circuit
(Figure 20406)
Check if the circuit is broken by using a multi-
meter:
- Set the multimeter to ON-OFF;
- Check if #21/#22 circuit (circuit between
pump contactor and controller) is conducted.

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7.5 Solenoid Valve Fault Internal leakage

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

Spool
7.5.2 Checking and Testing
Checking
Electromagnetic Coil - Check the solenoid valve connector for loos-
ening or poor connection of leads.

7.5.1 Faults and Causes Testing

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

7 b. Insufficient power supply

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

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- Remove the solenoid valve, take out the

spool and spool sleeve, clean with CCI4 to
enhance the flexibility of the moving of spool
within the spool sleeve. During disassembly,
pay attention to the sequence of assembly
and position of external wiring for correct re-
assembly and wiring, also check the oil mist
spray orifice for blockage and if the lubricant
is sufficient.

CAUTION
If the solenoid valve is found with the above
mechanical failures, it is recommended to re-
place the solenoid valve directly.

7.5.3 Control Circuit Troubleshooting

Solenoid Valve Control Circuit
(Figure 20407)
Check if the circuit is broken by using a multi-
meter:
- Set the multimeter to ON-OFF;
- Check if #22/#23 circuit (circuit between
solenoid valve and controller) is conducted.

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7.6 Reach Cylinder - Upon removal, the damage to cylinder

threads, oil port threads, cylinder cap threads,
7.6.1 Cylinder Removal Precautions piston rod surface and inner cylinder wall
should be prevented.
- Before removing the cylinder, be sure to reli-
eve the hydraulic circuit first, which is to lower In order to prevent piston rod from bending or
the lifting mast to the bottom. Otherwise, deformation, support it wooden block when
when removing the tubing connected with the placing.
cylinder, the pressured hydraulic oil within When removing seals, the use of sharp
the circuit may be sprayed out at high speed tools should be avoided, so as not to stab
along with the tubing, and there is risk of the seals. For the seals that are difficult to
causing personal injury. remove, soak them with boiled water, remove
Turn off the power source, so that the entire them when getting softened.
hydraulic system will stop functioning, then - Before removing, try to create conditions
the connecting tubing can be loosened; in
to prevent the cylinder parts from being
order to avoid the residual pressure within the
contaminated by the surrounding dust and
circuit, the tubing joint should be loosened
impurities. For example, try to disassemble
slowly, loosen the joint by half and shake the
the equipment in a clean environment; after
tubing to see if there is overflow of pressured
the disassembly, all parts should be covered
oil, and then go on with the removal;
with plastic, do not cover with cotton cloth or
- Cylinder is the powered actuator in hydraulic other cloth used during operation;
system. Therefore, before removing the - For the cylinder which is found with internal
cylinder from the equipment, the connection or external leakage during use, if the piston
part must be supported with appropriate rod or cylinder tube is not scratched, such
supporting to avoid personal injury or damage case may be due to wear or aged seals.
to the equipment;
- Cylinder is the powered actuator in hydraulic CAUTION
system. Therefore, before removing the
7 cylinder from the equipment, the connection
part must be supported with appropriate
When the seals need to be replaced, replace
with the complete set of seals in the cylinder
supporting to avoid personal injury or damage repair kit.
to the equipment;
- Pay special attention to the cylinder tube,
- Upon disassembly of the cylinder, you should piston rod and other moving parts for bumps
know the main structure of the cylinder to and scratches. If only minor damage, sand
avoid sightless removal. Due to the different the edge point around the damaged part with
size, structure, purpose of use of the fine stone and then polish the part smooth
cylinders, the sequences and methods used with metallographic sandpaper.
for removal are also different;
- When removing each part, do not hammer
forcefully, it such case cannot be avoided,
please lay a copper rod to avoid damage
to the parts; special tools must be used for
the parts having such requirements, do not
hammer forcefully or pry. Fine pitch threaded
cylinder cap, after being shaken loose,
loosen it with cylinder wrench with even force,
copper rod can be used to hammer the part
that cannot easily deform, do avoid violent
shocks.

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CAUTION
Cylinder Cap
- O-ring is quite flexible and easy to install,
but it must not be pulled up to the extent of
permanent deformation, nor scroll it while
installing;
Cylinder Wrenches - Y-ring or X-ring needs to be identified if it is
for shaft or hole to avoid misplacement;
- The removed O-rings and dust rings should
be replaced with new ones.
Piston Rod
- Cylinder parts must not be arbitrarily repla-
ced, the original products provided by the
manufacturer should be used;
- After maintenance and assembly of the cylin-
Cylinder Tube der is completed, pressure leak testing must
be carried out before it can be put operation
once again.
Before the testing, discharge the air within
the cylinder, run the cylinder in a small range
of movement for several times, and pay
attention if it is moving without blocking and if
there is uneven resistance during the moving.
Upon the pressure testing, raise the pressure
7.6.2 Cylinder Installation Precautions slowly and observe carefully for leaks.
- All parts should be cleaned up before asse-
mbly, then to be assembled after being
dried;(during assembly, apply appropriate
amount of hydraulic oil for lubrication)
7
- The tools used to install the seals must
be made of soft metal or suitable plastic,
without burrs and sharp edges on surfaces.
It is prohibited to use the tools that can
easily damage the surface of seals, such as,
screwdriver or other similar tools with hard
front edges.
Where the hydraulic seals to be installed
should be free of burrs, sharp edges and
cracks. If the installation of seals needs to
cross sharp edges, grooves or cuts, protective
devices must be used for protection. Before
installing, lubrication should be performed to
the seals and the mounting positions first with
hydraulic oil.

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7.6.3 Removal and Installation

- Lower the forks completely down, press the
emergency stop switch and turn off the key
switch;
- Remove pump and motor assembly;
(see Section 7.2.1)
- Unscrew the joint (5) , washer (4) and the
tubing (6) from the cylinder;

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- During the installation, hydraulic oil of

CAUTION the same specifications must be used for
Hydraulic oil may damage truck parts and cont- cleaning or lubrication.
aminate the environment. When removing joints - Secure the cylinder to hose clamp and gently
or tubings, place a clean container under it for clamp the cylinder bottom;
discharge of hydraulic oil.
- Unscrew the cylinder cap (3, Figure 20409)
- Unscrew the bolt (11); with cylinder wrench;
- Unscrew the screw (15) and knock out the - Remove the dust ring (1) and O-ring (2) from
pin shaft (16); the cylinder cap;
- Remove the wiring harness, cables and - Pull out the piston rod (5) from the cylinder
copper strips on the controller. And remove tube (8);
the electrical mounting plate from chassis; - Remove the support ring (6) and seal (7)
- Unscrew the joint (5) , washer (4) and the from the piston rod;
tubing (6) from the cylinder; - Clean with hydraulic oil of the same specifica-
- Unscrew the bolt (11); tions;
- Unscrew the screw (15) and knock out the - Replace the problem parts and assembly in
pin shaft (16); reverse steps.

CAUTION CAUTION
Before going on with the next step, please fix If the piston rode or cylinder tube is damaged,
the cylinder properly first. Be sure to avoid the please replace the entire cylinder.
falling of cylinder during removal, resulting in If the seals are aged or damaged, please
personal injury. replace the complete set of seals.
- Lift up the front frame (13) and remove the
right cylinder (8);
- Install the cylinder according to the reverse
order of removal ; 7
- Add hydraulic oil of the same specifications
into the tank, see Section 2.2.3;
- Pull out emergency stop switch and turn on
the key switch;
- Repeat Lift - Lower cylinder to discharge the
air within the tubings and cylinder;
- Check the hydraulic oil level and make sure
that the liquid is at standard level.

Cylinder Maintenance

CAUTION
- Use suitable hose clamps to avoid cylinder
deformation caused by severely tight hose
clamp.
- Carry out the maintenance work in a clean
environment to prevent impurities from
entering into cylinder, causing cylinder
damage.

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7.7 Hydraulic Troubleshooting

Fault Symptom Failure Causes Troubleshooting Measures

a. Insufficient oil; 1. Check the hydraulic oil level.

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

1. Check the amount of oil;

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

1. Discharge and clean, and add

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

a. Insufficient oil; 1. Check the hydraulic oil level;

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

a. Pressure adjustment screw too 1. Adjust to proper pressure

loose; through hydraulic pressure
Relief valve pressure b. Relief valve spring breakage or gauge.
6
unstable or too low deformation; 2. Replace the relief valve.
c. Relief valve spool wear or 3. Clean or replace the relief
blocked. valve.

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7.8 Hydraulic Symbol

Symbol Description Symbol Description

Tank
Pipe end below liquid
Explosion-proof valve
level

Tank
Pipe end above liquid
Check valve
level

Cylinder
Filter Single-acting direction

Service line
(Supply line or return
Relief valve
line)

Control line Throttle valve

(Drain line) With pressure
compensation device
7
Solenoid Valve
Connecting pipe Two-way two-pass

Port
(Test port)

Motor

Hydraulic pump

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8. ELECTRICAL SYSTEM

83
NOTE:

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8.1 Controller 8.1.1 Removal and Installation

Controller Functions Removal

Electrical control of this truck is mainly driven by - Remove the cover; (see Section 4.2)
traction controller and steering controller. - Remove the wiring harness, cables and copp-
- Controller: er strips on the controller;
traction controller: mainly used for the control - Unscrew the four screws (2) with a wrench
of drive motor and remove the traction controller (1);
Steering controller: mainly used for the control - Unscrew the four screws (4) with a wrench
of steering motor and remove the steering controller (3).
- Other:
Button switches, drive speed sensor, steering
speed sensor, interlock switch, limit switch,
potentiometer, speed mode switch, etc.

Fuse 1

Steering
Controller

Fuse 2

Main
Contactor

Traction
Controller
8

Installation
- Apply appropriate amount of thermal grease
on the back of controller;
- Place the controller onto the electrical mount-
ing plate, tighten the four screws with a
wrench;
- Plug the wiring harness and cables into cor-
responding ports.

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8.1.2 Controller Interface Function

Traction Controller (AC0)

A Interface
Pin No. Signal Name Description
A#1 NMC Negative of main contactor coil.
A#2 PMC Positive of main contactor coil .
Output for driving the electromechanical brake coil;
A#3 NEB
drives the load to -Batt. Maximum current: 3 A.
A#4 NPC Negative of pump contactor coil.
Positive of pump contactor coil and lowering
A#5 PPC/PEV
electrovalve coil.

8 A#6
A#7
NEV
CAN LOW
Negative of the lowering electrovalve coil.
Low level CAN-BUS voltage I/O.
A#8 -BATT -Batt.
A#9 ENC + Encoder Positive Supply (+5 or +12 Vdc).
A#10 ENC - Encoder Negative Supply (GND to minus battery).
A#11 HM (+B) Output for driving an hourmeter.
A#12 -BATT -Batt.
A#13 MOT TH Motor thermal sensor input.
A#14 SR2 Speed reduction 2 input. Active low (switch opened).
A#15 SR1 Speed reduction 1 input. Active low (switch opened).
A#16 +12V This output provides a +12 V signal for thr MDI PRC.
A#17 CAN HIGH High level CAN-BUS voltage I/O.

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A Interface - Continued
Pin No. Signal Name Description
A#18 CPOTB Brake potentiometer wiper.
A#19 ENC A Encoder Channel A.
A#20 ENC B Encoder Channel B.

B Interface
Pin No. Signal Name Description
B#1 KEY SW Connected to key switch, needs to connect a 6.3-10A fuse.
B#2 CM Public ports, providing start voltage.
Tiller request input. Must be connected to the tiller
B#3 TILLER SW
microswitch, active high.
B#4 H&S SW Hard & Soft request input.

B#5 BACKWARD SW Backward direction request input; it is active high.

B#6 FORWARD SW Forward direction request input; it is active high.

B#7 BELLY SW Quick inversion function input; it is active high.
B#8 LOWERING SW Lowering request input, active high.
B#9 LIFTING SW Lifting request input, active high.
B#10 CPOT Accelerator potentiometer wiper.
B#11 NPOT Negative of accelerator unit.
B#12 PPOT Potentiometer positive.

8
C Interface (handheld unit communication interface)
Pin No. Signal Name Description
C#1 PCLRXD Positive serial reception.
C#2 NCLRXD Negative serial reception.
C#3 PCLTXD Positive serial transmission.
C#4 NCLTXD Negative serial transmission.
C#5 GND Negative console power supply.
C#6 +12V Positive console power supply.
It must be connected to C8 for the Flash memory
C#7 FLASH
programming.
It must be connected to C7 for the Flash memory
C#8 FLASH
programming.

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Steering Controller (EPS-DC0)

A Interface
Pin No. Signal Name Description
A#1 DRIVE SWITCH Traction Travel Demand Input.
A#2 SW1 1st Toggle Switch.
A#3 SW2 2st Toggle Switch.
A#4 NK1 Safety Switch Lower Voltage Point.
A#5 K1 Safety Switch Higher Voltage Point.
Can Bus Low.
A#6 CANL
Connected to traction controller.
A#7 KEY Key Switch Signal Input Port.
A#8 CPOC2 / QL Stepper Motor Q line.

8 A#9
A#10
CPOC1 / DL
NPOC
Stepper Motor D line.
Twin SP POT Negative Supply (GND).
A#11 GND GND. Encoder Negative Supply
A#12 GND GND. SW1 & SW2 Negative.
A#13 GND GND. Motor Thermal Sensor Negative.
Can Bus High.
A#14 CANH
Connected to traction controller.

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B Interface
Pin No. Signal Name Description
B#1 NPOT FB POT Negative Supply.
B#2 PPOT FB POT Positive Supply.
B#3 THMOT Motor Thermal Sensor (KTY84-130) Input.
B#4 +5VDC Encoder Positive Supply.
B#5 CPOT Twin SP POT Positive Supply (5 Vdc).
B#6 CPOT FB POT Wiper.
B#7 CHB phase B of encoder.
B#8 CHA phase A of encoder.

C Interface (handheld unit communication interface)

Pin No. Signal Name Description
C#1 PCLRXD Positive serial reception.
C#2 NCLRXD Negative serial reception.
C#3 PCLTXD Positive serial transmission.
C#4 NCLTXD Negative serial transmission.
C#5 GND Negative console power supply.
C#6 +12V Positive console power supply.
It must be connected to C8 for the Flash memory
C#7 FLASH
programming.
It must be connected to C7 for the Flash memory
C#8 FLASH
programming.

Terminal stud 8
Pin No. Signal Name Description
- -B Negative of the battery.
- +B Positive of the battery.
Connection bars of the three motor phases; follow this
- FU, FV, FW
sequence and the indication on the motor.

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8.2 Fuse
The entire vehicle is installed with three fuses
altogether. When there is fuse failure, the truck
may not be able to run properly due to that.
Status
Function
Fuse 1 Fuse 2 Fuse 3
Fuse 1 200A × Ο Ο
Fuse 2 200A Ο × Ο
Fuse 3 10A Ο Ο ×
1 Drive × × ×
2 Lifting / Lowering × × ×
3 Steering × × ×
4 Traction Controller × × ×
5 Charge Gauge × × ×
6 Horn Ο Ο ×
7 Fan Ο Ο ×
× : Failure
8.2.1 Location of Fuses Ο : Normal

Fuse 1-2: installed on electrical mounting plate

Fuse 3: installed on main harness
★ Fuse position in electrical schematic diagram
Accelerator

8 POTLOW
CMD
FWD
REV
FUSE 3 10A

FUSE 2 200A CMD

FWD
REV
FUSE 1 200A

MOTOR

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8.2.2 Checking and Testing

Checking
- Check the fuses for damage, check the
connectors at terminal lugs for loosening or
poor connection of leads.

Testing
- Turn the key switch to "OFF", remove key;
pull out the battery plug and disconnect the
power supply.
- Set the multimeter to resistance measure-
ment: with black probe (-) connected to one
end of the fuse; red probe (+) connected to
another end of the fuse.
- Identify if the fuse is normal according to the
readings of resistance on the multimeter.
As shown in the following table:

Resistance
Judgment
Measurement
0Ω Normal
Failure
∞Ω
(replace the fuse)

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8.3 Main Contactor

This truck is using main contactor with norm-

ally-opened contacts. And the ON/OFF of the
contactors is controlled through controller, thus
to achieve the control of ON/OFF of the vehicle.
When the contactor coil is energized, the coil
current will create a magnetic field, making the - After the replacement, re-install in reverse
static stator core produce a steady magnetic order and tighten the two fastening screws
force to absorb the core and drive the contactor (4);
actions: normally-opened contact connected, so
- Following the reverse order of step 1, fast-
the circuit is disconnected.
en the main contactor onto the electrical
When the contactor coil is powered off, the mounting plate, and re-connect it according
magnetic force disappears, the pressure plate to the original connection methods.
is released along with the release of spring, and
the contact recovers: normally-opened contact
disconnected, so the circuit is disconnected.
8.3.2 Faults and Causes

8 8.3.1 Removal and Installation Fault Contact adhesion or slow release

Main contactor is installed on the electrical
a. Contact fusion welding;
mounting plate.
1 b. Contact spring pressure is too
- Remove the cables and wiring harness on low;
the main contactor, and remove the main Cause
c. Mechanical moving parts
contactor from the electrical mounting plate; blocked, shaft rusted or crooked;
- Unscrew the two fastening screws (4) with a d. Anti-force spring damaged.
Phillips screwdriver and remove the top cover Contact not absorbed or not fully
of contactor (3); Fault
absorbed
- Remove the auxiliary contact assembly
(2), replace the assembly or coil (6); (when a. Insufficient voltage of battery;
2 b. Main contactor coil open circuit;
replacing the contacts, replace in pairs)
Cause c. Mechanical moving parts
blocked, shaft rusted or crooked;
d. Control contact poor contact.

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8.3.3 Checking and Testing

Visual Inspection
- Check the surface and appearance of contac-
tor;
- Visually check the surface of contactor for
scratches, damages and stains;
- If any of the above case is found, please
replace with new contactor.

Coil Checks
- Disconnect the cables on the contactor;
- Check the resistance of the coil with a multi-
meter: measurement method is as shown in Contact Checks
Figure 20508; - Check if the surface of contact surface is
- Identify if the contactor is normal according to smooth and symmetrical;
the readings of resistance on the multimeter. - Separately provide the contact with a voltage
As shown in the following table: of 24V to observe if the contact can absorb;
Resistance - If the surface is uneven or the contact does
Judgment not absorb, replace the main contactor.
Measurement
Approx. 30 Ω Normal
Coil shorting
0Ω
(replace the contactor) 8.3.4 Control Circuit Troubleshooting
Coil breaking
∞Ω Main Contactor Control Circuit
(replace the contactor)
(Figure 20509)
Check if the circuit is broken by using a multi-
meter:

8
- Set the multimeter to ON-OFF;
- Check if #13/#14 circuit (circuit between main
contactor and controller) is conducted.

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8.4 Lifting Limit Switch Lifting limit switch pressed, lifting

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

8.4.3 Checking and Testing

Checking
- Check if the appearance of limit switch and
its wiring harness are in good condition, and
if the connectors are connected securely;
- Repeatedly press the limit switch to check if it
See Section 3.1 for mounting position of lifting can reset properly.
limit switch.
Testing
- Enter the TESTER Menu to check the status
8.4.1 Connection Mode of switches;(see Section 8.8)
Speed mode switch has 3 terminals. - Turn the key switch to "OFF", remove key.
The switch can be switched between open and Pull out the battery plug and disconnect the
close by toggling the roller lever to achieve the power supply;
control of connection and disconnection of the - Check the ON/OFF normally-open (NO)
circuit. terminal with a multimeter:
with handwheel at natural position, Terminal
(2) and (3) not conducted;
Press the handwheel, Terminal (2) and (3)
conducted.
- Check the ON/OFF normally closed (NC)
terminal with a multimeter: with handwheel

8 at natural position, Terminal (1) and (3)

conducted;
Press the handwheel, Terminal (1) and (3)
not conducted.

Normally-opened (NO):
Terminal (2) and Terminal (3) for connection of 8.4.4 Control Circuit Troubleshooting
wiring harness connector to switch base Lifting Limit Switch Control Circuit
(Figure 20512)
8.4.2 Faults and Causes Check if the circuit is broken by using a multi-
meter:
Fault Lifting mechanism cannot lift - Set the multimeter to ON-OFF;
1 a. Lifting limit switch failure; - Check if #5/#25 circuit (circuit between lifting
Cause b. Lifting limit switch with broken limit switch and controller) is conducted.
circuit.

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8.5 Key Switch 8.5.2 Faults and Causes

Key switch is used to START / STOP the truck. Turn the key switch to “ON”, the
Fault
vehicle won’t start
1
8.5.1 Removal and Installation a. Key switch failure;
Cause
b. Key switch circuit not conducted.
Removal
Turn the key switch to “OFF”, the
- Remove the bottom cover ;(See Sention 6.1) Fault
vehicle won’t stop
2
a. Key switch failure;
Cause
b. Key switch shorted (short circuit)

8.5.3 Checking and Testing

Checking
- Check if the appearance of key switch its
wiring harness are in good condition, and if
the connectors are connected securely.

Testing
- Check if the key switch circuit is conducted;
- Disconnect the key switch connector from - Carry out ON/OFF test to the key switch with
main wiring harness; a multimeter:
- Unscrew the nut and remove the key switch key switch at “OFF” position, open circuit;
place the key switch at “ON” position, the
from the mounting plate.
circuit is conducted.

Installation 8.5.4 Control Circuit Troubleshooting

- Install according to the reverse order of rem- Key Switch Control Circuit
oval.
(Figure 20514)

8 Check if the circuit is broken by using a multi-

meter:
- Set the multimeter to ON-OFF;
- Check if #0/#1 circuit is conducted.

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8.6 Charge Gauge 8.6.3 Checking and Testing

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

Charge gauge
with timer

Needle

M: for lead-acid battery

- Disconnect the charge gauge connector from Q: for maintenance-free battery
main wiring harness;
- Unscrew the nut and remove the charge gau-
ge from the mounting plate.

Installation 8.6.4 Control Circuit Troubleshooting

8
- Install according to the reverse order of rem- Charge Gauge Control Circuit
oval. (See Electrical Schematic Diagrams )
Check if the circuit is broken by using a multi-
meter:
8.6.2 Faults and Causes - Set the multimeter to ON-OFF;
- Check if #1/#8/#18 circuit is conducted.
Fault No display on the charge gauge
1 a. Charge gauge failure;
Cause b. Charge gauge circuit not
conducted.
Power capacity display not
Fault
accurate
2
a. Charge gauge wrong gear;
Cause
b. Charge gauge failure.

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8.7 Interlock Switch Interlock switch pressed, the

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

8.7.3 Checking and Testing

Checking
- Check if the appearance of interlock switch
and its wiring harness are in good condition,
and if the connectors are connected securely;
- Repeatedly press the interlock switch to che-
ck if it can reset properly.
- Normally-opened (NO):
Terminal (1) and Terminal (4) for connection
of wiring harness connector.
- Loosen the rotation cover; (see Section 4.2) (see Figure 20517)
- Disconnect the connection between interlock Testing
switch and main wiring harness; - Enter TESTER Menu to check the status of
- Unscrew the two screws (1) and nuts (2) with the switch; (see Section 8.8)
a wrench, and remove the mounting plate (3) - Check if the interlock switch circuit is condu-
from the joint holder (4); cted;
- Remove the interlock switch (5) from the
- Carry out ON/OFF test to interlock switch
mounting plate (3). with a multimeter:
Reset the interlock switch (original position),
Installation the circuit is disconnected;
Press the interlock switch, the circuit is con-
- Install according to the reverse order of rem-
ducted.
oval.
8.7.4 Control Circuit Troubleshooting
8 8.7.2 Faults and Causes Interlock Switch Control Circuit
(Figure 20517)
Interlock switch not pressed, the
Fault Check if the circuit is broken by using a multi-
vehicle can still travel
meter:
1 a. Interlock switch failure; - Set the multimeter to ON-OFF;
Cause b. Interlock switch shorted
(short circuit). - Check if #25/#8 circuit (circuit between inter-
lock switch and controller) is conducted.

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8.8 Handheld Unit (Optional) 8.8.2 Handheld Unit Menu Options

Handheld unit must be used together with con-
troller, if necessary, it can be purchased from 启动
Start
our company or dealer.

*CONSAFGZP100*
RS232CONSOLE
CAN CONSOLE
Display AUTOSCANCAN
CONSOLEUTILITIES
MENUCONSOLE

09：10
Power button
Navigation Parameter OK
button adjustment
button CANCONSOLE
EXIT Enter/OK SELECTNODE2
SELECTSUBNODE0
SELECT   BAUDRATE   125Kb

PRESSOKTOSTART
(PRESSF3FORAUTOSCAN)
Figure 80513
SELECT NODE :
2 = Traction Controller
8.8.1 Handheld Unit Connection 6 = Steering Controller
OK
- Remove rear hood; SELECT BAUDRATE : 125Kb
- Plug the handheld unit communication
cable into the handheld unit communication
interface of the controller; (see Section 8.1)
(Transmission speed must be
set to 125Kb) 8
- Turn on the key switch, pull out emergency
stop switch, the display of handheld unit will
be flashing: ADXT2SSEP0.16
if the connection is successful: the handheld
unit display will be flashing; **V**A**h
if failed: the display will have no display (check
if the circuit connection is normal). SMARTDRIVERKO

OK

Next Page

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Previous Page

OK

*MAINMENU*
PARAMETER CHANGE
TESTER
ALAARMS
PROGRAMVACC
SAVEPARAMETERS
RESTOREPARAMETERS
SETMODEL

- With Navigator keys (Figure 80513), you can

carry out menu switching;
- “OK”, select ENTER the menu.

PARAMETER CHANGE : parameter change

TESTER : vehicle running test
ALARMS : error alrms
PROGRAM VACC : accelerator match
SAVE PARAMETERS : read parameter
RESTORE PARAMETERS : write parameter
SET MODEL : set node
SET OPTIONS : set options
ADJUSTMENTS : parameter match
SPECIAL ADJUSTMENTS: special parameter
match
HARDWARE SETTING : hardware setting

* See “Handheld Unit Operation Manual” for

detailed operations
8

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8.8.3 TESTER Menu

The parameters in TESTER Menu are real-
time presentation of the running status of the
equipment.
Traction Controller (AC0)

Parameters Description Remark

BATTERY VOLTAGE Check the voltage of storage battery Display the current voltage ( V )
LIFT STOP - -
STEER ANGLE Check the drive wheel angle Display the current angle ( ° )
Check the status of emergency reverse If the function is triggered properly,
QUICK INVERSION
switch the value will change
Check the status of 2-stage speed reduction If the function is triggered properly,
CUTBACK SWITCH 2
switch the value will change
Check the status of 1-stage speed reduction If the function is triggered properly,
CUTBACK SWITCH
switch the value will change
If the function is triggered properly,
HANDLE/SEAT SW. Check the status of interlock switch
the value will change
If the function is triggered properly,
BACKWARD SWITCH Check the backward status of travel switch
the value will change
If the function is triggered properly,
FORWARD SWITCH Check the forward status of travel switch
the value will change
If the function is triggered properly,
DESCENT SWITCH Check the status of lowering switch
the value will change
If the function is triggered properly,
LIFTING SWITCH Check the status of lifting switch
the value will change
ACCELERATOR Check the output voltage of travel switch Display the current voltage ( V )
MOTOR TEMPERAT Check motor temperature Display the current temperature ( ℃ ) 8
TEMPERAT URE Check the temperature of controller Display the current temperature ( ℃ )
BATTERY CHARGE Check the remaining capacity of battery Display the current capacity ( % )
BATTERY CURRENT Check the current of battery Display the current value ( A )
CURRENT RMS Check the motor current Display the current value ( A )
Check the difference between output
SLIP VALUE frequency of controller and the measured Display the current difference( Hz )
frequency
ENCODER Check the motor speed Display the current difference( Hz )
FREQUENCY Check the output frequency of controller Display the current frequency( Hz )
VOLTAGE BOOSTER - -
MOTOR VOLTAGE Check the motor voltage Display the current voltage ( V )

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Steering Controller (EPS-DC0)

Parameters Description Remark

STEPPER MOTOR Check the voltage of stepper motor Display the current voltage ( V )
READ FBPT AT SW1 - -
SET POINT POT. - -
TRUCK SPEED - -
SLOPE PEAK - -
HZGH RESOL. AD - -
TRUCK MOVING - -
SM ALARM SWITCH - -
MM ALARM SWITCH - -
AUTO IN PROGRESS - -
ACW LIMIT LEVEL - -
CW LIMIT LEVEL - -
ENDSTROKE ACW - -
ENDSTROKE CW - -
ENC SPEED Check the speed of steering motor Display the current frequency( Hz )
MOTOR CURRENT Check the current of steering motor Display the current value ( A )
MOTOR VOLTAGE Check the voltage of steering motor Display the current voltage ( V )
FREQUENCY Check the output frequency of controller Display the current frequency( Hz )
MOTOR TEMPERAT Check the temperature of steering motor Display the current temperature ( ℃ )
TEMPERATURE Check the temperature of controller Display the current temperature ( ℃ )
FEEDBACK ENC. - -

8 FEEDBACK POT. - -

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8.9 Controller Error Message code (see Chapter 9 - Troubleshooting); while

the when the components failures which may
Electrical faults are mainly caused by electrical affect the ON/OFF of control circuit occur to
components failure or electrical circuit failure. the electrical circuit, the controller will alarm for
Wherein, when some components failures error, and fault information will be displayed on
which may not affect the ON/OFF of control the instrument.
circuit occur, the instrument won't display fault

8.9.1 Traction Controller

Error Message
Possible cause Fault elimination
Error Error text

It occurs when the embedded

Check the continuity of
WATCH DOG protection is not able
UVW. If the alarm occurs
either to cut off the power stage
8 WATCHDOG permanently, it is necessary
when not triggered or it is not able
to replace the controller.
to activate the power stage when
triggered.

It occurs due to a HW or SW defect Try to execute a CLEAR

of the non-volatile embedded EEPROM operation,if the
13 EEPROM KO
memory supporting the controller alarm still there,please
regulations. replace the controller.

It is probably a power failure or a It is necessary to replace

17 LOGIC FAILURE #3
logic failure the controller.

It occurs when the circuit, to

It is necessary to replace
18 LOGIC FAILURE #2 compensate for the dead times of
the controller.
the sine waves, is failed.

Check the battery voltage, if

it is too low, please charge

19 LOGIC FAILURE #1
This alarm signals that an over-
voltage / undervoltage protection
the battery. Check the all
connection of the B+ and
B-,the short time disconnect
8
operation has occurred.
will cause the alarm,if the
alarm always there,please
replace the controller.

Before to switch the main contactor

Check the connection of
on, the SW turns on sequence
phase UVW from controller
the Top side Power Mosfets and
to motor,check UVW is not
30 V M N LOW expects the phase V voltage
short to B- ,if the connection
increases toward the rail capacitor
is ok,please replace the
value. If the phase V does not
controller
increases this alarm occurs.

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Error Message
Possible cause Fault elimination
Error Error text

Before to switch the main contactor Check the connection of

on, the SW turns on sequence the phase UVW from controller
Bottom side Power Mosfets and to motor,check UVW is not
31 V M N HIGH
expects the phase V voltage falls to short to B+,if the connection
GND value. If the phase V remains is ok,please replace the
high level this alarm occurs. controller

The controller checks if the MC

contact is closed when the coil It is suggested to check
isn’t driven, trying to discharge the contactor contact, if it
37 CONTACTOR CLOSED
the capacitor bank. If they don’t is mechanically stuck or
discharge, the fault condition is pasted.
entered.

Two possible reasons:

the wires to the coil are
The main contactor coil has been
interrupted or not well
38 CONTACTOR OPEN driven by the logic board, but the
connected or the contact of
contactor does not close.
the contactor is not properly
working.

This test is carried out when the The problem could be in

motor is running, and it verifies that the current sensor or in
49 I=0 EVER
the current feedback sensor is not the related circuit.please
constantly stuck to 0. replace the controller.

This diagnosis is executed only

when the main contactor is opened
and asked to be closed (e.g. at key
on or when the main contactor is
If the alarm occurs perman-
opened and a new motion request
53 STBY I HIGH ently, it is necessary to
turns active). Then the outputs of
8 the Current amplifiers must be in
a narrow window close to 2.5 Vdc
replace the controller.

(from 2.26 V to 2.74 V). Otherwise

this STBY I HIGH alarm occurs.

In working condition, a resistance

1: At least a motor phase
connected between the key and
is not connected to the
the Rail Capacitors, keeps the Rail
controller or broken.
Capacitors charged before the Main
2: A Power failure or a
60 CAPACITOR CHARGE Contactor closes. When the voltage
Logic Failure occurred in
on the Rail Capacitors (measured
the controller.In this case it
on the phase V) is low and does not
is necessary to replace the
increase when the main contactor
controller.
is opened this alarm occurs.

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Error Message
Possible cause Fault elimination
Error Error text

Higher than 78 °C. Then the

maximum current decreases
proportionally with the temperature Improve the air cooling of
61 HIGH TEMPERATURE
increases from 78 °C up to 100 °C. the controller.
At 100 °C the current is limited to 0
Amps.

Check the temperature

It occurs when the temperature of sensor,if it is ok,and the
65 MOTOR TEMPERAT. the motor winding overtakes the motor is very hot,please
MOTOR OVERTEMP setting. improve the air cooling of
the motor.

It occurs when the battery charge

is calculated being less than 10%
66 BATTERY LOW Get the battery charged.
of the full charge and the BATTERY
CHECK setting is other than 0.

It is necessary to replace
69 CURRENT SENS. KO Current sensor failure
the controller.

This alarm occurs when the voltage Probably it is necessary

on the Main Contactor is higher to replace the controller
74 DRIVER SHORTED than expected: this means that the because the driver of the
Main Contactor Coil has a high Main Contactor is short
voltage although it is not supplied. circuited.

Check the coils of the Main

This alarm occurs when the voltage Contactor (CNA#1) is not
on the Main Contactor is smaller short circuited. If it isn’t,
75 CONTACTOR DRIVER than expected: this means that
the Main Contactor Coil has a null
voltage when supplied.
probably it is necessary
to replace the controller
because the driver of the
8
Main Contactor is broken.

Check the coils of the main

This alarm occurs when there is an contactor (CNA#1), of the
overload on one of the following electromechanical brake
76 COIL SHORTED
connections: CNA#1, CNA#3, (CNA#3), of the pump
CNA#4 and CNA#6. contactor (CNA#4), of the
electric valve (CNA#6).

(CPOT) voltage higher than VACC

78 VACC NOT OK MIN +1V while the traction enable Do the program Vacc
switch is open

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Error Message
Possible cause Fault elimination
Error Error text

Enter TESTER to facilitate

the troubleshooting):
a) A travel demand active
before key on
This is just a warning for an incorr- b) The tiller switch active
79 INCORRECT START
ect starting sequence. before key-on
c) The H&S input active
before key-on
d) The Quick inversion
active before key-on

The forward sw and backward sw Check the acclerator and

80 FORW + BACK
closed together the wire.

This alarm occurs when the PLD It is necessary to replace

99 INPUT ERROR #1
device has a failure the controller.

Pump contactor is not closed when Check whether the pump

230 PUMP CONT. OPEN
it should close contactor is failed.

Check whether the pump

231 PUMP CONT.CLOSED Pump contactor closed before key.
contactor is stick.

If after done the program

vacc ,the alarm still
232 VACC OUT RANGE Try to do PROGRAM VACC.
there ,please replace the
accelerator.

Check the detail alarm

234 EPS RELE OPEN There is some alarm in the EPS.
information in EPS.

8 235 CAN BUS KO EPS

The traction can't get information
from the EPS by CAN
Check the CAN bus line
from AC0 to EPS AC0.

Use voltage meter to

When the key is turned ON, the check battery voltage,if it
controller check the battery voltage is ok,please check power
236 WRONG SET BAT.
and verifies it is within a window supply cable,if every thing
around the nominal value. is ok,please replace the
controller.

This is just a warning when a Check the statue of lift and

238 LIFT LOW. ACTIVE Lifting/Lowering request is active lower sw,it should open
before key-on. when release.

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Error Message
Possible cause Fault elimination
Error Error text

This is just a warning when Lifting Never push lift and lower sw
239 LIFT + LOWER
and Lowering sw closed together. together

First of all, check the wiring.

If it is OK, try to disconnect
one to one the module
connected to the CAN Bus
It occurs if the controller does not
and check if this alarm
248 CAN BUS KO receive any message from the CAN
disappears. When you are
Bus line.
quite sure the problem is
in the present module, it is
necessary to replace the
controller.

When the output of the thermal

sensor on the base plate is higher
It is necessary to replace
250 THERMIC SENS. KO than 4.95 V or lower than 0.1 V, the
the controller.
sensor is assumed failed and this
alarm occurs.

The controller expects to receive

Check the communication
a message from a remote module
via CAN between the
252 WAITING FOR NODE via CAN Bus. When this message
controller and the other
is not received after a time out this
modules.
alarm occurs.

Check both the electric and

Two consecutive readings of the the mechanical encoder
253 ENCODER ERROR encoder speed are too much functionality.if there is no
different in between. mechanical loosen,please
replace a new one.

This alarm occurs when the

feedforward PWM generated
Check the all connection of
8
by the controller to supply the
the B+ and B-,the short time
Electromechanical Brake and the
disconnect will cause the
254 AUX OUTPUT KO actual feedback voltage on the
alarm,if the alarm always
Electromechanical Brake are not
there,please replace the
matched in between. The diagnosis
controller.
is made only when the Tiller Switch
is active.

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8.9.2 Steering Controller (EPS-ACO)

Error Message
Possible cause Fault elimination
Error Error text
Main uC and Slave uC
communicate via a local serial
interface. This alarm occurs when It is necessary to replace
6 SERIAL ERR #1
the slave uC does not receive the the controller.
communication from the main uC
through this serial interface.

It occurs if a test to write and read

one location in EEPROM fails. The
SW expects to read the written
value. It occurs also when the
hour counter gives different values It is necessary to replace
13 EEPROM KO
between the three redundant the controller.
locations in which it is recorded. It
occurs also when the busy bit of
the EEPROM does not rise within
12 msec.

This alarm occurs in the rest state if

the output of the voltage amplifier of It is necessary to replace
16 LOGIC FAILURE #4
the phase Vw-Vv have a drift larger the controller.
than ±0.25 V.

This alarm occurs in the rest state if

the output of the voltage amplifier of It is necessary to replace
17 LOGIC FAILURE #3
the phase Vu-Vw have a drift larger the controller.
than ±0.25 V.

This alarm occurs when the real

voltage between phases W and V It is necessary to replace
18 LOGIC FAILURE #2
of the motor is different from the the controller.
8 desired.
This alarm occurs when the real
voltage between phases W and U It is necessary to replace
19 LOGIC FAILURE #1
of the motor is different from the the controller.
desired.
This alarm occurs in the initial rest
state after key on if the outputs of It is necessary to replace
32 VMN NOT OK
the motor voltage amplifiers are not the controller.
in the window from 2.2 to 2.8 Vdc.

This alarm occurs only when the

setting CAN BUS is PRESENT.
Then the eps-ac0 waits for a via Find, on the traction
CAN information that the traction controller, the reason for
48 MAIN CONT. OPEN
controller has closed the main keeping the main contactor
contactor. If this information lacks open.
more than about 1.5 secs, this
alarm occurs.

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Error Message
Possible cause Fault elimination
Error Error text
This alarm occurs two ways:
1) In the initial rest state after key
on, if the outputs of the current
amplifiers are not comprised in the It is necessary to replace
53 STBY I HIGH window 2.2 to 2.8 Vdc. the controller.
2) After the initial diagnosis this
alarm occurs when the outputs of
the current amplifiers at rest have a
drift larger than ±0.15 V.

Improve the cooling of the

This alarm occurs if the
controller; otherwise it is
61 HIGH TEMPERATURE temperature of the controller base
necessary to replace the
plate overtakes 75 degrees.
controller.

This alarm occurs only when DIAG

M O TO R T E M P i s o n a n d t h e
thermal sensor inside the motor
measures a temperature higher Check the thermal sensor in
than 150 degrees. It occurs also the motor is right working. If
65 MOTOR TEMPERAT.
when trying to acquire the motor it is, improve the cooling of
resistance with a temperature in the the motor.
motor higher than 150 degree
(still with DIAG MOTOR TEMP to
ON).

This alarm occurs if the circuit to Check the motor is suited to

limit via hardware the current in the work with the eps-ac0 (not
70 HIGH CURRENT motor is either always active at key- oversized). Otherwise it is
on or repeatedly active when the necessary to replace the
motor is turning. controller.

Check the power fuse is OK.

Check the battery positive 8
This alarm occurs when the current arrives to the controller.
in the phase V of the motor is zero Check the continuity of
71 POWER FAILURE #3
and the motor is commanded for the wire in the phase V of
moving. the motor. Otherwise it is
necessary to replace the
controller.

Check the power fuse is OK.

Check the battery positive
This alarm occurs when the current arrives to the controller.
in the phase U of the motor is zero Check the continuity of
72 POWER FAILURE #2
and the motor is commanded for the wire in the phase U of
moving. the motor. Otherwise it is
necessary to replace the
controller.

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Error Message
Possible cause Fault elimination
Error Error text
Check the power fuse is OK.
Check the battery positive
This alarm occurs when the current arrives to the controller.
in the phase W of the motor is zero Check the continuity of
73 POWER FAILURE #1
and the motor is commanded for the wire in the phase W of
moving. the motor. Otherwise it is
necessary to replace the
controller.
It occurs in applications with
toggle switches when the applied Swap in between the two
83 BAD ENCODER SIGN frequency (FREQUENCY) and the encoder channels (CNB#7
motor speed (ENC SPEED) with CNB#8).
have opposite sign.

This alarm occurs if the command

potentiometer (CPOC1 on CNA#9
or CPOC2 on CNA#8) changes with
84 STEER SENSOR KO a jerk larger than MAX SP SLOPE Change the twin pot.
(see 12.4.6.3). This alarm is used to
catch a discontinuity in the voltages
of the command potentiometer.
This is just a warning to inform that
the steering controller is limiting
85 STEER HAZARD the angle in the steering direction. ——
No speed reduction occurs on the
traction.
The main uC sends an analog
signal towards the slave uC to reset
the slave uC on demand. When the
slave uC detects this analog signal It is necessary to replace
218 CLOCK PAL NOT OK
external to a window from 2.2 to 2.8 the controller.

8 and not in the range to generate

the reset on demand, the slave uC
raises this alarm.
When the safety contacts
are open, the voltage on
CNA#4 is expected to be
close to 0 Vdc and this is
independent from whether
the safety contacts are
It occurs when the voltage on connected to a plus battery
CNA#4 (NK1: Lower Potential or to a minus battery . In the
99 INPUT ERROR #1 Terminal of the Safety Contacts first case (safety contacts
(see 7.6) is higher than 12 V before connected to a plus
to turn the safety contacts closed. battery), when the safety
contacts are open, CNA#4
is connected to a minus
battery through a load. Only
a harness mistake may
connect NK1 to a higher
than 12 V voltage.

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Error Message
Possible cause Fault elimination
Error Error text

It occurs when the encoder

counting of the main uC is not It is necessary to replace
212 MICRO SLAVE #8
matched with the encoder counting the controller.
of the slave uC.

This alarm occurs if the frequency

and the amplitude of the voltages
from the stepper motor lines are
mismatched in between In normal It is necessary to replace
219 STEPPER MOTOR MISM
condition when the amplitude of the controller.
the stepper motor lines increases,
the frequency of the stepper motor
lines must increase too.

Search for a mechanical

This alarm occurs if the current in
problem locking the motor.
the steering motor stays close to
220 MOTOR LOCKED To make easier the fault
the maximum current longer than 1
catching, set DEBUG
sec.
OUTPUT to level 11.

It occurs in one of the following

conditions:
(Open loop application only) If the
slave uC detects the stator voltage
phasor rotates in the opposite
direction respect to the sign of the
It is necessary to replace
221 MICRO SLAVE #4 stepper motor speed, this alarm
the controller.
occurs. (Closed loop application
only) If the slave uC detects the
stator voltage phasor rotates in the
opposite direction respect to the
commanded position, this alarm
occurs. 8
In application with the
feedback potentiometer,
verify the feedback
In application with a feedback
potentiometer is not
potentiometer, this alarm occurs if
mechanically loosened.
the feedback potentiometer (CPOT
Check there is not a
on CNB#6) does not change (or
mechanical block of the
changes in the opposite direction)
steered wheel. Be sure the
its value even if commanded
222 FB POT LOCKED wiper has not reached its
to change. In application with
own electrical limit because
toggle switches with ENCODER
of too much angle of the
CONTROL to off, this alarm occurs
steered wheel. Besides,
if the feedback encoder counting
this alarm may occur at
does not change its value even if
the installation when the
commanded to change.
motor rotates in the wrong
direction turning away from
the wished

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Error Message
Possible cause Fault elimination
Error Error text

This alarm occurs if the feedback

potentiometer (CPOT on CNB#6)
changes with a jerk larger than 0.3 Change the feedback
223 JERKING FB POT
V in 16 msec. This alarm is used to potentiometer.
catch a discontinuity in the voltages
of the feedback potentiometer.

This alarm occurs when the

parameters to compensate for It is necessary to send the
the gain of the current amplifiers controller to Zapi to perform
225 CURRENT GAIN
(ADJUSTMENT #03 and the maximum current
ADJUSTMENT #04) have the regulation.
default values

Every 16msec, inside the code

cycle, the main uC rises and then
lowers an input for the slave uC
(SYNC). When the slave uC detects
no edge for more than 100 msec on
It is necessary to replace
226 NO SYNC this input, this alarm occurs. This is
the controller.
just a watch dog function: when the
main uC does not execute the code
cycle it does not update the SYNC
signal and the slave uC cuts off the
steer and traction.

Main uC and Slave uC

communicate via a local serial
interface. This alarm occurs when It is necessary to replace
227 SLAVE COM. ERROR
the main uC does not receive the the controller.
communication from the slave uC
8 through this serial interface.

This warning occurs only if

CAN BUS is PRESENT. At key-
on the eps-ac0 asks to the
traction controller to send a list of
parameters via CAN Bus. From
237 WAITING DATA ——
the request until the parameters
are correctly relieved, this warning
occurs. The steer is not activated
yet, and the safety relays remain
open when this warning is present.

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 ELECTRICAL SYSYTEM

Error Message
Possible cause Fault elimination
Error Error text

Check the potentiometer

connected to CNB#6 is right
working. If toggle switches
are connected to CNA#2
and CNA#3, verify they
are right working and the
setting AUX FUNCTION
11 is correct. Verify also
This alarm occurs for an error in
the sensor bearing in the
228 POSITION ERROR the redundant test of the feedback
motor (encoder) has not a
sensors.
slip (the sensor bearing has
two rings: one is connected
to the rotor shaft; the other
is connected to the motor
frame. Check these two
rings are strictly connected
to their structure without
slip.

This is a real alarm that cut off

the traction. It occurs at the initial
alignment if the straight-ahead
condition is not matched within
238 EPS NOT ALIGNED ——
6sec. Throughout this 6 secs delay,
the steer is not activated yet, the
safety relays are open and the
traction is stopped.

At key-on the eps-ac0 needs an

assent from the traction controller
to close the safety contacts and to

239 WAITING FOR TRAC

turn onto operational mode.
Until this assent is not relieved, this —— 8
warning occurs. The steer is not
activated yet and the safety relays
remain open when this warning is
present.

This condition is several

t i m e s d u e t o e i t h e r, a
mismatching between the
Encoder resolution used
It occurs when ENCODER
in the SW and the real
CONTROL is set ON and the real
241 ENCODER ERROR encoder resolution, or a
frequency does not pursuit the
wrong connection between
commanded frequency
the two encoder channels.
In this latest case exchange
in between the two encoder
channels.

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 ELECTRICAL SYSYTEM

Error Message
Possible cause Fault elimination
Error Error text

Check the continuity of the

This alarm occurs when the mean stepper motor connections.
voltage on the Quadrature line In particular the resistance
of the stepper motor (connection between CNA#8 and the
242 Q LINE SENSOR KO
CNA#8) is not null: the voltage on minus battery (with the
every stepper motor line is a sine stepper motor at rest) is
wave with null mean voltage. expected being very low
(close to 30 ohms).

Check the continuity of the

This alarm occurs when the mean stepper motor connections.
voltage on the Direct line of the In particular the resistance
stepper motor (connection CNA#9) between CNA#9 and the
243 D LINE SENSOR KO
is not null: the voltage on every minus battery (with the
stepper motor line is a sine wave stepper motor at rest) is
with null mean voltage. expected being very low
(close to 30 ohms).

This alarm occurs when the

acquiring the motor resistance or
when adjusting the parameters
245 DATA ACQUISITION Recycle the key.
to compensate for the gain of
the current amplifiers (maximum
current factory adjusted).

The parameters to compensate

for the gain of the current
amplifiers (ADJUSTMENT #03 and
ADJUSTMENT #04) are recorded
It is necessary to send the
in a not volatile memory (eeprom)
controller to Zapi to execute
244 GAIN EEPROM KO with a redundant handling. In fact

8 every adjustment is recorded in

three eeprom locations. If the
values in these three locations
the maximum current
regulation.

are different in between this alarm

occurs.

In stepper motor application, this

alarm occurs if the main uC is
detecting a direction of the stepper
motor not matched with the one
that the slave uC is detecting. In
closed loop application, this alarm
occurs if the main uC is detecting It is necessary to replace
246 MICRO SLAVE KO
a direction of the steering error not the controller.
matched with the one that the slave
uC is detecting. Furthermore, this
alarm occurs also if the main uC
is detecting no steering limitation
meanwhile the slave uC is detecting
e steering limitation.

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 ELECTRICAL SYSYTEM

Error Message
Possible cause Fault elimination
Error Error text

This alarm occurs only when the

setting CAN BUS is PRESENT. Check the CAN Bus
Then the eps-ac0 must receive the communication system and
247 CAN BUS KO event messages from the traction analyse the frames from
controller. If these messages lack the traction controller to the
more than about 1 sec, this alarm steer controllers.
occurs.

This alarm occurs for a fault on the

command potentiometer (CPOC1
on CNA#9, CPOC2 on CNA#8).
When a single command pot is Check the connections of
chosen, the alarm occurs if its wiper the potentiometer. This
248 S.P OUT OF RANGE (CPOC1) exits the range from 0.8 alarm occurs when one
Vdc to 4.2 Vdc. When the twin connection of the command
pot is chosen, the alarm occurs if potentiometer is broken.
the sum of the two wiper voltages
(CPOC1+CPOC2) exits the range
from 4.5 Vdc to 5.5 Vdc.

This alarm occurs for a fault on the Check the connections of

feedback potentiometer (CPOT on the feedback potentiometer.
249 F.B OUT OF RANGE CNB#6). This alarm occurs if CPOT This alarm occurs when one
exits the range from 0.3 Vdc to 4.7 connection of the feedback
Vdc. potentiometer is broken.

It occurs when the information on

the status bus between the main
uC and the slave uC is frozen It is necessary to replace
250 MICRO SLAVE
to the 0xFF value (the slave uC the controller.
does not update the status bus
configuration). 8
This alarm occurs if the slave uC
detects the safety contact, of the It is necessary to replace
251 KM OPEN
main uC, open when expected the controller.
being closed.

This alarm occurs if the main uC

detects the safety contact, of the It is necessary to replace
252 KS OPEN
slave uC, open when expected the controller.
being closed.

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 ELECTRICAL SYSYTEM

Error Message
Possible cause Fault elimination
Error Error text

This alarm occurs if the

connection CNA#5 (K1) is
around a voltage of 12 Vdc
when switching on the key.
This alarm occurs at key on if the
In fact, when the safety
slave uC detects the safety contact,
253 KM CLOSED contacts are open, K1 is
of the main uC, closed prior to be
expected being connected
commanded.
to a battery voltage (not 12
V). Search for a harness
problem or replace the
controller.

This alarm occurs if the

connection CNA#4 (NK1)
is around a voltage of 12
Vdc when switching on the
This alarm occurs if the main
key. In fact, when the safety
uC detects the safety contact, of
254 KS CLOSED contacts are open, NK1 is
the slave uC, closed prior to be
expected being connected
commanded.
to a minus battery voltage
(not 12 V). Search for a
harness problem or replace
the controller.

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 ELECTRICAL SYSYTEM

8.10 Cable Wiring Diagrams

No. Name No. Name

1 Power Cable 8 Drive Motor Cable U
2 Pump Motor Cable PA- 9 EPS Cable Negative Electrode C3
3 Pump Motor Cable PA+ 10 B Cable Negative Electrode
4 Steering Motor Cable W 11 EPS Cable Positive Electrode C2
5 Steering Motor Cable U 12 B Cable Positive Electrode
6 Drive Motor Cable W 13 Positive Electrode Cable C1
7 Drive Motor Cable V

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 ELECTRICAL SYSYTEM

8.11 Electrical Schematic Diagrams

（18） （1）
M
（18） （4） （1）

（18） （1）

（1）
（18）
（1） （0）
（25）
（26）
（10）
（12） （8） （25）
（11）
（8） （1）

（18）
M （3） （1）
（2） （1）
（6） （1）

（7） （2 5）
（5） （2 5）
NMC （13）
PMC/PEB
（14）

8
NEB （9） E-BRAKE

A4
NPC （2 1）
A5
PPC/PEV （2 2）
A6
NEV （2 3）
EV

（20）
（24）

（1 5）
（19）
（1 7）
（16）
（3 2）
A7 （2 7）
C3

C4

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 ELECTRICAL SYSYTEM

-BATT +BATT

（2 8） PPOT
B5

（2 9） CPOC1
A9
PM
（3 0） CPOC2
A8 MOTOR

（3 1） GND
A10

OPTION
CNB
5 1
M
（3 3） B2
（3 4） B6
（3 5） B1 8 4
8 1

（2 6） 14 7
CNA

（2 5）
KEY
（1） A7

（40）
（41）
（42）
8
（43）
ENCODER

（4 4）

（4 5）

（3 2） A14

（2 7） A6

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 8
MAIN WIRE
HARNESS
LIFTING
SOLENOID
ELBOW WIRE

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LIMIT SW. VALVE COIL INTERLOCK HARNESS TRAVEL SW.
CHARGE SW.
GAUGE

LIFT/LOWER
SW.

REVERSE SW.

-BATT POTENTIONMETER KEY SW.

ELECTRICAL SYSYTEM

SPEED
MAIN MODE SW.
8.12 Wiring Harness and Connectors

CONTACTOR
PUMP
CONTACTOR

120
+BATT
PROXIMITY SW.

PEDAL SW. ENCODER

FAN

E-BRAKE

DRIVE MOTOR
HORN
DRIVE MOTOR
9. TROUBLESHOOTING

121
NOTE:

122
 TROUBLESHOOTING

9.1 Preparation Before Troubleshooting

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

Battery Voltage Judgment

Greater than 24V Normal

24V Needs to be
Less than 24V
charged
9
i NOTE
Enter TESTER Menu to check the battery
voltage.(see Section 8.8)

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 TROUBLESHOOTING

9.2 Troubleshooting Solutions of Common Faults

Table 9.1 lists the common faults that may occur and handling
methods. Mainly consists of the following items:

Table 9.1 Troubleshooting of Common Faults

Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures

Power supply 1. Whole vehicle a. Power supply failure 1) Check the voltage of storage
failure power outrage b. Fuse failure battery (see Section 9.1.1)
2) Check the fuses
c. Emergency stop switch or circuit (see Section 8.2)
failure 3) Check key switch and its circuit
d. Key switch or circuit failure (see Section 8.5)
4) Check emergency stop switch
and its circuit
Travel Fault 1. Forward and rever- a. Interlock switch or its circuit Controller failure error, carry out
se moving failures of connection failure troubleshooting according to the
the vehicle, but other b. Electromagnetic brake locked fault code information on the
functions are normal (Non-mechanical failure, the instrument (see Section 8.9).
instrument will display fault code) 1) Check if the interlock switch or
the connection of its circuit is
c. Drive motor or its circuit normal; (See Section 8.7)
connection failure 2) Electromagnetic brake and its
d. Drive motor carbon brush connecting circuit;
failure (see Section 5.2)
3) Check the travel switch and its
e. Controller failure
connection circuit;
(see Section 6.3)
4) Check the drive motor and its
connection circuit;
(see Section 5.3)
5) Replace the controller.
2. The vehicle can Failures due to external factors: Controller failure error, carry out
travel at low speed, a. Electromagnetic brake locked troubleshooting according to the
but cannot travel at (Non-mechanical failure, the fault code information on the
instrument will display fault code) instrument (see Section 8.9).
high speed
b. Motor bearing blocked 1) Check the voltage of storage
battery (see Section 9.1.1)
c. Gearbox bearing blocked 2) Check the drive motor;
9 Failures due to internal factors:
a. Battery voltage deficiency
(see Section 5.3)
4) Check the electromagnetic
brake or its connection circuit
b. Speed mode switch failure (see Section 5.2)
c. Speed encoder of drive motor 5) Check speed mode switch and
its connection circuit;
d. Controller failure (see Section 8.8)
6) Remove the gearbox, check if
the gear rotation is smooth and
if there is blocking;
(see Section 5.5)
7) Replace the controller
* Carry out trouble shooting in accordance with the order listed
in the table, it can help you quickly identify problems and
resolve accordingly.

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 TROUBLESHOOTING

Table 9.1 Troubleshooting of Common Faults (continued)

Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures

Hydraulic 1. The vehicle cannot 1. Pump motor does not work: 1. Pump motor does not work:
Failure lift a. Pump motor or its circuit 1) Check the pump motor and its
connection failure connection circuit;
b. Pump contactor or its circuit (see Section 7.3)
connection failure 2) Check the pump contactor and
its connection circuit;
c. Lifting switch or its circuit (see Section 7.4)
connection failure 3) Check the lifting switch and its
d. Lifting limit switch or its circuit connection circuit;
connection failure (see Section 6.2)
4) Check the lifting limit switch
and its connection circuit;
(see Section 8.4)

2. Pump motor works: 2. Pump motor works:

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

2. The vehicle cannot a. Solenoid valve or its circuit 1) Check the lowering button and
be lowered connection failure its connection circuit;
b. Lowering switch or its circuit
connection failure 2)
(see Section 6.2)
Check the solenoid valve and
its connection circuit;
9
c. Valve failure; (see Section 7.5)
d. Cylinder deformation or blocked 3) Check the cylinder for
deformation, remove the
cylinder to check if the internal
assembly is normal ;
(see Section 7.6)
4) Clean or replace the valve;

* Carry out trouble shooting in accordance with the order listed

in the table, it can help you quickly identify problems and
resolve accordingly.

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 TROUBLESHOOTING

Table 9.1 Troubleshooting of Common Faults (continued)

Fault Fault Symptom Troubleshooting Order * Troubleshooting Measures

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

5. Unstable Lifting / a. Lifting mechanism loosening or 1) Check if the lifting mechanism

Lowering of Vehicle wear; is normal;
b. Poor lubrication of lifting (see Section 4.5)
mechanism;

Steering Fault 1. The vehicle cannot a. Potentiometer or its circuit Controller failure error, carry out
be steered (the connection failure troubleshooting according to the
vehicle can travel) b. Steering motor or its circuit fault code information on the
connection failure instrument (see Section 8.9).
1) Check if the mechanical
c. Proximity switch or its circuit connection between the
connection failure potentiometer and rocker
d. Steering controller failure is solid;
(see Section 6.4)
2) Check the potentiometer or its
connection circuit;
(see Section 6.4)
3) Check the steering motor or its
connection circuit;
(see Section 5.6)
5) Check the speed encoder or
its connection circuit.
(see Section 5.7)
5) Check the proximity switch or

9 its connection circuit.

(see Section 5.5)
6) Replace the controller.

Other Failures 1. Horn does not a. Horn switch or its circuit 1) Check the horn button and its
sound connection failure connection circuit;
b. Horn failure (see Section 6.2)
2) Check the horn and its
connection circuit.
(see Section 6.2)

* Carry out trouble shooting in accordance with the order listed

in the table, it can help you quickly identify problems and
resolve accordingly.

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APPENDIX

127
NOTE:

128
B SERVICE MANUAL - BATTERY

129
NOTE:

130
 SERVICE MANUAL - BATTERY

B1 Lead-acid Battery As for failure to comply with instructions 

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

WARNING B1-2.2 Discharging

- It is necessary to add water regularly, other- - Do not close or cover the ventilation openings
wise may cause damage to the battery due to with objects;
water loss. - When connecting or disconnecting the battery
- The water must be added after the battery is connector (such as, plug), the power supply
fully charged, adding water before charging must be disconnected first;
can cause electrolyte overflow. - In order to meet or exceed the rated batt-
- The amount of water to be added must be ery service life, the battery should avoid
strictly controlled, excessive adding of water excessive discharge during runtime (capacity
may lead to electrolyte overflow. less than 20% of the rated capacity);
- Only distilled water can be added, the adding - Re-charge the battery immediately after
of tap water or mineral water is prohibited. discharging without delay.

As for the decrease of battery capacity, or 
even damage to the battery due to failure 
to  comply  with  the  above  provisions,  the 
quality assurance will automatically void.

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 SERVICE MANUAL - BATTERY

B1-2.3 Charging B1-3 Maintenance & Care

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

B - The charger purchased separately must

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

Add distilled water, red buoy will float until while

rod appears under the red scale.

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 SERVICE MANUAL - BATTERY

- As for a group of normal batteries, when the

WARNING battery is discharged for 80% (the instrument
- Add only distilled water. alarms and prompts low battery, you should
recharge in a timely manner), the open circuit
- Before adding distilled water, check if the
voltage should be around 1.93V, specific
buoy can move up and down properly to
gravity of electrolyte (under 30°C) should be
prevent the buoy from failing to float up and
around 1.14.

B
resulting in excessive filling.
CAUTION
2) Filler cap without buoy And you can identify if the battery is fully
When adding water, stop filling when the discharged according to the specific gravity of
electrolyte level is higher than the protective battery electrolyte when the instrument alarms,
plate for 15~20 mm. and identify if the capacity indicated on the
instrument is accurate.
CAUTION
If  there  is  fault,  please  notify  ser vice 
Please operate the electric watering device in personnel for repairs.
accordance with its operating manual.

B1-3.4 Care
B1-3.3 Monthly Maintenance 1. Keep it clean
- Before the charging is completed (while - Battery surface should be clean and dry to
the charger is still energized), measure and prevent the occurrence of leakage currents;
record the voltage of battery cell the entire - Battery cables, terminals and connectors mu-
battery;
st be tightened and clean, a small amount of
- After the charging is completed, measure special grease should also be applied.
and record the electrolyte concentration and
temperature of the battery cell. WARNING
- Do not use a dry cloth or fabric to clean the
    How to tell if the battery is normal?
surface of the battery, so that to prevent the
- As for a normal set of fully charged batteries, occurrence of static electricity, resulting in
the voltage of each of the battery cell explosion;
should be around 2.08V, specific gravity of - Unplug the power plug;
electrolyte should be around 1.28; - Wipe clean with a damp cloth;
CAUTION - Please wear goggles, rubber boots and
rubber gloves.
After being fully charged, if the voltage of
battery cell is lower than 1.85V or the specific
gravity of electrolyte is less than 1.05, then that 2. Make sure that the cable insulation is not da-
battery cell has been damaged and needs to be maged and the connection layer has no signs
replaced. of heating.

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 SERVICE MANUAL - BATTERY

3. Make sure that the "+" and "-" output termin- B1-4 Storage
als are not sulfated (with white salt).
- When the battery is not used for a long time,
- Slight sulfation: clean top of the element with the battery should be filled up and stored in a
a damp cloth. dry, frost-free space.
- Severe sulfation: the battery must be remov- - Regular equalizing charge may help extend
ed for powerful cleaning; the battery base the service life of battery and ensure that the

B should also be cleaned.

- Very severe sulfation (or a large amount
capacity won't be reduced.

of electrolyte overflow): please contact the

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

Battery Fault Analysis

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

- Adding impure liquid:

1. Battery capacity is low
2. Electrolyte is turbid and of
abnormal color
3. Battery with severe self-
discharge

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Battery Fault Analysis

Fault Negative Phenomena Cause Handling Methods
Electrode 1. Battery capacity drops 1. Insufficient initial charge 1. Over-discharge method
plate sulfation during normal discharge 2. Long time of storage under 2. Repeated charging method
2. Density drops to be lower the state of discharge 3. Water treatment method

B
than normal value 3. Long-term insufficient
3. Voltage drops quickly when charged
discharging 4. Electrolyte density is too high
4. Start charging under high 5. Electrolyte level is too low,
voltage the upper part of electrode
5. Bubbles generated during plate is exposed outside of
charging the electrolyte
6. Coarse crystallization of 6. Impure electrolyte
PbSO4 7. Internal short circuit

Excessive 1. There is gray-brown 1. Brown precipitation is due to 1. Clean up the precipitation

shedding substance rising from the excessive large charging 2. Adjust the density
of active bottom when charging current 3. Battery needs to be
substances 2. Battery capacity reduced 2. White sediment is due to replaced if necessary
over-discharge
3. Battery electrolyte is impure

Battery 1. Color of battery filling cap 1. Charger voltage and current 1. Adjust and repair the
overcharged becomes yellow, and then are set too high charger
red 2. Charging time is too long 2. Adjust the charging system
2. Battery casing deformation 3. Frequent charging 3. Battery needs to be
3. Battery spacers 4. Less discharging, but much replaced in severe situations
carbonization, deformation charging
4. Positive electrode corrosion, 5. Charger failure
broken
5. Electrode pole rubber
bushing raised, aged and
cracked
6. Frequent water-adding,
electrolytic turbidity during
charging
7. Evenly shedding of active
substances from electrode
plate
8. Positive electrode plate
detonation

Battery Over- 1. Low static voltage 1. Go on using the battery 1. Supplementary charging
discharge 2. Electrolyte density is still despite of insufficient charge 2. Repair the vehicle
low after charging 2. Battery pack short circuit 3. Battery needs to be
3. Positive and negative 3. Small current long time replaced in severe situations
electrode plates curved or discharge
fractured

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Battery Fault Analysis

Fault Negative Phenomena Cause Handling Methods
Battery Short 1. Low static voltage below 2V 1. Electrode plate deformed and Battery needs to be replaced
Circuit 2. Electrolyte density is too low short circuit
3. High temperature during 2. Spacer missing or broken

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

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B2 Maintenance-free Battery B2-2 Use of Battery

B2-1 Safety and Warnings B2-2.1 Pre-use Checks

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

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B2-2.3 Charging B2-3 Maintenance & Care

- When charging, only DC can be used. Con- - Compared to lead-acid batteries, mainten-
nect the battery with proper charger for ance-free battery eliminates the maintenance
specification and size to avoid overload of to electrolyte.
circuit and interface, and to avoid electrolyte
foaming, leading to swollen battery;
Daily Maintenance
B - The charger purchased separately must be
checked by the after-sales service depart- - Charge the discharged battery;
ment of our company before it can be used; - Visual inspection for excessive dirtiness and
- When connecting the battery with the charg- mechanical damage after the charging.
er, the circuit switch should be at “OFF”
position, make sure the connection is correct. Supplementary Charging
It is prohibited to connect the battery with live
charger. - If the vehicle is not used for more than two
months, supplementary charging must be car-
- Before charging the battery, the charging spa-
ce should be ensured with good ventilation ried out to the battery to prevent permanent
without open flames and combustibles; battery damage;
when the temperature of electrolyte exceeds - Charging method is in accordance with the
40 degrees during charging, reduce the requirements of normal charging.
current or take physical cooling measures,
the charging must be stopped when the
temperature reaches 45 degrees;     How to tell if the battery is normal?
- When the battery voltage remains constant General diagnostic method for the quality of
(for more than 2 hours), and the load voltage battery is to fully charge the battery with good
of the battery is within the specified range charger, and then measure the load voltage with
between 20.8V~24.4V, it indicates that the a multimeter to check if the voltage is between
charging is completed. 20.8V~24.4V.

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C SCHEDULE

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NOTE:

140
 Operator's Daily Checklist

Date Operator

TruckNo. No.

Department
Runtime
MeterReading

DailyCheckItems O.K.( √ ) Remark

DriveWheel

LoadWheel/Casters

Horn

Lifting/LoweringControlFunctions

OptionalFeatures

Forward/ReverseControlFunctions

Steeringcontrolfunctions

BrakingFunctions

Checkhydraulicsystemforleaks:
cylinders,fittings,tubings,oiltank,etc.